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Makes 🢒 Chevrolet 🢒 2008 🢒 Tahoe - 4WD 🢒 General Information 🢒 Maintenance and Lubrication 🢒 Differential Carrier Assembly Final Assembly

Differential Carrier Assembly Final Assembly 8.25 F4WD

Special Tools

    • J 8092 Universal Driver Handle - ¾ in - 10
    • J 21474-18 Long Nut
    • J 33842 Pilot Bearing Installer
    • J 36609 Axle Tube Bearing Installer
    • J 36616 Axle Mount Bushing Remover/Installer
    • J 45225 Axle Seal Installer
  1. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
  2. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 9.25 inch axle - right side.

    3. Object Number: 685960 Size: SH
  3. Install the differential adjuster nut lock, 9.25 inch axle - left side.

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

  4. Install the differential adjuster nut lock bolt.

    5. Tighten
    Tighten the differential adjuster lock nut bolt to 20 N·m (15 lb ft).

  5. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    6. Object Number: 205917 Size: SH
  6. Install the clutch shaft to the differential carrier case half.

    7. Object Number: 847064 Size: SH

    Important: The following service procedure is for the 9.25 inch axle.

  7. Install the vent hose connector.

    8. Tighten
    Tighten the vent hose connector to 28 N·m (21 lb ft).

    Important: The following service procedure is for the 8.25 inch axle.


    Object Number: 1690209 Size: SH
  8. Install the vent hose (1) to the vent connector (2).

    9. Tighten
    Tighten the vent hose connector (2) to 20 N·m (15 lb ft).


    Object Number: 1486568 Size: SH
  9. Using the J 45225  (1) and the J 8092  (2), install the new left side axle shaft seal.
  10. Install the new left side inner axle shaft retainer ring.

    11. Object Number: 1332794 Size: SH
  11. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
  12. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear
  13. Using a soft faced mallet, drive the inner shaft into the differential case side gear until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  14. Ensure that the inner shaft is properly retained in the differential case side gear by pulling back on the inner shaft.

    15. Object Number: 834254 Size: SH

    Important: Clamp only on the mounting flange of the inner axle shaft housing.

  15. Install the inner axle shaft housing into a vise.

    16. Important: When installing the bearing, ensure that the square shoulder of the bearing is facing inward.

  16. Using the J 36609  (1) and the J 8092  (2), install the bearing.

    17. Object Number: 1486575 Size: SH
  17. Using the J 45225  (1) and the J 8092  (2), install the new right side inner axle shaft seal.

    18. Object Number: 2047154 Size: SH
  18. Install the following components into the inner shaft housing:
    19. 18.1. The inner axle shaft (1)--Carefully tap the inner axle shaft into place with a soft-faced mallet.

            Important: Use chassis grease in order to hold the thrust washer in place.

    18.2. The thrust washer, with tabs (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.
    18.3. The new retainer ring (6) onto the inner axle shaft (1)
    18.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment.
    18.5. The clutch gear shim (8)
    18.6. The clutch sleeve (9)
    18.7. The clutch fork assembly (10)
    18.8. The clutch fork inner spring (9)
    18.9. The inner axle housing gasket

    Important: The following service procedure is for the 9.25 inch axle ONLY.

  19. Apply sealant to the inner shaft housing to differential carrier sealing surface. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    20. Object Number: 893259 Size: SH
  20. Install the inner shaft housing to the differential carrier assembly case.
  21. If servicing the 8.25 inch axle, install the inner shaft housing bolts.

    22. Tighten
    Tighten the inner shaft housing bolts to 73 N·m (54 lb ft).

  22. If servicing the 9.25 inch axle, install the inner shaft housing bolts.

    23. Tighten
    Tighten the inner shaft housing bolts to 40 N·m (30 lb ft).

  23. Install the drain plug and the washer.
  24. Install the fill plug and the washer.

    25. Tighten
    Tighten the drain plug and the fill plug to 33 N·m (24 lb ft).

    Notice: Refer to Component Fastener Tightening Notice in the Preface section.


    Object Number: 893264 Size: SH

    Important: Apply the correct sealant to the threads of the front axle actuator. Refer to Adhesives, Fluids, Lubricants, and Sealers.

  25. Install the front drive axle actuator.

    26. Tighten
    Tighten the front drive axle actuator to 20 N·m (15 lb ft).


    Object Number: 2047519 Size: SH

    Important: The following service procedures are for the 9.25 inch axle ONLY.

  26. Using the J 21474-18 (2), J 36616-2 (1), and the J 36616-1 (1), install the differential carrier bushing (3).

    27. Object Number: 2047520 Size: SH

    Important: The following service procedures are for the 9.25 inch axle ONLY.

  27. Using the J 21474-18 (2), J 36616-2 (1), and the J 36616-1 (1), install and the differential carrier assembly bushing.
  28. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement.

Differential Carrier Assembly Final Assembly 8.25 S4WD and 9.25

Special Tools

    • J 8092 Universal Driver Handle - ¾ in - 10
    • J 33842 Pilot Bearing Installer
    • J 36609 Axle Tube Bearing Installer
    • J 36616 Axle Mount Bushing Remover/Installer
    • J 45225 Axle Seal Installer
  1. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
  2. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 9.25 inch axle - right side.

    3. Object Number: 685960 Size: SH
  3. Install the differential adjuster nut lock, 9.25 inch axle - left side.

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

  4. Install the differential adjuster nut lock bolt.

    5. Tighten
    Tighten the differential adjuster lock nut bolt to 20 N·m (15 lb ft).

  5. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    6. Object Number: 695745 Size: SH
  6. Using the J 33842 , install the clutch shaft pilot bearing.

    7. Object Number: 205917 Size: SH
  7. Install the clutch shaft to the differential carrier case half.

    8. Object Number: 847064 Size: SH
  8. If servicing the 9.25 inch axle, install the vent hose connector.

    9. Tighten
    Tighten the vent hose connector to 28 N·m (21 lb ft).


    Object Number: 1690209 Size: SH
  9. If servicing the 8.25 inch axle, install the vent hose (1) to the vent connector (2).

    10. Tighten
    Tighten the vent hose connector (2) to 20 N·m (15 lb ft).


    Object Number: 1486568 Size: SH
  10. Using the J 45225  (1) and the J 8092  (2), install the new left side axle shaft seal.
  11. Install the new left side inner axle shaft retainer ring.

    12. Object Number: 1332794 Size: SH
  12. Install the left side inner axle shaft by doing the following:
    13. 12.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
    12.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear.
    12.3. Using a soft-faced mallet, drive the inner shaft into the differential case side gear until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  13. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear

    14. Object Number: 834254 Size: SH
  14. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
    15. 14.1. Install the inner axle shaft housing into a vise.
    14.2. Clamp only on the mounting flange of the inner axle shaft housing.
    14.3. Using the J 36609  (1)  and the J 8092  (2), install the bearing.

    Object Number: 1486575 Size: SH
  15. Using the J 45225  (1) and the J 8092  (2), install the new right side inner axle shaft seal.

    16. Object Number: 892812 Size: SH
  16. Install the following components into the inner shaft housing:
    17. 16.1. Using a soft faced mallet, install the inner axle shaft (1).

            Important: Use chassis grease in order to hold the thrust washer in place.

            Important: Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.

    16.2.  Install the thrust washer (with tabs) (5).
    16.3. Install the thrust washer (without tabs) (6).
    16.4. Install the new retainer ring (7) onto the inner axle shaft (1).
    16.5. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment.
    16.6. Install the clutch gear shim (9).
    16.7. Install the clutch sleeve (8).
    16.8. Install the clutch fork assembly (11).
    16.9. Install the clutch fork inner spring (10).
    16.10. Install the inner axle housing gasket.

    Important: The following service procedure is for the 9.25 inch axle ONLY.

  17. Using the correct sealant, apply sealant to the inner shaft housing to differential carrier sealing surface. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    18. Object Number: 893259 Size: SH
  18. Install the inner shaft housing to the differential carrier assembly case.
  19. If servicing the 8.25 inch axle, install the inner shaft housing bolts.

    20. Tighten
    Tighten the inner shaft housing bolts to 73 N·m (54 lb ft).

  20. If servicing the 9.25 inch axle, install the inner shaft housing bolts.

    21. Tighten
    Tighten the inner shaft housing bolts to 40 N·m (30 lb ft).

  21. Install the drain plug and the washer.
  22. Install the fill plug and the washer.

    23. Tighten
    Tighten the drain plug and the fill plug to 33 N·m (24 lb ft).

    Notice: Refer to Component Fastener Tightening Notice in the Preface section.


    Object Number: 893264 Size: SH
  23. Install the front drive axle actuator.

    24. Apply sealant to the threads of the front axle actuator. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    Tighten
    Tighten the front drive axle actuator to 20 N·m (15 lb ft).


    Object Number: 892851 Size: SH

    Important: The following service procedures are for the 9.25 inch axle ONLY.

  24. Install the lower differential carrier assembly bushing by performing the following steps:
    25. 24.1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
    24.2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.

    Object Number: 893253 Size: SH

    Important: The following service procedures are for the 9.25 inch axle ONLY.

  25. Install the upper differential carrier assembly bushing by performing the following steps:
    26. 25.1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
    25.2. While holding the forcing screw, slowly tighten the J 21474-18  until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
  26. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement.