Special Tools

1. Remove the differential side bearings as appropriate.
2. Remove the inboard spacer.



3. Remove the ring gear bolts.

Discard the ring gear bolts.

Caution: Do not pry the ring gear from the case. This will damage the ring gear and differential case.

4. Remove the ring gear from the differential case assembly.



5. Remove the pinion shaft lock pin using a hammer and a punch.



6. Remove the pinion shaft using a hammer and brass drift.




Note: Mark the pinion gears and the thrust washers top and bottom.

7. Rotate the side gears until the pinion gears are in the opening of the case. Remove the pinion gears and thrust washers.

Note: Mark the side gears and the thrust washers left and right

8. Remove the side gears and the thrust washers.

1. Lubricate all parts with an axle lubricant, GM P/N 12345841 (Canadian P/N 10953512) or equivalent.
2. Install new thrust washers to the new side gears.

Note: Install the side gears to the same side that the side gears were on when removed.

3. Install the side gears to the differential case assembly.

Note: Install the pinion gears to the same side that the pinion gears were on when removed.

4. Install the new pinion gears to the differential without the thrust washers.

4.1.	Install the pinion gears to the side gears so that the holes in the pinion gears are 180 degrees apart.

4.2.	Rotate the pinion gears into place. Verify that the pinion gears line up with the pinion shaft holes.

5. Rotate the pinion gears toward the differential opening in order to allow enough space for the pinion gear thrust washers to slide in.
6. Install the new pinion gear thrust washers.
7. Rotate the pinion gears into place. Verify that the pinion gears line up with the pinion shaft holes.
8. Install the new pinion shaft.
9. Align the pinion shaft lock pin hole with the hole in the differential case assembly and the pinion shaft.



10. Install the new pinion shaft lock pin.
11. Peen the metal from the case over the pinion shaft lock pin in 2 places that are 180 degrees apart.




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

12. Install the ring gear to the differential case assembly.

Align the holes in the differential case assembly and the holes in the ring gear.

Caution: Refer to Fastener Caution in the Preface section.

13. Install new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case assembly.

Tighten
Tighten the ring gear bolts in sequence to 298 N·m (220 lb ft).

Note: The inboard spacer must be the same size as the spacer that was removed.

14. Install one new hardened 0.689-0.838 mm (0.027-0.033 in) inboard spacer onto each side of the differential case assembly.

Measure the spacer thickness using a micrometer to verify the spacer size.




15. Install the differential side bearing by doing the following:

15.1.

In order to protect the differential case, install the J 8107-3 in the case on the side opposite of the bearing installation.

15.2.

Install the differential side bearing.

15.3.

Install the J 24430  (2) and the J 8092  (1) over the differential side bearing.

15.4.

Drive the differential side bearing into position using the J 24430 and the J 8092 .