Tools Required

1. Install the pinion bearing cups into the differential carrier assembly. Refer to Front Differential Drive Pinion Gear Bearing Cup Installation .
2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.



3. Install the inner pinion bearing onto the pinion gear using the J 36614 .
4. Install the new collapsible spacer onto the pinion gear.
5. Lubricate the pinion bearings with axle lubricant, GM P/N 12378261 (Canadian P/N 10953455) or equivalent meeting GM Specification 9986115.



6. Install the outer pinion bearing into the left differential carrier case half.



7. Install the pinion oil seal using J 36366 .



8. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.



10. Install the pinion yoke.

Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.



12. Install the washer.



13. Install the new pinion nut.
14. If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and the new pinion nut can be installed:

14.1.

Remove the pinion nut washer.

14.2.

Install the old pinion nut.

14.3.

Tighten the nut until a few of the shaft threads show through the nut so that the washer and the new pinion nut can be installed.

14.4.

Remove the old pinion nut.

14.5.

Install the pinion nut washer.

14.6.

Install the new pinion nut.




15. Install the J 8614-01 onto the pinion yoke as shown.

Notice: Refer to Fastener Notice in the Preface section.

Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

16. Tighten the pinion nut while holding the J 8614-01 .

Tighten
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

17. Remove the J 8614-01 .
18. Measure the rotating torque of the pinion using an inch-pound torque wrench.

Specification
The rotating torque of the pinion should be 1.1-2.3 N·m (10-20 lb in) for used bearings, or 1.7-3.4 N·m (15-30 lb in) for new bearings.

19. If the rotating torque measurement is below 1.0 N·m (10 lb in) for used bearings, or 1.7 N·m (15 lb in) for new bearings, re-install the J 8614-01 and continue to tighten the pinion nut.

Tighten
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.1-2.3 N·m (10-20 lb in) for used bearings, or 1.7-3.4 N·m (15-30 lb in) for new bearings.

20. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.

21. Remove the J 8614-01 .
22. Assemble the right side differential adjuster nut into the differential nut sleeve until fully seated.
23. Install the right side differential adjuster nut assembly and the new adjuster lock nut tab into the right side differential carrier case half.



24. Drive the right side differential adjuster nut assembly and the new adjuster lock nut tab into the differential carrier case half until seated using the J 36609  (2) and the J 8092  (1).



25. Install the right side differential case side bearing cup into the differential carrier case using the J 36603  (2) and the J 8092  (1).
26. Install the left side differential adjuster nut assembly into the left side differential carrier case half.



27. Install the left side axle shaft bearing into the differential adjuster nut sleeve using the J 36609  (2) and the J 8092  (1).



28. Install the differential case assembly into the left differential carrier case half.
29. Install the right differential carrier case half to the left differential carrier case half.

Do not use sealer at this time.

If the carrier case halves do not make complete contact, use the J 36599-A in order to back out the right differential adjuster nut sleeve.

30. Install the differential carrier case bolts.

Tighten
Tighten the differential carrier case bolts to 78 N·m (58 lb ft).

31. Install the differential carrier assembly into a vise.



32. Turn the left side differential adjuster nut sleeve in using the J 36615 until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
33. Turn the right side differential adjuster nut sleeve in using the J 36599-A until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
34. Rotate the pinion several times in order to seat the bearings.
35. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

Specification
The rotating torque of the pinion and differential assembly should be 2.8-5.1 N·m (25-45 lb in) for used bearings, or 3.4-6.2 N·m (30-55 lb in) for new bearings.

36. If the rotating torque measurement is below 2.8 N·m (25 lb in) for used bearings, or 3.4 N·m (30 lb in) for new bearings, tighten the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
37. If the rotating torque measurement is above 5.1 N·m (45 lb in) for used bearings, or 6.2 N·m (55 lb in) for new bearings, loosen the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
38. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.

39. Measure the drive pinion to ring gear backlash. Refer to Backlash Inspection and Adjustment .