Tools Required

1. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.



2. Install the inner pinion bearing onto the pinion gear using the J 33785 .
3. Install the new collapsible spacer onto the pinion gear.
4. Lubricate the inner and the outer pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.

Important: Stake the new deflector at 3 new equally spaced positions. You must stake the new deflector in such a way that you do not damage the pinion sealing surface.

5. Install the new deflector by doing the following:

5.1.	Make sure the sealing surface of the pinion yoke is clean of burrs, if applicable.

5.2.	Install the new deflector onto the pinion yoke by tapping the deflector evenly using a hammer and a brass drift in small increments.

5.3.	Stake the new deflector to the pinion yoke in 3 positions.

6. Install the left differential carrier case into the J 33837 .

Tighten the attaching bolts securely.

7. Install the outer pinion bearing.




Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing.

8. Install the oil seal by doing the following:

8.1.	Position the oil seal in the bore.

8.2.	Install the J 33782 over the oil seal.

8.3.	Strike the J 33782 with a hammer until the seal flange seats on the axle housing surface.

9. Install the pinion gear, the selectable shim with inner pinion bearing and the new collapsible spacer, into the left differential carrier case.
10. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
11. Install the pinion yoke.

Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

12. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
13. Install the washer and a new pinion nut.



14. Install the J 8614-01 onto the pinion yoke as shown.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

15. Tighten the pinion nut while holding the J 8614-01 .

Tighten
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

16. Measure the rotating torque of the pinion using an inch-pound torque wrench.

Specification
The rotating torque of the pinion should be 1.0-2.8 N·m (10-25 lb in) for used bearings, or 1.7-3.4 N·m (15-30 lb in) for new bearings.

17. If the rotating torque measurement is below 1.0 N·m (10 lb in) for used bearings, or 1.7 N·m (15 lb in) for new bearings, continue to tighten the pinion nut.

Tighten
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 N·m (3-5 lb in) greater than the torque recorded during removal for used bearings, or 1.7-3.4 N·m (15-30 lb in) for new bearings.

18. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.




19. Install the left inner axle shaft bearing into the differential adjuster nut sleeve using the J 8092  (1) and the J 42211  (2).
20. Install the left inner axle shaft bearing and the differential bearing adjuster nut into the left differential carrier case.
21. Install the left differential case bearing cup into the left differential carrier assembly case half using the J 23423-A and the J 8092 .
22. Using the J 42213 , turn the left differential adjuster nut sleeve clockwise 2 revolutions.
23. Install the right inner axle shaft bearing into the right differential adjuster nut sleeve using the J 8092  (1) and the J 33788  (2).



24. Install the right differential bearing adjuster assembly and the right differential case side bearing cup into the right differential carrier case half using the J 23423-A  (2) and the J 8092  (1).
25. Install the differential case assembly into the left differential carrier case half.
26. Install the right differential carrier case half to the left differential carrier case half.

Do not use sealer at this time.

If the carrier case halves do not make complete contact, use the J 33792 in order to back out the right differential adjuster nut sleeve.

27. Install the differential carrier case bolts.

Tighten
Tighten the differential carrier case bolts to 50 N·m (37 lb ft).

28. Install the differential carrier assembly into a vise.
29. While rotating the pinion yoke back and forth, turn the right side differential adjuster nut sleeve clockwise using the J 33792 until 0.0254-0.0762 mm (0.001-0.003 in) of backlash can be felt between the ring gear and the drive pinion.

If the backlash specification cannot be obtained, turn the left side differential adjuster nut sleeve counterclockwise using the J 42213 one notch at a time until the backlash specification can be obtained.

30. Using the J 42213 , turn the left side differential adjuster nut sleeve clockwise in order to preload the differential side bearings against the differential side bearing cups.

Tighten
Tighten the differential adjuster nut to 75 N·m (55 lb ft).

31. Rotate the pinion several times in order to seat the pinion and differential side bearings.
32. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench.

Specification
The rotating torque of the pinion and differential assembly should be 3.4-6.2 N·m (30-55 lb in) for new bearings or 2.8-5.1 N·m (25-45 lb in) for used bearings.

33. If the rotating torque measurement is below 2.8 N·m (25 lb in) for used bearings, or 3.4 N·m (30 lb in) for new bearings, adjust the differential side bearing preload using the following steps:

33.1.

Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.

33.2.

Using the J 33792 and the J 42213 , turn the left and the right side differential adjuster nut sleeves in or clockwise one notch.

33.3.

Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

33.4.

Compare the new measurement to the specification listed in step 32. If the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications

34. If the rotating torque measurement is above 5.1 N·m (45 lb in) for used bearings, or 6.2 N·m (55 lb in) for new bearings, adjust the differential side bearing preload using the following steps:

34.1.

Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.

34.2.

Using the J 33792 and the J 42213 , turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch.

34.3.

Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

34.4.

Compare the new measurement to the specification listed in step 32. If the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.

35. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.

36. Measure the drive pinion to ring gear backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment .
37. Once the bearing preload and drive pinion to ring gear backlash is within specifications, perform a gear tooth contact pattern check to ensure proper contact between the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
38. Complete the assembly of the differential carrier. Refer to Differential Carrier Assembly Final Assembly .