GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2001 🢒 GMC C Sierra - 2WD 🢒 Driveline/Axle 🢒 Rear Drive Axle 🢒 Differential Overhaul

Differential Overhaul 9.5 Inch Axle

Tools Required

    • J 8092 Driver Handle
    • J 22888-D Side Bearing Puller Kit
    • J 29710 Differential Side Bearing Installer

Disassembly Procedure

    Object Number: 680400 Size: SH
  1. Remove the differential side bearings by performing the following steps:
    2. 1.1. Install the differential assembly into a vise.
    1.2. Install the J 8107-3  (1) and the J 22888-20A  (2) as shown.
    1.3. Remove the differential side bearings using the J 22888-20A .

    Object Number: 680402 Size: SH

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

  2. Remove the gear bolts. Discard the bolts.

    3. Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

  3. Remove the ring gear from the differential case.

    4. Drive the ring gear off with a brass drift if necessary.


    Object Number: 680404 Size: SH
  4. Remove the differential pinion gears and the differential side gears by performing the following steps:
    5. 4.1. Remove the pinion shaft lock bolt.
    4.2. Remove the pinion shaft.
    4.3. Drive the pinion gear thrust washer out from the differential case using a hammer and a brass drift.
    4.4. Roll the differential pinion gears out of the differential case.
    4.5. Remove the differential side gears and the side gear thrust washers.

    Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure
  1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  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 gears and the thrust washers to their original locations.


    Object Number: 680404 Size: SH
  4. Install the differential pinion gears by performing the following steps:
    5. 4.1. Position one of the pinion gears between the differential side gears.
    4.2. Install the second pinion gear directly opposite of the first gear between the differential side gears.
    4.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.
    4.4. Install the pinion gear thrust washers using a hammer and a brass drift.
  5. Install the pinion shaft.

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

  6. Install a new pinion shaft lock bolt.

    7. Tighten
    Tighten the new pinion shaft lock bolt to 50 N·m (37 lb ft).

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


    Object Number: 680451 Size: SH
  7. Install the ring gear to the differential case.
  8. Install the new ring gear bolts.

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

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

    10. Tighten
    Tighten the ring gear bolts in sequence to 140 N·m (103 lb ft).


    Object Number: 651740 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 8107-3 in the case on the side opposite the bearing installation.
    10.2. Install the J 29710  (2) and the J 8092  (1) onto the differential case bearing as shown.
    10.3. Drive the bearing onto the case using the J 29710 and the J 8092 .

Differential Overhaul 10.5 Inch Axle

Disassembly Procedure
  1. Remove the differential side bearings. Refer to Differential Side Bearings Replacement .

    2. Object Number: 739940 Size: SH

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

  2. Remove the ring gear bolts.

    3. Notice: Refer to Ring Gear Removal Notice in the Preface section.

  3. Remove the ring gear from the differential case.

    4. Drive the ring gear off with a brass drift if necessary.

  4. Separate the differential case assembly.

    5. Object Number: 739941 Size: SH

    Important: If the differential pinion gears, the differential side and the thrust washers are to be reused, mark the components so they can be re-installed in their original location in the differential case.

  5. Remove the following from the differential case:
    6. • The thrust washers
    • The differential pinion gears
    • The differential pinion spider

    Object Number: 739943 Size: SH
  6. Remove the differential side gears.

Assembly Procedure
  1. Lubricate the differential side gears and the differential pinion gears with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.

    2. Object Number: 739943 Size: SH
  2. Install the differential side gears into the differential case.

    3. If the original differential side gears are being used, install the gears in the original location.


    Object Number: 739941 Size: SH
  3. Assemble the differential pinion gears and the thrust washers to the differential spider as shown.

    4. If the original differential pinion gears, the thrust washers and the differential spider are being used, install the components in the original locations.


    Object Number: 739964 Size: SH
  4. Assemble the differential case halves.

    5. Align the arrow in the differential case as shown.

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

  5. Install the ring gear to the differential case.

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


    Object Number: 739940 Size: SH
  6. Install the new ring gear bolts.

    7. Hand start each bolt in ensure the ring gear is properly installed to the differential case.

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

    8. Tighten
    Tighten the ring gear bolts in sequence to 165 N·m (122 lb ft).

  8. Install the differential side bearings. Refer to Differential Side Bearings Replacement .

Differential Overhaul 11.5 Inch Axle

Tools Required

    • J 8092 Driver Handle
    • J 22888-D Side Bearing Remover Kit
    • J 44420 Differential Bearing and Hub Seal Installer

Disassembly Procedure

    Object Number: 680400 Size: SH
  1. Remove the differential side bearings by performing the following steps:
    2. 1.1. Install the differential assembly into a vise.
    1.2. Install the J 8107-5 (1) and the J 22888-20A  (2) as shown.
    1.3. Remove the differential side bearings using the J 22888-20A .

    Object Number: 866503 Size: SH

    Important: The ring gear bolts have right-hand threads.

  2. Remove the gear bolts. Discard the bolts.

    3. Object Number: 866502 Size: SH

    Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

  3. Remove the ring gear from the differential case.

    4. Drive the ring gear off with a brass drift if necessary.


    Object Number: 850793 Size: SH
  4. Locate the end of the pinion shaft with the pilot hole.

    5. Object Number: 911230 Size: SH
  5. Remove the pinion shaft by performing the following steps:
    6. 5.1. Place a brass drift onto the end of the pinion shaft with the pilot hole.
    5.2. Drive the pinion shaft through the differential case using a hammer and the brass drift.

    Object Number: 911232 Size: SH
  6. Remove the retaining ring from the pinion shaft. Discard the retaining ring.

    7. Object Number: 911236 Size: SH
  7. Remove the differential pinion gears and the pinion gear thrust washers by rolling the gears out through the differential case opening.
  8. Remove the differential side gears and the thrust washers.

    9. Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure

    Object Number: 911232 Size: SH
  1. Install the new retaining ring onto the pinion shaft.
  2. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  3. Install the differential side gear thrust washers to the differential side gears.
  4. Install the differential side gears and thrust washers into the differential case.

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


    Object Number: 911236 Size: SH
  5. Install the differential pinion gears and the thrust washers into the differential case by performing the following steps:
    6. 5.1. Install the thrust washers to the pinion gears.
    5.2. Position one of the pinion gears with the thrust washer between the differential side gears.

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

    5.3. Install the second pinion gear with the thrust washer between the differential side gears directly opposite of the first gear.
    5.4. Rotate the differential side gears until the pinion gears and the thrust washers are directly opposite the opening in the differential case.

    Object Number: 911245 Size: SH
  6. Install the pinion shaft into the differential case by performing the following steps:
    7. 6.1. Insert the side of the pinion shaft with the pilot hole into the differential case.
    6.2. Slide the pinion shaft through the differential case until the retaining ring is against the differential case.
    6.3. Carefully drive the pinion shaft into the differential case using a hammer and a brass drift.

    Ensure that the pinion shaft retaining ring is seated in the channel within the differential case.


    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 to the differential case.

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


    Object Number: 866503 Size: SH
  8. Install the new ring gear bolts.

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

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

    10. Tighten
    Tighten the ring gear bolts in sequence to 237 N·m (175 lb ft).


    Object Number: 651740 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 8107-5 in the case on the side opposite the bearing installation.
    10.2. Install the J 44420  (2) and the J 8092  (1) onto the differential case bearing as shown.
    10.3. Drive the bearing onto the case using the J 44420 and the J 8092 .

Differential Overhaul 8.6 Inch Axle

Tools Required

    • J 8092 Driver Handle
    • J 21784 Side Bearing Installer
    • J 22888-D Side Bearing Puller Kit

Disassembly Procedure

    Object Number: 680400 Size: SH
  1. Remove the differential side bearings by performing the following steps:
    2. 1.1. Install the differential assembly into a vise.
    1.2. Install the J 8107-2  (1) and the J 22888-20A  (2) as shown.
    1.3. Remove the differential side bearings using the J 22888-20A .

    Object Number: 680402 Size: SH

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

  2. Remove the gear bolts. Discard the bolts.

    3. Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

  3. Remove the ring gear from the differential case.

    4. Drive the ring gear off with a brass drift if necessary.


    Object Number: 680404 Size: SH
  4. Remove the differential pinion gears and the differential side gears by performing the following steps:
    5. 4.1. Remove the pinion shaft lock bolt.
    4.2. Remove the pinion shaft.
    4.3. Roll the differential pinion gears out of the case with the pinion gear thrust washers.
    4.4. Remove the differential side gears and the side gear thrust washers.

    Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure
  1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  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 gears and the thrust washers to their original locations.


    Object Number: 680404 Size: SH
  4. Install the differential pinion gears and pinion gear 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 gears directly opposite the of the first gear.
    4.3. Rotate the differential side gears until the pinion gears is directly opposite the opening in the differential case.
    4.4. Install the thrust washers.

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

  5. Install the pinion shaft.

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

  6. Install a new pinion shaft lock bolt.

    7. Tighten
    Tighten the new pinion shaft lock bolt to 36 N·m (27 lb ft).

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


    Object Number: 680451 Size: SH
  7. Install the ring gear to the differential case.
  8. Install the new ring gear bolts.

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

  9. Tighten the ring gear bolts. Tighten the 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 (90 lb ft).


    Object Number: 651740 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 21784  (2) and the J 8092  (1) onto the differential case bearing as shown.
    10.3. Drive the bearing onto the case using the J 21784 and the J 8092 .