GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1998 🢒 GMC Suburban - 2WD 🢒 Driveline/Axle 🢒 Front Drive Axle 🢒 Differential Carrier Assembly Final Assembly

Tools Required

    • 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. 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.

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

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

  3. Install the differential adjuster nut lock bolt.

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


    Object Number: 1332740 Size: SH
  4. Remove the differential carrier assembly bolts.

    5. Object Number: 1332738 Size: SH
  5. Remove the right differential carrier case half.
  6. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly.

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

  7. Apply a bead of sealer to 1 differential carrier case half sealing surface. Use the correct sealer. Refer to Sealers, Adhesives, and Lubricants .
  8. Install the right differential carrier case half.
  9. Install the differential carrier case bolts.

    10. Tighten
    Tighten the differential carrier case bolts to 47 N·m (35 lb ft).

  10. Lubricate the clutch shaft pilot bearing with axle lubricant. Use the correct fluid. Refer to Sealers, Adhesives, and Lubricants .

    11. Object Number: 695745 Size: SH
  11. Install the clutch shaft pilot bearing using the J 33842 .

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

    13. Object Number: 847064 Size: SH
  13. Install the vent hose connector.

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


    Object Number: 1486568 Size: SH
  14. Install the new left side axle shaft seal using theJ 45225  (1) and the J 8092  (2).
  15. Install the new left side inner axle shaft retainer ring.

    16. Object Number: 1332794 Size: SH
  16. Install the left side inner axle shaft by doing the following:
    17. 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.


    Object Number: 834254 Size: SH
  17. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
    18. 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).

    Object Number: 1486575 Size: SH
  18. Install the new right side inner axle shaft seal using the J 45225  (1) and the J 8092  (2).
  19. Install the inner axle shaft into the inner shaft housing.

    20. Carefully tap the inner axle shaft into place with a soft-faced mallet.


    Object Number: 892810 Size: SH
  20. For the 8.25 inch axle, assemble the following components into the inner shaft housing:
    21. 20.1. Install the inner axle shaft (1).
    20.2. Place the inner axle housing on end so that the splines of the inner axle shaft are facing up.

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

    20.3. Install the thrust washer (5).

    Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing (4).

    20.4. Install the new retainer ring (7) into the clutch gear (6).
    20.5. Install the clutch gear (6) onto the inner axle shaft (1).

    Drive the clutch gear into place with a plastic hammer.

    20.6. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    20.7. Install the clutch gear shim (9).
    20.8. Install the clutch sleeve (8).
    20.9. Install the clutch fork assembly (11).
    20.10. Install the clutch fork inner spring (10).

    Object Number: 892812 Size: SH
  21. For the 9.25 inch axle, install the following components into the inner shaft housing:
    22. 21.1. Install the inner axle shaft (1).
    21.2. Place the inner axle housing on end so that the splines of the inner axle shaft are facing up.

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

    21.3. Install the thrust washer (5).

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

    21.4. Install the second thrust washer (6) into the inner axle shaft housing.
    21.5. Install the new retainer ring (7) onto the inner axle shaft (1).
    21.6. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    21.7. Install the clutch gear shim (9).
    21.8. Install the clutch sleeve (8).
    21.9. Install the clutch fork assembly (11).
    21.10. Install the clutch fork inner spring (10).
  22. Apply sealant to the inner shaft housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .

    23. Object Number: 893259 Size: SH
  23. Install the inner shaft housing to the differential carrier assembly case.
  24. Install the inner shaft housing bolts.

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

  25. Install the drain plug and the washer.
  26. Install the fill plug and the washer.

    27. 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
  27. Install the front drive axle actuator.

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

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


    Object Number: 892851 Size: SH
  28. Install the lower differential carrier assembly bushing by performing the following steps:
    29. 28.1. 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.
    28.2. 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
  29. Install the upper differential carrier assembly bushing by performing the following steps:
    30. 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.