Special Tools

1. Install the right side differential adjuster lock over the differential bearing adjuster.

Caution: Refer to Fastener Caution in the Preface section.




2. Install the right side differential bearing adjuster lock bolt and tighten to 8 N·m (71 lb in).



3. Install the left side differential bearing adjuster lock over the differential adjuster.



4. Install the left side differential bearing adjuster lock bolt and tighten to 8 N·m (71 lb in).



5. Remove the differential carrier assembly bolts.
6. Remove the right differential carrier case half.
7. Clean the sealing surface of each half of the differential carrier case and the inner shaft housing to differential carrier assembly.

The surfaces must be clean of all the grease and the oil.

8. Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or the equivalent to one side of the differential carrier case half sealing surface.
9. Install the right differential carrier case half.
10. Install the differential carrier case bolts and tigthen to 48 N·m (35 lb ft).



11. Install the lower inner shaft housing bushing by performing the following steps:

11.1.

Install the inner shaft housing into a vise.

11.2.

Place the lower inner shaft housing bushing over the bushing bore.

11.3.

Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown.

Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut.

11.4.

Install the lower inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.

11.5.

Remove the inner shaft housing from the vise.

11.6.

Install the inner shaft housing into the vise.

Clamp on the inner shaft housing tube.




12. Install the upper inner shaft housing bushing by performing the following steps:

12.1.

Install the inner shaft housing into a vise.

12.2.

Place the upper inner shaft housing bushing over the bushing bore.

12.3.

Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown.

Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut.

12.4.

Install the upper inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.




13. Install the bearing with the square shoulder in using the J 42211  (2) and the J 8092  (1).



14. Install the new axle shaft seal using the J 42738 .
15. Remove the inner shaft housing from the vise.
16. Install the differential carrier assembly into a vise.
17. Apply sealant GM P/N 1052492 (Canadian P/N 10953466) or equivalent to the inner housing to differential carrier assembly sealing surface.
18. Install the inner shaft housing to the differential carrier assembly.



19. Install the inner shaft housing to differential carrier assembly bolts and tighten to 48 N·m (35 lb ft).
20. Install the new inner shaft retaining ring.




Note: Do not nick or cut the inner shaft oil seal.

21. Install the inner shaft into the inner shaft housing by performing the following steps:

21.1.

Carefully guide the inner shaft through the inner shaft housing until the retaining ring on the inner shaft contacts the differential case side gear.

21.2.

Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.

21.3.

Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.




22. Install the inner shaft seal cover.



23. Install the inner shaft seal cover bolts and tighten to 18 N·m (13 lb ft).
24. Install the new inner shaft retaining ring.




Note: Do not nick or cut the inner shaft oil seal.

25. Install the left inner shaft into the differential carrier assembly by performing the following steps:

25.1.

Carefully guide the inner shaft through the oil seal until the retaining ring on the inner shaft contacts the differential case side gear.

25.2.

Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.

25.3.

Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.




26. Install the lower differential carrier assembly bushing by performing the following steps:

26.1.

Install the differential carrier assembly bushing into the differential carrier assembly bushing bore.

26.2.

Install the J 45850-2 (3), the J 45850-3 (2), the forcing screw, the thrust bearing, and the nuts (1, 4-5) over the differential carrier assembly bushing as shown.

26.3.

Install the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J 45850 .




27. Install the upper differential carrier assembly bushing by performing the following steps:

27.1.

Install the differential carrier assembly bushing into the differential carrier assembly bushing bore.

27.2.

Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown.

27.3.

Install the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J 45850 .

28. Install the drain plug and the washer and tighten to 33 N·m (24 lb ft).
29. Fill the axle with lubricant with the proper fluid. Refer to Front Axle Lubricant Replacement.
30. Install the fill plug and the washer and tighten to 33 N·m (24 lb ft).