Differential Carrier Assembly Assemble

Differential Carrier Assembly Assemble

Special Tools

* J 8092 - Universal Driver Handle - 3/4 in - 10

* J 8614-01 - Flange and Pulley Holding Tool

* J 23423-A - Case Bearing Race Installer

* J 33782 - Pinion Oil Seal Installer

* J 33785 - Pinion Bearing Installer

* J 45224 - Side Bearing Adjuster

* J 45232 - Differential Bearing Adjuster Needle Bearing Installer - LH

For equivalent regional tools, refer to Special Tools Front Drive Axle.

1. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.




2. Install the inner pinion bearing (2) onto the pinion gear using the J 33785 - installer (1).




3. Install the new collapsible spacer onto the pinion gear.

4. Lubricate the inner and the outer pinion bearings with the proper axle lubricant. Refer to Fluid and Lubricant Recommendations Fluids.




5. Install the outer pinion bearing.




6. Install the oil seal by doing the following:

1. Position the oil seal in the bore.

2. Install the J 33782 - installer over the oil seal.

3. Strike the J 33782 - installer with a hammer until the seal flange seats on the axle housing surface.

7. Install the pinion gear, the selectable shim with inner pinion bearing and the new collapsible spacer, into the left differential carrier case.

8. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.

Caution: Refer to Pinion Flange/Yoke Installation Caution Pinion Flange/Yoke Installation Caution.

9. Install the pinion yoke.

10. Install the washer and a new pinion nut.
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 new pinion nut can be installed:

1. Remove the pinion nut washer.

2. Install the old pinion nut.

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

4. Remove the old pinon nut.

5. Install the pinion nut washer

6. Install the new pinion nut.




11. Install the J 8614-01 - holding tool onto the pinion yoke as shown.

Caution: Refer to Fastener Caution Fastener Caution.

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

12. Tighten the pinion nut while holding the J 8614-01 - holding tool.
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

13. Measure the rotating torque of the pinion using an inch-pound torque wrench.

The rotating torque of the pinion should be 1.7-3.4 Nm (15-30 lb in) for new bearings or 1.0-2.3 Nm (10-20 lb in) for used bearings.

14. If the rotating torque measurement is below 1.7 Nm (15 lb in) for new bearings or 1.0 Nm (10 lb in) for used bearings, continue to tighten the pinion nut.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.7-3.4 Nm (15-30 lb in) for new bearings or 1.0-2.3 Nm (10-20 lb in) for used bearings.

15. 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.




16. Install the left side differential carrier bearing, print side out, to the left side differential adjuster using the J 45232 - installer - LH (2) and the J 8092 - driver handle - 3/4 in - 10 (1).




17. Install the left inner shaft bearing and the differential bearing adjuster into the left differential carrier case using the J 45224 - adjuster.

18. Install the left differential case bearing cup into the left differential carrier assembly case half using the J 23423-A - installer and the J 8092 - driver handle - 3/4 in - 10.




19. Install the right differential bearing adjuster into the differential case half using the J 45224 - adjuster.




20. Install the right differential case side bearing cup into the right differential carrier case half using the J 23423-A - installer (2) and the J 8092 - driver handle - 3/4 in - 10 (1).

21. Install the differential case assembly into the left differential carrier case half.

22. 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, back out the right differential adjuster nut using the J 45224 - adjuster.

23. Install the differential carrier case bolts and tighten to 48 Nm (35 lb ft).




24. Turn the right side differential adjuster nut sleeve clockwise 11/2 revolutions using the J 45224 - adjuster.




25. Using the J 45224 - adjuster , turn the left differential adjuster nut sleeve clockwise in order to preload the differential side bearings against the differential side bearing cups and tighten to 75 Nm (55 lb ft).

26. Rotate the pinion several times in order to seat the pinion and differential side bearings.

27. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench.

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

28. If the rotating torque measurement is below 2.8 Nm (25 lb in) for used bearings, or 3.4 Nm (30 lb in) for new bearings, adjust the differential side bearing preload using the following steps:

1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.

2. Using the J 45224 - adjuster , turn the left and the right side differential adjuster nut sleeves in or clockwise one notch.

3. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

4. Compare the new measurement to the specification listed in step 29, if the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side 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

29. If the rotating torque measurement is above 5.1 Nm (45 lb in) for used bearings, or 6.2 Nm (55 lb in) for new bearings, adjust the differential side bearing preload using the following steps:

1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.

2. Using the J 45224 - adjuster , turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch.

3. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

4. Compare the new measurement to the specification listed in step 29, if the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side 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

30. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated.
Recheck the rotating torque and adjust if necessary.

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