GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 Savana - AWD 🢒 Driveline/Axle 🢒 Front Drive Axle 🢒 Differential Carrier Assembly Final Assembly

Tools Required

    • J 42211 Axle Bearing Installer
    • J 42738 Seal Installer
    • J 45850 Front Axle Bushing Remover/Installer
    • J 8092 Universal Driver Handle - ¾ in - 10

    Object Number: 896913 Size: SH
  1. Install the right side differential adjuster lock over the differential bearing adjuster.

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


    Object Number: 896915 Size: SH
  2. Install the right side differential bearing adjuster lock bolt.

    3. Tighten
    Tighten the right side differential bearing adjuster lock bolt to 8 N·m (71 lb in).


    Object Number: 892677 Size: SH
  3. Install the left side differential bearing adjuster lock over the differential adjuster.

    4. Object Number: 892676 Size: SH
  4. Install the left side differential bearing adjuster lock bolt.

    5. Tighten
    Tighten the left side differential bearing adjuster lock bolt to 8 N·m (71 lb in).


    Object Number: 892681 Size: SH
  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.

    8. 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.

    11. Tighten
    Tighten the differential carrier case bolts to 48 N·m (35 lb ft).


    Object Number: 892385 Size: SH
  11. Install the lower inner shaft housing bushing by performing the following steps:
    12. 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.


    Object Number: 892380 Size: SH
  12. Install the upper inner shaft housing bushing by performing the following steps:
    13. 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.

    Object Number: 892394 Size: SH
  13. Install the bearing with the square shoulder in using the J 42211  (2) and the J 8092  (1).

    14. Object Number: 892397 Size: SH
  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. Object Number: 892376 Size: SH
  19. Install the inner shaft housing to differential carrier assembly bolts.

    20. Tighten
    Tighten the inner shaft housing to differential carrier assembly bolts to 48 N·m (35 lb ft).

  20. Install the new inner shaft retaining ring.

    21. Object Number: 892402 Size: SH

    Important: 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:
    22. 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.

    Object Number: 892674 Size: SH
  22. Install the inner shaft seal cover.

    23. Object Number: 892661 Size: SH
  23. Install the inner shaft seal cover bolts.

    24. Tighten
    Tighten the inner shaft seal cover bolts to 18 N·m (13 lb ft).

  24. Install the new inner shaft retaining ring.

    25. Object Number: 892655 Size: SH

    Important: 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:
    26. 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.

    Object Number: 897615 Size: SH
  26. Install the lower differential carrier assembly bushing by performing the following steps:
    27. 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 .

    Object Number: 893246 Size: SH
  27. Install the upper differential carrier assembly bushing by performing the following steps:
    28. 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.

    29. Tighten
    Tighten the drain plug 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.

    31. Tighten
    Tighten the fill plug to 33 N·m (24 lb ft).