- Bend the differential adjuster nut lock tabs over the differential adjuster
nut sleeves, 8.25 inch axle - both sides, 9.25 inch axle -
right side.
- Install the differential adjuster nut lock, 9.25 inch axle - left side.
Notice: Refer to Fastener Notice in the Preface section.
- Install the differential adjuster nut lock bolt.
Tighten
Tighten the differential adjuster lock nut bolt to 20 N·m (15 lb ft).
- Remove the differential carrier assembly bolts.
- Remove the right differential carrier case half.
- Clean the sealing surface of each half of the differential carrier case
and the inner axle housing to differential carrier assembly.
The surfaces must be clean of all the grease and the oil.
- Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or
the equivalent to one differential carrier case half sealing surface.
- Install the right differential carrier case half.
- Install the differential carrier case bolts.
Tighten
Tighten the differential carrier case bolts to 47 N·m (35 lb ft).
- Lubricate the clutch shaft pilot bearing with axle lubricant. Refer to
Fluid and Lubricant Recommendations
in Maintenance and
Lubrication.
- Install
the clutch shaft pilot bearing using the J 33842
.
- Install the clutch shaft to the differential carrier.
- Install the vent hose connector.
Tighten
Tighten the vent hose connector to 28 N·m (21 lb ft).
- Install the new left side axle shaft seal using the J 36600
, 8.25 inch axle, or the J 22833
, 9.25 inch axle.
- Install the new left side inner axle shaft retainer ring.
- Install the left side inner axle shaft by doing the following:
| 16.1. | Install the left side inner shaft into the differential carrier assembly
until the inner shaft is seated against the differential side gear. |
| 16.2. | 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. |
| 16.3. | Drive the inner shaft into the differential case side gear using a soft-faced
mallet until the retaining ring on the inner shaft is fully seated within the groove
in the differential case side gear. |
Pull back on the inner shaft to ensure that the inner shaft is properly retained
in the differential case side gear.
- Install the right side bearing by performing the following steps:
| 17.1. | Install the inner axle shaft housing into a vise. |
Clamp only on the mounting flange of the inner axle shaft housing.
| 17.2. | Install the bearing with the square shoulder in using the J 36609
(1) and the J 8092
(2). |
- Install the right side inner axle shaft seal by performing the following
steps:
| • | Install the inner axle shaft housing into a vise. |
| • | Clamp only on the mounting flange of the inner axle shaft housing. |
| • | Install the new axle shaft seal using the J 36600
, 8.25 inch axle, or the J 22833
, 9.25 inch axle. |
- Install the inner axle shaft into the inner axle shaft housing.
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.
- For the 8.25 inch axle, assemble
the following components into the inner axle shaft housing:
| 20.1. | Install the thrust washer (5) into the inner axle shaft housing (4). |
Ensure the tabs on the thrust washer align with the slot in the inner axle shaft
housing.
| 20.2. | Install the new retainer ring (7) onto the clutch gear (6). |
| 20.3. | Install the clutch gear (6) onto the inner axle shaft (1). |
Drive the clutch gear into place with a plastic hammer.
| 20.5. | Install the clutch gear shim (9). |
| 20.6. | Install the clutch sleeve (8). |
| 20.7. | Install the clutch fork assembly (11). |
| 20.8. | Install the clutch fork inner spring (10). |
Important: Use chassis grease in order to hold the thrust washer in place.
- For the 9.25 inch axle, install the
following components into the inner axle shaft housing:
| 21.1. | Install the thrust washer (5) into the inner axle shaft housing (4). |
Ensure the tabs on the thrust washer align with the slot in the inner axle shaft
housing.
| 21.2. | Install the second thrust washer (6) into the inner axle shaft
housing. |
| 21.3. | Install the new retainer ring (7) onto the inner axle shaft (1). |
| 21.5. | Install the clutch gear shim (9). |
| 21.6. | Install the clutch sleeve (8). |
| 21.7. | Install the clutch fork assembly (11, 12, 13, 14). |
| 21.8. | Install the clutch fork inner spring (10). |
- Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent
to the inner axle housing to differential carrier sealing surface.
- Install the inner axle shaft housing to
the differential carrier case.
- Install the inner axle shaft housing bolts.
Tighten
Tighten the inner axle shaft housing bolts to 40 N·m (30 lb ft).
- Install the drain plug and the washer.
- Install the fill plug and the washer.
Tighten
Tighten the drain plug and the fill plug to 33 N·m (24 lb ft).
- Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent
to the threads of the front axle actuator.
- Install the front drive axle actuator.
Tighten
Tighten the front drive axle actuator to 20 N·m (15 lb ft).
- Install the lower differential carrier assembly
bushing by performing the following steps:
| 29.1. | 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. |
| 29.2. | 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. |
- Install the upper differential carrier assembly bushing by performing the following
steps:
| 30.1. | 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. |
| 30.2. | 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. |
