Differential Replacement Except Dana 286 Axle

1. Clean the rear axle housing with steam.

Important: Shift the two speed rear axle into LOW range, if equipped.

2. Block the wheels.
3. Remove the rear axle housing drain plug.
4. Remove the propeller shaft. Refer to the following list in order to select the correct procedure:

•	One-Piece Propeller Shaft Replacement in Propeller Shaft

•	Two-Piece Propeller Shaft Replacement in Propeller Shaft

•	Three-Piece Propeller Shaft Replacement in Propeller Shaft

•	Four-Piece Propeller Shaft Replacement in Propeller Shaft

•	Tandem Axle Propeller Shaft Replacement in Propeller Shaft

5. Remove the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
6. Remove the shift motor assembly, if equipped. Refer to Two Speed Rear Axle Shift Motor Replacement .



7. Remove the following components from the differential carrier assembly:

•

The bolts

•	The washers

•	The stud nuts, if equipped

•	Do not remove the top 2 fasteners.

8. Support and secure the differential carrier assembly to a floor jack.

8.1.	Remove the top 2 fasteners.

8.2.	Remove the differential carrier assembly.

9. Clean the axle housing and the differential carrier assembly mating surfaces.
10. Clean the axle housing bowl interior using Engine Degreaser GM P/N 1050436 (Canadian P/N 992878) or the equivalent. Dry the housing bowl immediately with clean rags and compressed air.
11. Inspect the axle housing for the following conditions:

•

Cracks

•	Loose Studs

•

Nicks

•

Burrs

Important: 

1. Install the Silicone Sealer (RTV) GM P/N 1052366 or equivalent on the rear axle housing surface.
2. Install the differential carrier assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: 

•	Ensure that the threads are clean and free of grease.

•	Apply 272 Threadlocker GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of each differential carrier bolt.

3. Install the following differential carrier components:

•	The washers

•

The bolts

•	The nuts, if equipped

Tighten
Tighten the differential carrier bolts and nuts to the torques listed in Fastener Tightening Specifications .

4. Install the rear axle shift motor assembly, if equipped. Refer to Two Speed Rear Axle Shift Motor Replacement .
5. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
6. Install the propeller shaft.
7. Install the propeller shaft. Refer to the following list in order to select the correct procedure:

•	One-Piece Propeller Shaft Replacement in Propeller Shaft

•	Two-Piece Propeller Shaft Replacement in Propeller Shaft

•	Three-Piece Propeller Shaft Replacement in Propeller Shaft

•	Four-Piece Propeller Shaft Replacement in Propeller Shaft

•	Tandem Axle Propeller Shaft Replacement in Propeller Shaft

8. Install the rear axle lubricant. Refer to Rear Axle Lubricant Level Inspection .
9. Remove the wheel blocks.

Differential Replacement Dana 286 Axle

Tools Required

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
3. Loosen the bearing cap bolts.

Do not remove the bearing cap bolts at this time.




4. Install the J 24385-C onto the axle housing as shown.



5. Install the J 25025  (2), the J 8001-1 and the J 8001-2  (1), the J 34178  (3), and the J 8001-3 and the J 8001-4  (4) onto the axle housing as shown.
6. Preload the dial of the J 8001-3 by pushing the J 8001-3 against the edge of the J 24385-C until the needle of the J 8001-3 has moved approximately 3/4 of a turn clockwise.
7. Rotate the indicator housing to align the indicator needle of the J 8001-3 and the dial indicator face to ZERO.

Notice: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.

8. Spread the axle housing by turning the clevis screw of the J 24385-C clockwise while observing the J 8001 .

Spread the housing just enough to remove the differential assembly.

9. Remove the J 25025-B , the J 8001-1 , the J 8001-2 , the J 34178 , the J 8001-3 and the J 8001-4 from the axle housing.
10. Remove the bearing cap bolts.

Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Important: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.

11. Remove the bearing caps.
12. Remove the differential assembly.
13. Remove the J 24385-C .
14. Remove the ring gear. Refer to Drive Pinion and Ring Gear Replacement .
15. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .

1. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
2. Install the ring gear. Refer to Drive Pinion and Ring Gear Replacement .
3. Determine the differential side bearing shim pack size and side bearing preload for the differential assembly. Refer to Differential Carrier Bearing Preload Adjustment .
4. Install the J 24385-C onto the axle housing.



5. Install the J 25025-B  (4), the J 8001-1 and the J 8001-2  (5, 1), the J 34178  (2), and the J 8001-3 and the J 8001-4  (3) onto the axle housing as shown.
6. Preload the dial of the J 8001-3 by pushing the J 8001-3 against the edge of the J 24385-C until the needle of the J 8001-3 has moved approximately 3/4 of a turn clockwise.
7. Rotate the indicator housing to align the indicator needle of the J 8001-3 and the dial indicator face to ZERO.

Notice: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.

8. Spread the axle housing by turning the clevis screw of the J 24385-C clockwise while observing the J 8001 .

Spread the housing just enough to install the differential assembly.

9. Remove the J 25025-B , the J 8001-1 , the J 8001-2 , the J 34178 , the J 8001-3 and the J 8001-4 from the axle housing.
10. Install the differential assembly.
11. Remove the J 24385-C .

Important: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.

12. Install the bearing caps.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

13. Install the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 108 N·m (80 lb ft).

14. Install the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
15. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement .
16. Lower the vehicle.