GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Colorado Pickup - 4WD 🢒 Driveline/Axle 🢒 Front Drive Axle 🢒 Front Differential Case Assemble

Front Differential Case Assemble W/O E-Locker

Tools Required

    • J 8092 Universal Driver Handle - ¾ in - 10
    • J 25299 Side Bearing Installer
  1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations.

    2. Object Number: 680404 Size: SH
  2. Install the differential side gear thrust washers to the differential side gears.
  3. Install the differential side gears and thrust washers into the differential case.

    4. If the same differential side gears and the thrust washers are being used, install the side gears and the thrust washers to their original locations.

  4. Install the differential pinion gears and thrust washers by performing the following steps:
    5. 4.1. Position one pinion gear between the differential side gears.
    4.2. Position the second pinion gear between the differential side gear directly opposite of the first gear.
    4.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.
    4.4. Install the thrust washers.

    Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.

  5. Install the pinion gear shaft.

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Install the new pinion gear shaft lock bolt.

    7. Tighten
    Tighten the new pinion shaft lock bolt to 25 N·m (18 lb ft).


    Object Number: 866505 Size: SH

    Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

  7. Install the ring gear onto the differential case.

    8. Important: The ring gear bolts have left-hand threads.

  8. Install the new ring gear bolts.

    9. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

  9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

    10. Tighten
    Tighten the ring gear bolts in sequence to 120 N·m (89 lb ft).


    Object Number: 680453 Size: SH
  10. Install the differential side bearings by performing the following steps:
    11. 10.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation.
    10.2. Install the J 25299  (2) and the J 8092  (1) onto the differential case bearing as shown.
    10.3. Install the differential case bearings using the J 33790 and the J 8092 .