Rear Drive Axle Chevrolet Avalanche II

Axle Preload and Backlash Specifications

Differential Adjustment Shim Specifications

8.6 Inch Axle Differential Adjustment Shims Specifications

9.5/9.5LD Inch Axle Differential Adjustment Shims Specifications

Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers

Locking Differential Thrust Block Sizes

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Diagnostic Starting Point - Locking/Limited Slip Rear Axle

Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exist. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Locking/Limited Slip Rear Axle in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Locking/Limited Slip Rear Axle in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Symptoms - Locking/Limited Slip Rear Axle

Review the system and operation in order to familiarize yourself with the system functions. Refer to Locking Differential Description and Operation .

Visual/Physical Inspection

1. Inspect the system for the following: Loose or missing fasteners Obvious damage or conditions which may cause the symptom.
2. Check the system for proper operation. Refer to «Locking Differential Diagnosis»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-diagnosis) .

Symptom List

Refer to a system diagnostic procedure from the following list in order to diagnose the symptom

1. Locking Rear Axle Does Not Lock
2. Locking Rear Axle Locks in Turns
3. «Locking Rear Drive Axle Chatters in Turns»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle)
4. «Noise in Addition to Normal Clutch Engagement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__noise-in-addition-to-normal-clutch)

Review the system and operation in order to familiarize yourself with the system functions. Refer to Rear Drive Axle Description and Operation .

Rear Axle Noise

The proper diagnosis is an important part of rear axle repair. In axle work, one of the most difficult conditions to diagnose is noise. Locating a broken axle shaft or broken differential gear presents little or no problems, but locating and isolating axle noise can be an entirely different matter.

Any gear driven unit, especially an automotive drive axle where the engine torque multiplication occurs at a 90 degree turn in the driveline, produces a certain amount of noise. Therefore, an interpretation must be made for each vehicle in order to determine where the noise is normal or if a problem actually exists. A certain amount of noise must be expected and cannot be eliminated by conventional repairs or adjustment.

Normal axle noise can be described as a slight noise heard only at a certain speed or under unusual or remote conditions. For example, the noise tends to reach a peak at speeds from 60-100 km/h (40-60 mph) depending on road and load conditions, or on gear ratio and tire size. This slight noise is in no way indicative of trouble in the axle assembly.

Driveline noises may confuse even the best technician. Vehicle noises coming from tires, transmission, propeller shaft, universal joints, and front or rear wheel bearings are often mistaken for axle noise.

1. Inspect the system for loose or missing fasteners.
2. Inspect the system for leaking components.
3. Inspect the system for obvious damage or conditions which may cause the symptom.

Refer to a system diagnostic procedure from the following list in order to diagnose the symptom

1. «Rear Drive Axle Noises»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle)
2. «Noisy in Drive»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__noisy-in-drive)
3. «Noisy When Coasting»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__noisy-when-coasting)
4. «Intermittent Noise»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__intermittent-noise)
5. «Constant Noise»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__constant-noise)
6. «Noisy on Turns»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__noisy-on-turns)

Gear Noise

Gear noise or whine is audible from 32-89 km/h (20-55 mph) under 4 driving conditions

1. Drive- Acceleration or heavy pull
2. Road Load-Vehicle driving load or constant speed
3. Float-Using enough throttle to keep the vehicle from driving the engine, the vehicle slows down gradually but the engine still pulls slightly
4. Coast-Throttle is closed and the vehicle is in gear

Gear noise most frequently has periods where the noise is more prominent, usually between 48-64 km/h (30-40 mph) and 80-85 km/h (50-53 mph). Gear whine is corrected by either ring and pinion gear replacement or adjustment, depending on the mileage of the gearset.

Bearing Noise

Faulty bearings produce a rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise/hum will pulsate at a constant vehicle speed. This indicates a bad pinion or a bad rear axle side bearing. This noise can be confused with rear wheel bearing noise. Inspect and replace the bearings and the affected components as required.

Rear Wheel Bearing Noise

A rough rear wheel bearing produces a noise which continues with the car coasting at low speed and the transmission in neutral. The noise may diminish some when the brakes are gently applied. The noise may also change when performing side-to-side maneuvers with the vehicle.

A rough/noisy rear wheel bearing can be heard by spinning the rear wheels by hand and listening at the hubs for the noise. Inspect and replace the bearings and the affected components as needed.

Knock at Low Speeds

A low speed knock can be caused by a differential case side gear bore that has worn oversize. Inspect the side gears and differential case and replace the components as necessary.

Backlash Clunk

Excessive backlash clunk under acceleration or deacceleration can be caused by any of the following

1. Worn differential pinion shaft
2. Worn differential pinion and/or side gear teeth
3. Worn thrust washers
4. Excessive clearance between the side gears and the axle shafts
5. Excessive clearance between differential side gears and the bore in the case
6. Excessive drive pinon and ring gear backlash

Inspect, adjust or replace the affected components as necessary.

Noisy in Drive

Noisy When Coasting

Intermittent Noise

Constant Noise

Noisy on Turns

Straight Roller Bearing Diagnosis

Consider the following factors when diagnosing a bearing condition

1. Note the general condition of all parts during disassembly and inspection.
2. Classify the failure with the aid of the illustrations.
3. Determine the cause.
4. Make all repairs following recommended procedures.

Scheme 6

Light pattern on races and rollers can be caused by fine abrasives. Clean all of the parts including the housings. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 7

Heavy pattern on races and rollers can be caused by fine abrasives. Clean all of the parts including the housing. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 8

Surface indentations in the raceway can be caused by roll either under impact loading or vibration while the bearing is not rotating. Replace the bearing if rough or noisy. Replace the shaft if damaged.

Scheme 9

Surface depressions on race and rollers can be caused by hard particles of foreign material. Clean all of the parts, including the housing. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 10

Flaking of surface metal results from fatigue, usually at one edge of race and rollers. Replace the bearing. Clean all related parts. Replace the shaft if damaged.

Scheme 11

Flaking of surface metal results from fatigue, usually at both edges of the race and rollers. Replace the bearing. Clean all related parts. Replace the shaft if damaged.

Scheme 12

Outer misalignment due to a foreign object. Replace the bearing. Ensure races are properly seated. Replace the shaft if the bearing operating surface is damaged.

Scheme 13

Corrosion set up by a small relative movement of parts with no lubrication. Replace the bearing. Clean all the relative parts. Check the seals. Check for proper fit and lubrication. Replace the shaft if damaged.

Scheme 14

Smearing of metal due to slippage. Slippage can be caused by poor fits, lack of lubrication, overheating, overloads or handling damage. Replace the bearing. Clean all the related parts. Check for proper fit and lubrication.

Tapered Roller Bearing Diagnosis

Consider the following factors when diagnosing bearing condition

1. General condition of all parts during disassembly and inspection
2. Classify the failure with the aid of the illustrations.
3. Determine the cause.
4. Make all repairs following recommended procedures.

Scheme 15

Pattern on the races and the rollers caused by fine abrasives. Clean all of the parts and the housings. Check the seals and the bearings. Replace any leaky, rough, or noisy bearings.

Scheme 16

Pattern on the roller ends caused by fine abrasives. Clean all of the parts and the housings. Check the seals and the bearings. Replace any leaky, rough, or noisy bearings.

Scheme 17

Metal smears on the roller ends due to overheating, lubricant failure, or lubricant overload. Replace the bearing. Check the seals. Check for proper lubrication.

Scheme 18

Bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. Replace the bearings. Check the seals. Check for proper lubrication.

Scheme 19

A damaged cage due to improper handling or improper tool usage. Replace the bearing.

Scheme 20

Wear around the outside diameter of the cage and the roller pockets caused by abrasive material. Wear caused from inefficient lubrication. Clean the related parts and the housings. Check the seals. Replace the bearings.

Scheme 21

Surface depressions on the race and the rollers caused by hard particles of foreign matter. Clean all the parts and the housings. Check the seals. Replace rough or noisy bearings.

Scheme 22

Corrosion caused by small relative movement of parts with no lubrication. Replace the bearing. Clean the related parts. Check the seals. Check for proper lubrication.

Scheme 23

Smearing of the metal due to slippage. Slippage can be caused by the following factors

1. Poor fits
2. Lubrication
3. Overheating
4. Overloads
5. Handling damage

Replace the bearings. Clean the related parts. Check for proper fit and lubrication.

Scheme 24

Discoloration ranging from light brown to black. This discoloration is caused from incorrect lubrication or moisture. Reuse the bearing if you can remove the stains with light polishing. Reuse the bearing if there is no evidence of overheating. Check the seals and the related parts for damage.

Scheme 25

Heat discoloration ranges from faint yellow to dark blue. This discoloration results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal. A file drawn over a hard part will glide readily with no metal cutting. Replace the bearings if overheating damage is indicated. The tempered part will fail the file test. Check the seals and the other related parts.

Scheme 26

A misaligned outer race due to a foreign object. Clean the related parts. Replace the bearing. Ensure the races are properly sealed.

Scheme 27

Cracked race due to improper fit, cocking, or poor bearing seats. Replace the bearing. Correct bearing seats.

Scheme 28

Flaked surface metal that results from fatigue. Replace the bearing. Clean all related parts.

Scheme 29

Surface indentations in the race way caused by the rollers under impact loading or caused from vibration while the bearing is not rotating. Replace a rough or noisy bearing.

Rear Axle Lubricant Leak Diagnosis

Rear axle lubricant leaks can occur at the following locations

1. Axle tube to differential carrier housing joint
2. Axle shaft oil seal
3. Axle housing porosity
4. Differential housing cover gasket
5. Drain plug
6. Fill plug
7. Pinion yoke oil seal
8. Vent tube

Determining the Cause

While most rear axle leaks may be easy to find, determining the cause may not be. A thorough inspection of the area around the leak may assist in determining the cause of the leak.

Oil Seals

Lubricant leaks from a oil seal may be caused by any of the following

1. An improperly installed seal
2. A distorted seal
3. A worn seal
4. A worn shaft
5. A brittle seal lip
6. A hardened seal lip

To determine the actual cause of the leak, clean the area around the leak. Observe the area of the leak and determine the if the seal or another component is causing the leak. A worn seal surface will cause a leak at the sealing lip while a misaligned seal or a seal installed into a housing with an excessive bore will cause the seal to leak at the outside surface of the seal. Hardened or cracked seal lips usually indicate the axle is operating beyond the normal temperature limits for the axle. A seal whose sealing surface has been nicked or cut may indicate that the shaft has a rough, burred, or gouged surface and will need to be inspected before the seal can be replaced.

Gaskets

A leak at a gasket is usually caused by a poor fit of the components on each side of the gasket surface. Inspect each component for distortion and for nicks or gouges that may prohibit the gasket from sealing properly.

Rear Axle Housing

Rear axle housing lubricant leaks usually occur at the following locations

1. Drain Plug
2. Fill Plug

Drain and fill plug leaks are usually caused by a loose plug. These leaks can by repaired by either tightening the plug or by using an approved sealer on the threads on the plug.

Other leaks such as axle tube to differential carrier housing or porosity leaks require the replacement of the rear axle housing.

Locking Differential Diagnosis

1. Place the vehicle on a frame-contact hoist, allowing free rotation of the rear wheels.
2. Hold 1 wheel stationary. Slowly rotate the other wheel approximately 1/2 revolution per second in both the forward and reversed directions. The wheel should rotate freely. The differential is locking and is broken if both wheels attempt to turn together.
3. Raise the hoist to maximum height with 1 person in the vehicle.
4. Start the engine. Ensure that the engine is operating at low idle speed (warm engine).
5. Apply the service brake. Place the automatic transmission in drive. Depress the clutch and place the transmission in first gear with a manual transmission.
6. Lock 1 rear wheel by pulling one parking brake cable from under the vehicle with the aid of an assistant.
7. Release the service brakes or disengage the clutch slowly enough to start the free wheel turning. The locked rear wheel remains stationary.
8. Increase the speed of the free wheel. The differential will lock, causing the rotating wheel to stop or both wheels to turn at the same speed. The engine, if equipped with manual transmission, may stall. In order to cause the differential to lock, you may need to accelerate the engine until approximately 16 km/h (10 mph) is indicated on the vehicle speedometer. If the indicated speed can be increased beyond 32 km/h (20 mph) without causing the differential to lock, the unit is not functioning properly. Rapid release of the brakes or clutch, or rapid acceleration of the engine, will invalidate the test.
9. Lock the opposite rear wheel and repeat the procedure.

Locking Rear Axle Does Not Lock

Locking Rear Axle Locks in Turns

Noise in Addition to Normal Clutch Engagement

Rear Axle Lubricant Level Inspection (10.5 Inch Axle)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Make sure the vehicle is level.
3. Clean the area around the rear axle fill plug.
4. Remove the rear axle fill plug 1 and inspect the lubricant level.
5. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
6. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
7. Install the rear axle fill plug 1 and tighten to 33 N.m (24 lb ft).
8. Remove the support and lower the vehicle.

Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)

Note. All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Ensure the vehicle is level.
3. Inspect the rear axle for leaks. Repair as necessary.
4. Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug.
6. Inspect the lubricant level: Specification: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. Specification: The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle.
7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
8. Install the rear axle fill plug and tighten to 33 N.m (24 lb ft).
9. Lower the vehicle.

Removal Procedure

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the fill plug (1).
3. Remove the rear axle drain plug (1).
4. Drain the lubricant into a suitable container.

Installation Procedure

1. Install the rear axle drain plug and tighten to 33 N.m (24 lb ft).
2. Fill the rear axle with the proper fluid. Refer to «Approximate Fluid Capacities»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) and «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
3. Install the fill plug and tighten to 33 N.m (24 lb ft).
4. Remove the support and lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug.
4. Remove the rear axle cover. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Drain the lubricant into a suitable container.

1. Install the rear axle cover. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to «Approximate Fluid Capacities»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) and «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
3. Install the rear axle fill plug and tighten to 33 N.m (24 lb ft).
4. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the drain plug.
3. Remove the fill plug.

1. Install the drain plug and tighten to 33 N.m (24 lb ft).
2. Fill the rear drive axle. Use the proper fluid, refer to «Approximate Fluid Capacities»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) . For the proper capacity, refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
3. Install the fill plug and tighten to 33 N.m (24 lb ft).
4. Remove the support and lower the vehicle.

Note. Notice the routing of the vent hose to ensure the correct positioning for reassembly.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the vent hose from the rear axle vent hose connector.
3. Remove the vent hose from the retaining clip on the frame.

1. Install the vent hose to the clip on the frame.
2. Install the vent hose on the rear axle vent hose connector.
3. Remove the support and lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. For the 9.5 inch axle, drain the rear axle. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the rear axle housing cover bolts (1).
4. Remove the rear axle housing cover (2) and the gasket (3) from the axle housing.
5. If the rear axle housing cover gasket is found to be damaged, DO NOT re-use. Replace with NEW.
6. Drain the remaining axle lubricant into a suitable container.

1. If the gasket is to be re-used, clean the sealing surfaces of the rear axle housing and the rear axle cover with a suitable cleaner.
2. Install the rear axle housing cover gasket (3) and the cover (2) to the rear axle housing.
3. Install the rear axle housing cover bolts (1) and tighten to 30 N.m (20 lb ft).
4. Install the drain plug for the 9.5 inch axle. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Fill the rear axle with the proper axle lubricant. Refer to «Rear Axle Lubricant Level Inspection (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-105) or «Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-86) .
6. Remove the support and lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Drain the rear axle. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the rear axle cover bolts (1), cover (2), and the gasket (3).
4. Remove any gasket material from the rear axle housing and/or axle housing cover.

1. Position the axle housing cover (2) and the gasket (3) on the rear axle.
2. Install the NEW axle housing cover bolts (1) and tighten to 40 N.m (30 lb ft).
3. Fill the rear drive axle with the proper fluid. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the support and lower the vehicle.

Special Tools

1. J 2619-01: Slide Hammer W/ 1/2 x 13 Adapter
2. J 45859: Axle Shaft Remover/Installer

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake caliper mounting bracket. Refer to «Rear Brake Caliper Bracket Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-1500) or «Rear Brake Caliper Bracket Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-2500) .
4. Remove the rear wheel speed sensor. For the Hybrid vehicles, refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) . For the non Hybrid vehicles (1500 series), refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) . For the non Hybrid vehicles (2500 series), refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) .
5. Remove the rear axle housing cover and the gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
6. Remove the pinion shaft locking bolt.
7. On axles without a locking differential, remove the pinion shaft.
8. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
9. On axles with a locking differential, use a screwdriver, or a similar tool, to enter the differential case and rotate the C-lock (1) until the C-lock aligns with the thrust block (2).
10. Push the flange of the axle shaft (1) toward the differential.
11. Remove the C-lock from the button end of the axle shaft.
12. Remove the axle shaft from the housing.
13. Using the J 2619-01: slide hammer (1) and the J 45859: remover/installer (2) to remove the axle shaft from the housing.

1. Install the axle shaft into the rear axle housing, allowing the splines to engage the differential side gear.
2. On axles without a locking differential, place the C-lock on the button end of the axle shaft.
3. On axles with a locking differential, keep the pinion shaft partially withdrawn.
4. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
5. Pull the shaft flange outward in order to seat the C-lock in the differential gear.
6. Align the hole in the pinion shaft with the bolt hole in the differential case.
7. Install the new pinion shaft locking bolt. For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 N.m (27 lb ft). For the 9.5 LD inch axle, tighten the pinion shaft locking bolt to 50 N.m (37 lb ft).
8. Install the rear axle housing cover and the gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. Install the brake caliper mounting bracket. Refer to «Rear Brake Caliper Bracket Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-1500) or «Rear Brake Caliper Bracket Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-2500) .
10. Install the rear wheel speed sensor. For the Hybrid vehicles, refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) . For the non Hybrid vehicles (1500 series), refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) . For the non Hybrid vehicles (2500 series), refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) .
11. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
12. Fill the rear axle with the proper axle lubricant. Refer to «Rear Axle Lubricant Level Inspection (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-105) or «Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-86) .
13. Lower the vehicle.

1. J 2619-01: Slide Hammer W 1/2 x 13 Adapter
2. J 8092: Universal Driver Handle 3/4 x 10 inch
3. J 21128: Axle Pinion Oil Seal Installer
4. J 23690: Axle Bearing Installer
5. J 44685: Rear Axle Seal and Bearing Remover
6. J 45857: VSES Wheel Bearing Remover

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the rear axle housing cover. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the axle shaft. Refer to «Rear Axle Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Using the J 44685: remover (1) and the J 2619-01: hammer (2), remove the rear axle shaft seal.
6. Using the J 45857: remover (1) and the J 2619-01: hammer (2), remove the rear axle shaft seal, bearing and the wheel speed sensor reluctor ring, if equipped.

1. Install the rear wheel speed sensor reluctor ring, if equipped. For vehicles with the HP2 (Hybrid) option, refer to «Rear Wheel Speed Sensor Ring Replacement»(ref-339135-S36523290092009090300000) . For vehicles that are NON-Hybrid less than 3900 kg (8600 lbs) GVW, refer to «Rear Wheel Speed Sensor Ring Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-less-than-3900-kg-8600-lb-gvw__rear-wheel-speed-sensor-ring-replacement) . For vehicles that are NON-Hybrid greater than/equal to 3900 kg (8600 lbs) GVW, refer to «Rear Wheel Speed Sensor Ring Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-greater-thanequal-to-3900-kg-8600-lb-gvw) .
2. Using the J 23690: installer (1) and the J 8092: driver (2), install the axle shaft bearing.
3. Using the J 21128: installer, install the axle shaft seal.
4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube.
5. Install the rear axle shaft. Refer to «Rear Axle Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
6. Install the rear axle housing cover. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
8. Fill the rear axle. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. Remove the support and lower the vehicle.

Scheme 30

1. J 2222-C: Wheel Bearing Nut Wrench
2. J 8092: Universal Driver Handle - 3/4 x 10 inch
3. J 24426: Outer Wheel Bearing Race Installer
4. J 24427: Inner Wheel Bearing Race Installer
5. J 44419: Hub Bearing Installer
6. J 44420: Differential Bearing Installer

Note. The wheel hub seal must be replaced anytime the wheel hub assembly is removed from the axle housing.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake caliper bracket. Refer to «Rear Brake Caliper Bracket Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-1500) or «Rear Brake Caliper Bracket Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-2500) .
4. Remove the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Remove the axle nut retaining ring.
6. Remove the key.
7. Using the J 2222-C: wrench, and loosen the adjusting nut.
8. Remove the adjusting nut.
9. Remove the hub from the axle housing.
10. Remove the rotor, if necessary. Refer to «Rear Brake Rotor Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) or «Rear Brake Rotor Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) .
11. Using a suitable seal removal tool, remove the oil seal from the wheel hub.
12. Remove the inner hub bearing.
13. Using a brass drift and a hammer, remove the inner hub bearing cup.
14. Remove the retaining ring from the wheel hub.
15. Using the J 24426: installer (2) and the J 8092: handle (1), remove the outer hub bearing and bearing cup.

1. Lubricate the following with a light coat of high melting point EP bearing lubricant: The outer wheel bearing The inner wheel bearing The outer wheel bearing cup The inner wheel bearing cup The axle hub spindle
2. Install the outer bearing into the wheel hub.
3. Using the J 44419: installer (2) and the J 8092: handle (1), install the outer bearing cup into the wheel hub.
4. Install the retaining ring into the groove.
5. Using the J 24426: installer (2) and the J 8092: handle (1), turn the wheel hub over and seat the outer bearing assembly against the retaining ring.
6. Turn the wheel hub over and install the inner bearing cup.
7. Using the J 24427: installer (2) and the J 8092: handle (1), install the inner bearing cup into the wheel hub.
8. Install the inner bearing.
9. Using the J 44420: installer (2) and the J 8092: handle (1), install the new oil seal.
10. Install the rotor, if necessary. Refer to «Rear Brake Rotor Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) or «Rear Brake Rotor Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) .
11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle.
12. Install the wheel hub to the axle housing.
13. Using the J 2222-C: wrench, install the adjusting nut to the hub.
14. Adjust the wheel bearings. Refer to «Wheel Bearing Adjustment»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
15. Install the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
16. Install the brake caliper bracket. Refer to «Rear Brake Caliper Bracket Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-1500) or «Rear Brake Caliper Bracket Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-2500) .
17. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
18. Inspect and add axle lubricant to the axle housing, if necessary. Refer to «Rear Axle Lubricant Level Inspection (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-105) or «Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-86) .
19. Lower the vehicle.

1. J 8614-01: Holder/Remover
2. J 44414: Oil Seal Installer

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the rear wheel axle shafts. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the rear brake rotors. Refer to «Rear Brake Rotor Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) or «Rear Brake Rotor Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) .
5. Remove the propeller shaft from the vehicle. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints)
6. Using an inch-pound torque wrench, measure the amount of torque required to rotate the pinion..
7. Place an alignment mark between the pinion and the pinion yoke.
8. Using the J 8614-01: holder/remover and holding it, remove the pinion nut.
9. Remove the washer.
10. Using the J 8614-2 (2) and the J 8614-3 (3), remove the pinion yoke.
11. Using a suitable tool, remove the drive pinion seal (1).

1. Using the J 44414: installer, install a new pinion oil seal.
2. Apply sealant to the splines of the pinion yoke. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
3. Using a soft faced hammer, install the drive flange (1) onto the pinion shaft until a few treads show through the drive flange (1).
4. Install the washer (2) and the nut (3).
5. Using and holding the J 8614-01: holder/remover, tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearing.
6. Using an inch-pound torque wrench, tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3- 5 lb in) greater than the rotating torque recorded during removal.
7. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.
8. Install the propeller shaft assembly. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
9. Install the axle shafts. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
10. Install the rear brake rotors. Refer to «Rear Brake Rotor Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) or «Rear Brake Rotor Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system) .
11. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
12. Inspect and add axle lubricant to the axle housing, if necessary. Refer to «Rear Axle Lubricant Level Inspection (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-105) or «Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-86) .
13. Remove the support and lower the vehicle.

1. J 8092: Universal Driver Handle 3/4 in-10
2. J 8608: Pinion bearing Cup Installer
3. J 24433: Pinion Bearing Installer
4. J 37624: Pinion Bearing Installer
5. J 44414: Pinion Oil Seal Installer

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Drain the axle lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the rear axle shafts. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the rear propeller shaft from the vehicle. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
5. Remove the drive pinion flange/yoke and/or oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
6. Using a hydraulic press and an appropriate tool, remove the pinion.
7. Remove the collapsible spacer.
8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup.
9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup.

1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer.
2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer.
3. Apply sealant to surface of the selective shim. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
4. Install the pinion gear bearing retainer and bolts tighten to 88 N.m (65 lb ft)..
5. Install the drive pinion flange/yoke and/or oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
6. Install the rear propeller shaft from the vehicle. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
7. Install the rear axle shafts. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Fill the axle with axle lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. Remove the support and lower the vehicle.

J 22536: Pinion Remover

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the pinion flange/yoke and the oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Using the J 22536: remover and a hammer, remove the drive pinion from the housing.
5. Remove and discard the collapsible spacer from the pinion.
6. Remove the pinion bearings and the cups. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
7. Remove and discard the ring gear bolts. Use NEW ring gear bolts ONLY.
8. Using a brass drift, remove the ring gear from the differential.

1. Install the ring gear to the differential case.
2. Install the NEW ring gear bolts and tighten to 120 N.m (89 lb ft). in a criss cross pattern to draw and seat the ring gear and the differential carrier.
3. Install the selective shim onto the pinion. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Pinion Depth Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Pinion Depth Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-105-inch-axle)
4. Install the inner pinion bearing to the pinion. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Install a NEW collapsible spacer.
6. Lubricate the pinion bearings with axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
7. Install the outer pinion bearing into the axle housing.
8. Install the pinion drive gear into the axle housing.
9. Install the drive pinion flange/yoke. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
10. Install the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
11. Fill the axle with lubricant. Use the proper fluid. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
12. Remove the support and lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the differential case assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the drive pinion housing assembly. Refer to «Drive Pinion Housing and/or Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove and discard the gear bolts. Replace with NEW only.
5. Using a brass drift and a hammer, remove the ring gear from the differential case.

1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case.
2. Install the ring gear to the differential case.
3. Hand tighten the new ring gear bolts.
4. Install the NEW ring gear bolts and tighten to 120 N.m (89 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case.
5. Install the drive pinion housing assembly. Refer to «Drive Pinion Housing and/or Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
6. Install the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
7. Fill the axle with the proper lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Remove the support and lower the vehicle.

1. J 8092: Universal Driver Handle - 3/4 in - 10
2. J 8608: Pinion Bearing Cup Installer
3. J 8614-01: Flange Holder and Remover
4. J 22761: Side Bearing Installer
5. J 22912-B: Bearing Remover
6. J 24433: Pinion Bearing Installer
7. J 37624: Pinon Bearing Installer
8. J 44414: Pinion Oil Seal Installer

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the pinion yoke and the oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the drive pinion housing assembly. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Using a press and the appropriate tool, remove the drive pinion gear pinion.
6. Remove the collapsible spacer.
7. Using the J 22912-B: remover and a hydraulic press, remove the inner drive pinion bearing.
8. Using a brass drift and a hammer, remove the outer pinion bearing cup.
9. Using a brass drift and a hammer, remove the inner pinion bearing cup.
10. Using a brass drift and a hammer, remove the pinion gear pilot bearing.

1. Position the drive pinion gear pilot bearing (1) in the differential housing (2).
2. Using the J 22761: installer (1) and the J 8092: handle (2), install the drive pinion gear pilot bearing in the differential housing (3).
3. Using the J 37624: installer (2) and the J 8092: handle (1), install the inner pinion bearing cup in the pinion gear bearing retainer.
4. Using the J 8608: Pinion Bearing Cup Installer (2) and the J 8092: handle (1), install the outer pinion bearing cup in the pinion gear bearing retainer.
5. Using the J 24433: installer and a hydraulic press, install the inner pinion bearing.
6. Install the new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
8. Install the outer pinion bearing into the pinion bearing retainer.
9. Using the J 44414: installer, install the new pinion oil seal.
10. Install the pinion in the pinion gear bearing retainer.
11. Install the drive pinion flange/yoke. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle)
12. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 in) shim to build pinion depth.
13. Install the pinion gear bearing retainer to the axle housing. Refer to «Drive Pinion Housing and/or Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle)
14. Using an inch-pound torque wrench, measure the rotating torque of the pinion should be between 1.0-2.3 N.m (10-20 lb in) for used bearings or 1.7-3.4 N.m (15-30 lb in) for new bearings.
15. 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, use the J 8614-01: holding tool and continue to tighten the pinion nut, in small increments, as needed, until the rotating torque is between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.
16. 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.
17. Install the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
18. Adjust the differential side bearing preload. Refer to «Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
19. Adjust the drive pinion gear pinion depth, if needed. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Pinion Depth Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Pinion Depth Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-105-inch-axle) .
20. Adjust the backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
21. Fill the axle with lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
22. Remove the support and lower the vehicle.

1. DT 47688: Pinion Bearing Remover
2. J 8092: Universal Drive Handle 3/4 in-10
3. J 8611-01: Pinion Bearing Cup Installer
4. J 22828: Input Shaft Gear Installer
5. J 22912-B: Bearing Puller
6. J 36614: Inner Pinion Bearing Installer
7. J 45870: Inner Pinion Bearing Race Installer

Disassemble Procedure

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the differential drive pinion gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. For the 8.6 inch axle, use the DT 47688: remover and a press remove the drive pinion bearing and the spacer.
5. For the 9.5LD inch axle, use the J 22912-B: puller and a press to remove the drive pinion bearing.
6. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup from the axle housing.
7. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup from the axle housing.

Assemble Procedure

1. Using the J 8092: handle (2) and the J 8611-01: installer (1), install the outer pinion bearing cup.
2. Using the J 8092: handle (2) and the J 45870: installer (1), install the inner pinion bearing cup.
3. Determine the selective shim thickness for the drive pinion. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Pinion Depth Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Pinion Depth Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-105-inch-axle) .
4. Install the shim (1) on the differential drive pinion gear (2).
5. Using the J 22828: installer or the J 36614: installer and a hammer, install the inner pinion bearing until the pinion bearing seats on the drive pinion shim.
6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with the axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
8. Install the outer pinion bearing (2) into the differential drive pinion gear (1).
9. Install the drive pinion flange/yoke and or oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
10. Using an inch-pound torque wrench, measure the rotating torque of the drive pinion should be between 1.0-2.3 N.m (10-20 lb in) for used bearings and 1.7-3.4 N.m (15-30 lb in) for new bearings.
11. 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, continue to tighten the pinion nut in small increments, as needed, until the desired rotating torque specificationas are reached as indicated in steps 10 and 11..
12. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.
13. Recheck the rotating torque and adjust if necessary.
14. Install the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
15. Fill the axle with lubricant. Use the proper fluid. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
16. Remove the support and lower the vehicle.

J 24429: Side Bearing Backlash Spanner

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the rear axle shafts. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the rear axle housing cover and the gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the differential bearing adjuster nut retainers.
5. Remove the bearing caps and bolts.
6. Using the J 24429: spanner, loosen the adjusters.
7. Remove the differential assembly.
8. Remove the bearing cups.
9. Remove the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
10. Remove the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

1. Install the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Lubricate the differential side bearings with axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
4. Place the case, with the bearing cups installed, into the axle housing.
5. Install the bearing caps and the bolts.
6. Using the J 24429: spanner, turn the adjusters evenly on each side until snug against the differential.
7. Adjust the differential side bearing preload. Refer to «Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Adjust the backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
9. Perform a gear tooth contact pattern check. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .
10. Tighten the bearing cap bolts to 185 N.m (136 lb ft).
11. Install the axle shafts and new gaskets. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
12. Install the rear axle housing cover and a new gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
13. Fill the axle with the proper lubricant. Refer to «Approximate Fluid Capacities»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) and «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
14. Remove the lower the vehicle.

J 24429: Side Bearing Backlash Spanner

Note. Group and mark the shims together as originally removed. If you remove or replace the differential ring and pinion gear set, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other of the components ( pinion and ring gear set, bearings. etc.) then you may reinstall the differential carrier with the original shims in their original locations. ALWAYS perform a gear tooth contact pattern check, even when you remove only the differential carrier.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the right side differential bearing adjuster nut lock.
4. Remove the bearing cap bolts and caps.
5. For the 8.6 inch axle, install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.
6. For the 8.6 inch axle, rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.
7. Using the J 24429: spanner, loosen the differential bearing adjuster nut.
8. Remove the differential assembly.
9. Remove the bearing cups, the shims, and the spacers as necessary.
10. Remove the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
11. Remove the differential ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

1. Install the differential ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Using the proper axle lubricant, lubricate the differential side bearings. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
4. Place the differential case, with the bearing cups installed, into the axle housing.
5. Install the bearing caps and the bolts.
6. Adjust the differential side bearing preload. Refer to «Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
7. Adjust the backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
8. Perform a gear tooth contact pattern check. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .
9. Tighten the bearing cap bolts to 75 N.m (55 lb ft) for the 8.6 inch axle or 85 N.m (63 lb ft) for the 9.5/9.5LD inch axle.
10. Install the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
11. Fill the axle with the proper lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
12. Lower the vehicle.

1. J 8092: Universal Driver Handle - 3/4 in - 10
2. J 8107-4: Side Bearing Remover Plug
3. J 21784: Side Bearing Installer
4. J 22888-D: Side Bearing Puller
5. J 22888-20 A: Side Bearing Puller
6. J 29710: Differential Side Bearing Installer
7. J 36597: Side Bearing Remover Pilot
8. J 44420: Differential Bearing Installer

1. Remove the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Remove the differential side bearings by doing the following: For the 8.6 inch axle, install the differential assembly into a vise. For the 10.5 inch axle, place a block of wood on each side of the differential assembly. Install the differential assembly into a vise. For the 8.6 inch axle, install the J 22888-20A: puller (2) and the J 8107-4: plug (1) over the differential case side bearing bore. Using the J 22888-20A: puller (2), and the J 8107-4: plug (1) or the J 36597: pilot (1), remove the differential side bearings.

1. For the 8.6 inch and the 10.5 inch axles, install the differential side bearings by doing the following: To protect the differential case for the 8.6 inch axle, install the J 8107-4: plug in the case on the side opposite the bearing installation. For the 8.6 inch axle, install the J 21784: installer (2) and the J 8092: handle (1), on the differential case bearing as shown. Using a hammer and the J 21784: installer (2) or the J 29710: installer (2) and the J 8092: handle (1), install the side bearings.
2. Install the differential assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the rear tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the vent hose from the rear drive axle.
4. Remove the electronic suspension control sensor, if equipped. For the left side, refer to «Electronic Suspension Rear Position Sensor Replacement - Left Side»(/chevrolet/avalanche/ii-2006-2013/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) . For the right side, refer to «Electronic Suspension Rear Position Sensor Replacement - Right Side»(/chevrolet/avalanche/ii-2006-2013/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) .
5. Remove the rear wheel speed sensors from the rear drive axle. For the Hybrid vehicles, refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) . For the non Hybrid vehicles (1500 series), refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) .
6. Remove the rear brake calipers, and relocate to the side. Refer to «Rear Brake Caliper Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-1500-series) or «Rear Brake Caliper Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-2500-series) .
7. Drain the rear axle. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Remove the propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
9. Remove the rear axle tie rod. Refer to «Rear Axle Tie Rod Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
10. Remove the rear stabilizer shaft, if equipped. Refer to «Stabilizer Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
11. Remove the rear brake pipe retaining bracket bolt (1).
12. Remove the rear brake junction block retaining bolt (2) at the rear axle cover.
13. Secure the rear brake pipes to the frame with mechanics wire or equivalent.
14. Remove the rear brake pipe from the retaining strap (1).
15. Remove the brake pipe retaining bracket bolt (2).
16. Support the rear drive axle with a hydraulic jack stand.
17. Remove the lower control arm bolts from the rear the drive axle. Refer to «Rear Axle Lower Control Arm Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
18. Remove the upper control arm bolts from the rear drive axle. Refer to «Rear Axle Upper Control Arm Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
19. With the aid of an assistant, lower the drive axle.
20. Remove the rear coil springs.
21. Lower the rear drive axle assembly.
22. Transfer parts, if needed.

1. Position the rear drive axle assembly under the vehicle.
2. With the aide of an assistant, raise the rear drive axle into place.
3. Install the rear coil springs on the rear drive axle.
4. Install the upper control arms to the rear drive axle. Refer to «Rear Axle Upper Control Arm Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
5. Install the lower control arms to the rear drive axle. Refer to «Rear Axle Lower Control Arm Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
6. Install the lower shock absorber bolts to the rear drive axle. Refer to «Shock Absorber Replacement (1500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) or «Shock Absorber Replacement (2500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
7. Remove the hydraulic jack stand from the rear drive axle assembly.
8. Install the rear brake pipe retaining bracket bolt (1) and tighten to 20 N.m (15 lb ft)..
9. Install the rear brake junction block retaining bolt (2) at the rear axle cover and tighten to 20 N.m (15 lb ft)..
10. Install rear drive axle the vent hose.
11. Install the rear stabilizer shaft, if equipped. Refer to «Stabilizer Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
12. Install the rear wheel speed sensors. For the Hybrid vehicles, refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) . For the non Hybrid vehicles (1500 series), refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) .
13. Install the rear axle tie rod. Refer to «Rear Axle Tie Rod Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
14. Install the rear brake calipers. Refer to «Rear Brake Caliper Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-1500-series) or «Rear Brake Caliper Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-2500-series) .
15. Install the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
16. Install the air level sensors. For the left side, refer to «Electronic Suspension Rear Position Sensor Replacement - Left Side»(/chevrolet/avalanche/ii-2006-2013/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) . For the right side, refer to «Electronic Suspension Rear Position Sensor Replacement - Right Side»(/chevrolet/avalanche/ii-2006-2013/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) .
17. Fill the rear drive axle with fluid. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
18. Install the rear tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
19. Remove the supports and lower the vehicle.
20. Calibrate the air level control, if needed. Refer to «Suspension Position Calibration (Without Z95)»(/chevrolet/avalanche/ii-2006-2013/remont/electronic-suspension/#suspension-control-system-suspension-leveling) or «Suspension Position Calibration (With Z95)»(/chevrolet/avalanche/ii-2006-2013/remont/electronic-suspension/#suspension-control-system-suspension-leveling) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Place jack stands in the front of the vehicle.
3. Drain the rear axle of fluid. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
5. Remove the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
6. Remove the vent hose from the rear axle.
7. Remove the mounting bolt and the rear brake junction block from the rear axle housing.
8. Remove the retaining bolt for the rear brake line from the rear axle housing.
9. Remove the rear wheel speed sensors from the rear axle. Refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) .
10. Remove the rear brake calipers and relocate to the side. Refer to «Rear Brake Caliper Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-1500-series) or «Rear Brake Caliper Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-2500-series) .
11. Remove the rear park brake cables from the rear brake calipers. For the left side, refer to «Parking Brake Rear Cable Replacement - Left Side»(/chevrolet/avalanche/ii-2006-2013/remont/parking-brake-system/#parking-brake-system) . For the right side, refer to «Parking Brake Rear Cable Replacement - Right Side»(/chevrolet/avalanche/ii-2006-2013/remont/parking-brake-system/#parking-brake-system) .
12. Remove the rear shock absorber lower mounting bolts and nuts from the mounting brackets. Refer to «Shock Absorber Replacement (1500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) or «Shock Absorber Replacement (2500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
13. Remove the stabilizer shaft from the rear axle, if equipped. Refer to «Stabilizer Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
14. Support the rear axle assembly with a suitable hydraulic jack stand.
15. Remove the U-bolt nuts, anchor plates and spacers from the rear leaf springs. Refer to «Leaf Spring Replacement (2500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
16. With the aide of an assistant, lower the rear axle assembly and remove from the vehicle.
17. Transfer parts, if needed.

1. With the aide of an assistant, lift the rear drive axle into place.
2. Align the U-bolts, nuts, anchor plates and spacers from the rear leaf springs to the rear drive axle. Refer to «Leaf Spring Replacement (2500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
3. Install the rear shock absorber lower mounting bolts and nuts in the mounting brackets. Refer to «Shock Absorber Replacement (1500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) or «Shock Absorber Replacement (2500)»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
4. Remove the hydraulic jack from the rear drive axle.
5. Install the rear brake junction block and mounting bolt on the rear axle housing and tighten to 22 N.m (16 lb ft)..
6. Install the rear brake line retaining bolt on the rear axle housing and tighten to 22 N.m (16 lb ft)..
7. Install the rear drive axle vent hose.
8. Install the rear stabilizer shaft on the rear drive axle. Refer to «Stabilizer Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/suspension-rear/#rear-suspension-system) .
9. Install the rear wheel speed sensors. Refer to «Rear Wheel Speed Sensor Replacement»(ref-339135-S35236907912009090300000) .
10. Install the rear brake calipers. Refer to «Rear Brake Caliper Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-1500-series) or «Rear Brake Caliper Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-2500-series) .
11. Install the rear park brake cables on the rear brake calipers. For the left side, refer to «Parking Brake Rear Cable Replacement - Left Side»(/chevrolet/avalanche/ii-2006-2013/remont/parking-brake-system/#parking-brake-system) . For the right side, refer to «Parking Brake Rear Cable Replacement - Right Side»(/chevrolet/avalanche/ii-2006-2013/remont/parking-brake-system/#parking-brake-system) .
12. Install the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
13. Fill the rear drive axle with fluid. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
14. Install the tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/avalanche/ii-2006-2013/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
15. Remove the jack stands from the from of the vehicle.
16. Remove the supports and lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the axle lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the rear axle assembly. Refer to «Rear Axle Replacement (8.6,, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the brake caliper brackets. Refer to «Rear Brake Caliper Bracket Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-1500) or «Rear Brake Caliper Bracket Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-2500) .
5. Remove the rear axle cover housing and gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
6. Remove the rear brake shield. Refer to «Rear Brake Shield Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-shield-replacement) .
7. Remove the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Remove the differential. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. Remove the drive pinion. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
10. Remove the drive pinion shaft yoke and the seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

1. Install the drive pinion. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the differential case. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Adjust the side bearing preload. Refer to «Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Carrier Bearing Preload Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Adjust the backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
5. Perform a gear tooth contact pattern check. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .
6. Install the rear brake shield. Refer to «Rear Brake Shield Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-shield-replacement) .
7. Install the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Install the rear axle housing cover and gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. Install the brake caliper brackets. Refer to «Rear Brake Caliper Bracket Replacement (1500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-1500) or «Rear Brake Caliper Bracket Replacement (2500 Series)»(/chevrolet/avalanche/ii-2006-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-2500) .
10. Install the rear axle. Refer to «Rear Axle Replacement (8.6,, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
11. Fill the axle with lubricant. Refer to «Differential Oil Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Oil Replacement (9.5LD Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
12. Lower the vehicle.

Disassembly Procedure

1. Remove the differential ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle)
2. Remove the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove and discard the differential pinion gear shaft lock bolt (2). Replace with NEW only.
4. Remove the differential pinion gear shaft (1).
5. Roll the differential pinion gears (7) and the thrust washers (6) out of the differential case 2).
6. Remove the differential side gears (5) and the thrust washers (4).

Assembly Procedure

1. Lubricate the pinion and side gears using the proper axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
2. Install the differential side gear thrust washers (4) to the differential side gears (5).
3. Install the differential side gears (5) and thrust washers (4) into the differential case (2).
4. Position one pinion gear (7) between the differential side gears (5).
5. Position the second pinion gear (7) between the differential side gears (5).
6. Rotate the differential side gears (5) until the pinion gears (7) are directly opposite the opening in the differential case (2).
7. Rotate the pinion gears (7) toward the differential opening.
8. Install the thrust washers (6) on the pinion gears (5).
9. Rotate the pinion gears until they are aligned with the holes in the differential case (2) for the pinion shaft (1).
10. Install the pinion shaft (1).
11. Install the NEW differential pinion gear shaft locking bolt and tighten to. For the 8.6 inch axle, tighten the pinion bolt to 36 N.m (27 lb ft). For the 9.5 inch axle, tighten the pinion bolt to 50 N.m (37 lb ft).
12. Install the differential ring gear to the differential case. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
13. Install the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

1. Remove the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Remove the differential ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Separate the differential case (1).
4. Remove the pinion gears (2), thrust washers (1) and the differential spider (3) from the differential case (6).
5. Remove the differential side gears (4) and the thrust washers (5) from the differential case (5).

1. Apply a small amount of the proper gear lubricant to the differential side gears and the differential pinion gears. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
2. Install the thrust washers (5) differential side gears (4) into the differential case (6).
3. Install the differential pinion gears (2), thrust washer (1) on the differential spider (3).
4. Position the differential thrust washers (1), pinion gears (2) and the spider (3) in the differential case (5).
5. Align the arrows on the differential case halves before
6. Position the differential side gear (3) and the thrust washer (3) on the differential pinion gears (4).
7. Install the differential case half (1).
8. Install the differential ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. Install the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

Bearings Inspection

Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component repair after assembly.

1. Lubricate the bearings with axle lubricant. Inspect the bearings for smooth rotation.
2. Inspect the bearing rollers for wear.
3. Inspect the bearing cups for wear, cracks, brinelling, and scoring.

Differential Inspection

1. Check the pinion gear shaft for unusual wear.
2. Check the pinion and the side gear teeth for wear, cracks, scoring and spalling.
3. Check the thrust washers for wear.
4. Check the fit of the side gears in the differential case and on the axle shafts.
5. Check the differential case for cracks and scoring and replace all of the worn parts as necessary.

Pinion and Ring Gear Inspection

Ring and pinion gears are matched sets. When replacement of one or the other is necessary, both the ring and pinion gear must be replaced.

1. Check the pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear.
2. Check the pinion gear splines for wear.
3. Check the pinion flange/yoke splines for wear.
4. Check the fit of the pinion gear splines on the pinion flange/yoke.
5. Check the sealing surface of the pinion flange/yoke for nicks, burrs or rough tool marks that could damage the seal and cause an oil leak.
6. Check for worn or broken parts and replace as necessary.

Rear Axle Housing Inspection

Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component repair after assembly.

1. Inspect for nicks or burrs that could prevent the outer diameter of the pinion seal from sealing. Remove any burrs.
2. Inspect the bearing cup bores for nicks or burrs. Remove any burrs that are found.
3. Inspect the housing for cracks. Replace the housing if any cracks are found.
4. Inspect the housing for foreign material such as metal chips, dirt, or rust.

Shims Inspection

Inspect the shims for cracks and chips. Replace the damaged shims.

1. J 8001: Dial Indicator Set
2. J 21777-B: Pinion Setting Gage Set

Adjustment

1. Lubricate the pinion bearings with the proper axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
2. Install the pinion bearings into the rear axle housing.
3. Install the J 21777-35 (1), the J 21777-43 (2), the J 21777-42 (3), and the J 21777-29 (4) in the rear axle housing.
4. Using a inch pound torque wrench and holding the J 21777-43, tighten the nut of the J 21777-43 until a rotating torque of 1.7 N.m (15 lb in) is obtained.
5. Check the rotating torque of the assembly. If the torque is less than 1.7 N.m (15 lb in), tighten the nut on the J 21777-43 until a rotating torque of 1.7-2.3 N.m (15-20 lb in) is obtained.
6. Install the J 21777-45 (1, 2) to the J 21777-1 (3) in the rear axle housing.
7. Install the differential bearing caps.
8. Install the bearing cap bolts to 75 N.m (55 lb ft)..
9. Rotate the J 21777-1 within the J 21777-45.
10. Align the plunger of the J 21777-1 (1) to the gage block setting of the J 21777-29.
11. Loosely clamp the J 8001: indicator on the stem on the J 21777-1.
12. Place the contact pad of the J 8001: indicator on the mounting post of the J 21777-1.
13. With the contact pad of the J 8001: indicator touching the mounting post of the J 21777-1, loosen the lock nut on the J 8001: indicator and push down on the J 8001: indicator until the needle the J 8001: indicator has turned 3/4 of a turn clockwise.
14. Tighten the clamp on the J 8001: indicator finger tight.
15. Move the plunger of the J 21777-1 back and forth until the needle of the J 8001: indicator indicates the greatest deflection.
16. At the greatest point of deflection, move the housing of the J 8001: indicator until the needle indicates zero.
17. Move the plunger of the J 21777-1 back and forth again to verify the zero setting. Adjust the housing of the J 8001: indicator as necessary to set the needle to zero.
18. Rotate the plunger of the J 21777-1 away from the J 21777-29 until it no longer touches the J 21777-29.
19. The value indicated on the J 8001: indicator is the thickness of the shim needed in order to set the depth of the pinion.
20. Select the shim that indicates the proper thickness.
21. Remove the pinion depth setting tools.
22. Remove the pinion bearings.
23. Install the pinion shim between the pinion gear and the inner pinion bearing. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

1. J 8001: Dial Indicator Set
2. J 21777-85: Gage and Plate
3. J 21777-86: Side Bearing Disc
4. J 34925: Pinion Setting Gage Set

1. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/avalanche/ii-2006-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
2. Install the pinion bearings into the rear axle housing.
3. Install the J 21777-8 (1), the J 21777-43 (2), the J 21777-42 (3), and the J 21777-85 (4) in the rear axle housing.
4. Using a inch pound torque wrench and holding the J 21777-43 stationary, slowly tighten the nut of the J 21777-43 until a rotating torque of 1.1-2.2 N.m (10-20 lb in) is obtained.
5. Using an inch-pound torque wrench, measure the rotating torque of the assembly which should be 1.1-2.3 N.m (10-20 lb in)..
6. If the rotating torque of the assembly is less than 1.1N.m (10 lb in), continue to tighten the nut on the J 21777-43 until a rotating torque of 1.1-2.3 N.m(10-20 lb in) is obtained.
7. Install the J 21777-86 (1), (2) and the J 21777-1 (3) in the rear axle housing.
8. Install the differential bearing caps.
9. Install the differential bearing cap bolts and tighten to 85 N.m (63 lb ft)..
10. Rotate the J 21777-1 within the J 21777-86.
11. Align the plunger of the J 21777-1 (1) to the J 21777-85: gage and plate (2).
12. Loosely clamp the J 8001: indicator (1) on the stem on the J 21777-1.
13. Place the contact pad of the J 8001: indicator on the mounting post of the J 21777-1.
14. With the contact pad of the J 8001: indicator touching the mounting post of the J 21777-1, loosen the lock nut on the J 8001: indicator and push down on the J 8001: indicator until the needle the J 8001: indicator has turned 3/4 of a turn clockwise.
15. Tighten the clamp on the J 8001: indicator finger tight.
16. Move the plunger of the J 21777-1 back and forth until the needle of the J 8001: indicator indicates the greatest amount of deflection.
17. At the greatest point of deflection, move the housing of the J 8001: indicator until the needle indicates ZERO.
18. Move the plunger of the J 21777-1 back and forth again to verify the ZERO setting. Adjust the housing of the J 8001: indicator as necessary to set the needle to ZERO.
19. Rotate the plunger of the J 21777-1 away from the J 21777-85 until it no longer touches the J 21777-85.
20. The value indicated on the J 8001: indicator is the thickness of the shim needed in order to set the depth of the pinion.
21. Select the shim that indicates the proper thickness.
22. Remove the pinion depth setting tools.
23. Remove the pinion bearings.
24. Install the pinion shim between the pinion gear and the inner pinion bearing. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

Pinion Depth Adjustment (10.5 Inch Axle)

1. Install the differential, if necessary. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 in) shim to build pinion depth.
3. Install the pinion gear bearing retainer.
4. Install the pinion gear bearing retainer bolts and tighten to 88 N.m (65 lb ft)..
5. Adjust the backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
6. Perform a gear tooth pattern check on the pinion and the ring gear. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .
7. If the gear tooth contact pattern indicates a high or a low flank contact pattern, adjust the pinion depth by doing the following: Remove the pinion gear bearing retainer bolts. Remove the pinion gear bearing retainer. Remove the shim. If the gear tooth contact pattern shows a high flank contact pattern, install a shim one size larger. If the gear tooth contact pattern shows a low flank contact pattern, install a shim one size smaller. Install the new shim to the pinion gear bearing retainer. Install pinion gear bearing retainer. Install pinion gear bearing retainer bolts and tighten to 88 N.m (65 lb ft). . Inspect the gear tooth contact pattern of the pinion and the ring gear. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) . If the gear tooth pattern is still incorrect, adjust the shim thickness as necessary and recheck the gear tooth pattern of the pinion and the ring gear.
8. Inspect the backlash between the pinion and the ring gear and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .

The pinion shims are available in the following sizes

Shim Sizes

1. 0.15 mm (0.006 in)
2. 0.18 mm (0.007 in)
3. 0.20 mm (0.008 in)
4. 0.23 mm (0.009 in)
5. 0.25 mm (0.010 in)
6. 0.28 mm (0.011 in)
7. 0.30 mm (0.012 in)
8. 0.33 mm (0.013 in)
9. 0.36 mm (0.014 in)
10. 0.38 mm (0.015 in)
11. 0.41 mm (0.016 in)
12. 0.43 mm (0.017 in)
13. 0.46 mm (0.018 in)
14. 0.48 mm (0.019 in)
15. 0.51 mm (0.020 in)
16. 0.53 mm (0.021 in)
17. 0.56 mm (0.022 in)
18. 0.58 mm (0.023 in)
19. 0.61 mm (0.024 in)

Wedge Method

Special Tools

1. J 25588: Side Bearing Shim Installer
2. J 22779: Side Bearing Backlash Gage

Note. The differential side bearing preload adjustment must be completed before the backlash adjustment can be started. In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally. Measure the service shims and the spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack. Do not use or reuse the original cast iron production shims. Use service shims and spacers instead.

1. Install the drive pinion, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Using an inch pound torque wrench, measure the rotating torque of the drive pinion, it should be 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.1-2.3 N.m (10-20 lb in) for used bearings.
3. If the rotating torque for the drive pinion bearings is not within specifications, adjust as necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Install the differential assembly with the differential side bearings and differential side bearing cups into the axle housing.
5. Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing.
6. Side the differential assembly towards the service spacer in order to hold the spacer in place.
7. Install the J 22779: gage into the right side of the axle housing.
8. Tighten the knob on the J 25588: installer until there is moderate drag when the J 22779: gage is moved.
9. Remove the J 22779: gage.
10. Remove the service spacer.
11. Using a micrometer, measure the thickness of the service spacer.
12. Using a micrometer, measure the thickness of the J 22779: gage in 3 locations. Calculate the average of the 3 measurements.
13. Add the thickness of the service spacer, measured in step 11 to the average thickness of the J 22779: gage, measured in step 12. The resulting value is the total service shim thickness without preload for the axle.
14. Insert one BENT 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
15. Install the J 22779: gage into the left side of the axle housing. The J 22779: gage must be installed between the service spacer and the differential side bearing cup.
16. While rotating the ring gear back and forth, tighten the knob on the J 22779: gage until there is approximately 0.025-0.051 mm (0.001-0.002 in) of backlash between the ring gear and the drive pinion.
17. Once the correct amount of backlash is obtained, remove the J 22779: gage.
18. Remove the differential assembly with the differential side bearings and the differential side bearing cups.
19. Remove the BENT service shim.
20. Using a micrometer, measure the thickness of the J 22779: gage in 3 locations. Calculate the average of the 3 measurements. This value is the left side service shim thickness without preload.
21. In order to determine the right side service shim thickness, subtract the service shim thickness for the left side of the axle, calculated in step 20, from the total service shim thickness, calculated in step 13. This value is the service shim thickness for the right side of the axle without preload.
22. In order to preload of the differential side bearings and set the backlash to approximately 0.127-0.223 mm (0.005-0.009 in), take the value determined in step 21 and add 0.203 mm (0.008 in) service shim thickness to this amount.
23. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of service shims equaling the thickness determined in step 20. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness.
24. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of service shims equaling the thickness determined in step 22. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness.
25. Install the differential assembly with the differential side bearings and the differential side bearing cups.
26. Install the left side service spacer and service shim into the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
27. Install the right side service spacer between the axle housing and the differential side bearing cup.
28. Install the right side service shim into the axle housing using the J 25588: installer, if necessary. The service shim must be installed between the service spacer and the differential side bearing cup.
29. Install the differential bearing caps and the bolts and tighten to 75 N.m (55 lb ft).
30. Rotate the pinion several times to ensure the drive pinion and differential side bearings have seated.
31. Using an inch pound torque wrench, measure the rotating torque of the drive pinion and differential side bearings which should be 0.57-1.13 N.m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier.
32. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in step 2, from the drive pinion and differential case bearing preload, measured in step 31. Multiply the value obtained by the axle ratio. The differential side bearing preload should be 1.7-4.0 N.m (15-35 lb in).
33. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
34. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
35. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Shim Method

Special Tools J 25588: Side Bearing Shim Installer

Note. The differential side bearings must have preload before the backlash adjustment can be started. In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally. Measure the service shims and the service spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack. Do not use or reuse the original cast iron production shims. Use service shims and service spacers instead.

1. Install the drive pinion, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Using an inch pound torque wrench, measure the rotating torque of the drive pinion which should be 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.1-2.3 N.m (10-20 lb in) for used bearings.
3. If the rotating torque for the drive pinion bearings is not within specifications, adjust as necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Install the differential assembly with the differential side bearings and bearing cups into the axle housing.
5. Insert one BENT 1.016 mm (0.040 in) thick service shim into the right side axle housing. Side the differential assembly towards the bent service shim in order to hold the shim in place.
6. While holding the differential assembly against the bent service shim, install one 4.318 mm (0.170 in) thick service spacer into the left side axle housing.
7. Move the differential assembly to the right until the ring gear contacts the drive pinion. Once the ring gear contacts the drive pinion, continue to move the ring gear towards the drive pinion to until all backlash is removed.
8. While holding the ring gear against the drive pinion, insert progressively larger service shims between the service spacer and the differential side bearing cup until a moderate resistance can be felt.
9. Once the largest service shim has been determined, measure the thickness of the shim using a micrometer. Measure the service shim in 3 locations. Calculate the average of the 3 measurements. Use the average as the thickness for the shim. Record the measurement.
10. Install the service shim that was just measured back into the left side of the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
11. Remove the BENT shim from the right side of the axle housing.
12. Insert one 4.318 mm (0.170 in) thick service spacer into the right side axle housing.
13. Move the differential assembly towards the left side of the axle housing. While holding the differential assembly against the left side shim pack, insert progressively larger service shims between the service spacer and the differential side bearing cup until a moderate resistance can be felt.
14. Once the largest service shim has been determined, measure the thickness of the shim using a micrometer. Verify the thickness of the service shim. Measure the service shim in 3 locations. Calculate the average of the 3 measurements. Use the average as the thickness for the shim. Record the measurement.
15. In order to preload the differential side bearing and set the initial backlash to approximately 0.127 mm (0.005 in), adjust the thickness of left and right side shims by doing the following: Subtract 0.152 mm (0.006 in) from the measurement recorded for the left side shim in step 9. Record the measurement. Add 0.356 mm (0.014 in) to the measurement recorded for the right side shim in step 14.
16. Select the correct service shim thickness for each side corresponding to the measurements determined above. Calculate the average of the 3 measurements. Use the average as the thickness for the shim.
17. Install the left side service shim into the axle housing.
18. Move the differential assembly towards the left side of the axle housing.
19. Using the J 25588: installer, install the right side service shim into the axle housing..
20. Install the differential bearing caps and bolts and tighten to 75 N.m (55 lb ft).
21. Rotate the pinion several times to ensure the bearings have seated.
22. Using an inch-pound torque wrench, measure the rotating torque of drive pinion and differential case side bearings which should be 0.57-1.13 N.m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier.
23. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and the differential case bearing preload, measured in Step 23. Multiply the value obtained by the axle ratio.The differential side bearing preload should be 1.7-4.0 N.m (15-35 lb in).
24. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
25. Once the differential side bearing preload is within specifications, measure the backlash between the ring gear and the drive pinion and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
26. Once backlash and differential side bearing preload is within specifications, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

1. J 22779: Side Bearing Shim Gauge
2. J 24429: Side Bearing Backlash Spanner

Note. Ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used. The drive pinion bearing preload must be within specifications before the differential side bearing preload adjustment can be performed. The differential side bearings must be initially preloaded in order to determine the backlash of the gear set. After the backlash is set, the final bearing preload is set.

1. Remove the differential assembly, if necessary.
2. Using an inch-pound torque wrench, measure the rotating torque of the drive pinion bearing. should be 1.7-3.4 N.m (15-30 lb in) for new bearings and 1.1-2.3 N.m (10-20 lb in) for used bearings.
3. If the rotating torque of the drive pinion is less than: 1.7 N.m (15 lb in) for new bearings or 1.1 N.m (10 lb in) for used bearings, tighten the pinion in small increments until the specified rotating torque is obtained.
4. If the rotating torque of the drive pinion is greater than 3.4 N.m (30 lb in) for new bearings or 2.3 N.m (20 lb in) for used bearings, replace the collapsible spacer. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
5. Install the differential assembly, if necessary.
6. Support the differential assembly in order to prevent the differential assembly from falling out of the axle housing.
7. Slide the differential case assembly towards the right side axle housing until the ring gear contacts the drive pinion. This is the ZERO backlash point.
8. If the ZERO backlash cannot be obtained, turn the differential bearing adjuster nut into the axle housing using the J 24429 until the differential ring gear fully contacts the drive pinion to obtain the ZERO backlash. See «Special Tools»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
9. While holding the ring gear against the pinion, turn the differential bearing adjuster nut out from the axle housing using the J 24429 until it contacts the differential side bearing. See «Special Tools»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
10. Using the J 24429: spanner, turn the adjuster nut out from the rear axle housing an additional 2 slots.
11. Install the adjuster nut lock and the adjuster nut lock bolt.
12. Remove the left side differential bearing cap bolts.
13. Remove the left side differential bearing cap.
14. Install the J 22779 into the left side axle housing between the differential bearing bore and the differential bearing cup. See «Special Tools»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
15. Tighten the knob of the J 22779: gauge until there is moderate drag when the J 22779: gauge is moved.
16. Remove the J 22779: gauge and measure it at three different points.
17. Calculate the average of the 3 measurements. The value is the shim thickness required in order to set the initial backlash of the differential assembly.
18. Select a service shim of approximately the same thickness to install into the rear axle housing.
19. Install the service shim into the axle housing between the differential bearing bore and the differential bearing cup.
20. Install the left side differential bearing cap and the bolts.
21. Remove the differential bearing adjuster nut lock bolt and the lock.
22. Using the J 24429: spanner, tighten the differential bearing adjuster nut to ensure that the differential case assembly has a solid contact with the service shim.
23. Rotate the pinion several times in order to seat the bearings.
24. Using the J 24429: spanner, loosen the differential bearing adjuster nut until the nut is free from the differential side bearing.
25. Using the J 24429: spanner, the differential bearing adjuster nut until the differential bearing adjuster nut contacts the bearing.
26. Using the J 24429: spanner, tighten the differential bearing adjuster nut additional 3 slots for new bearings and an additional 2 slots for used bearings
27. Install the right differential bearing adjuster nut lock.
28. Install the right differential bearing adjuster nut lock bolt.
29. Tighten the differential bearing cap bolts to 85 N.m (63 lb ft).
30. Tighten the differential bearing adjuster nut lock bolt to 26 N.m(19 lb ft).
31. Using an inch-pound torque wrench, measure the drive pinion and differential case side bearing preload should be 0.57-1.13 N.m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier. Record the measurement.
32. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 32.
33. Multiply the value obtained by the axle ratio. The differential case side bearing preload should be 1.7-4.0 N.m (15-35 lb in).
34. Using the J 24429: spanner to tighten the adjuster nut one slot at a time in or out if the differential case side bearing preload is not within specifications.
35. Once the differential side bearing preload is correct, measure the drive pinion to differential assembly backlash and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .
36. Differential side bearing shims are available in the following sizes: Shim Sizes: 5.59 mm (0.220 in) 5.64 mm (0.222 in) 5.69 mm (0.224 in) 5.74 mm (0.226 in) 5.79 mm (0.228 in) 5.84 mm (0.230 in) 5.89 mm (0.232 in) 5.94 mm (0.234 in) 5.99 mm (0.236 in) 6.05 mm (0.238 in) 6.10 mm (0.240 in) 6.15 mm (0.242 in) 6.20 mm (0.244 in) 6.25 mm (0.246 in) 6.30 mm (0.248 in) 6.35 mm (0.250 in) 6.40 mm (0.252 in) 6.45 mm (0.254 in) 6.50 mm (0.256 in) 6.55 mm (0.258 in)

J 24429: Side Bearing Backlash Spanner

Note. The differential side bearing preload is adjusted by the 2 adjusting nuts in the bearing bore. The bore and the bearing cap provide the mating threads for the bearing nut. The differential must be initially preloaded in order to determine the backlash of the gear set. After the backlash is set, the final bearing preload is set. The rotating torque of the drive pinion must be within specifications before the pinion gear bearing retainer can be installed.

1. Install the pinion gear bearing retainer or the drive pinion. Refer to «Drive Pinion Housing and/or Seal Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Install the differential side bearing adjuster nuts.
4. Install the differential case assembly.
5. Install the differential bearing caps and bolts.
6. To establish the zero backlash point, slide the differential case assembly towards the right side axle housing until the ring gear contact the pinion.
7. Using the J 24429: spanner and holding the holding the differential ring gear against the drive pinion, turn the left differential bearing adjuster nut out from the axle housing until it contacts the differential side bearing.
8. Using the J 24429: spanner, turn the right differential bearing adjuster nut out from the axle housing until it contacts the differential side bearing.
9. Using the J 24429: spanner, back off the left adjusting nut approximately 2 slots in order to obtain the initial backlash adjustment.
10. Install the left adjuster nut lock and the adjuster nut lock bolt.
11. Using the J 24429: spanner, firmly tighten the right differential bearing adjuster nut in order to force the differential case assembly into solid contact with the left differential adjuster nut.
12. Rotate the pinion several times in order to seat the bearings.
13. Using the J 24429: spanner, loosen the right differential bearing adjuster nut until the nut is free from the differential side bearing.
14. Using the J 24429: spanner, tighten the right differential bearing adjuster nut until the differential bearing adjuster nut contacts the bearing.
15. Once the right differential bearing adjuster contacts the differential bearing, tighten the differential bearing adjuster nut. using the J 24429 the following additional amounts:. See «Special Tools»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
16. Using the J 24429: spanner, tighten the differential bearing adjuster nut an additional 2 slots for used bearings or an additional 3 slots for new bearings.
17. Install the right differential bearing adjuster nut lock.
18. Install the right differential bearing adjuster nut lock bolt.
19. Tighten the bearing cap bolts to 185 N.m (136 lb ft)..
20. Tighten differential bearing adjuster nut lock bolts to 27 N.m (20 lb ft).
21. Measure the ring gear to pinion backlash and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Backlash Adjustment (9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-95-ld-axle) or «Backlash Adjustment (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-105-inch-axle) .

Preliminary Inspection

Note. Ensure the brakes are fully released and do not drag.

Pull or push the tire at the top back and forth in order to test the wheel bearing play.

1. Use a pry bar under the tire as an alternative.
2. If the wheel bearing adjustment is correct, the movement will be barely noticeable.
3. If the movement is excessive, adjust the bearings.

J 2222-C Wheel Bearing Nut Wrench

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/avalanche/ii-2006-2013/remont/hoistjack/#general-information) .
2. Remove the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the hub adjuster nut retaining ring.
4. Remove the adjuster nut lock key.
5. Tighten the wheel bearing adjusting nut using the J 2222-C . Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder and tighten the adjusting nut to 70 N.m (52 lb ft).
6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C .
7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight.
8. Insert the adjusting nut lock key into the keyway using one of the following procedures: If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. NOTE: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key.
9. Install the retaining ring.
10. Install the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
11. Inspect the lubricant level and add, if necessary. Refer to «Rear Axle Lubricant Level Inspection (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-105) or «Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-lubricant-level-inspection-86) .
12. Lower the vehicle.

1. J 8001: Dial Indicator Set
2. J 25025-1: Guide Pins
3. J 25588: Side Bearing Shim Installer

1. Measure the rotating torque of the drive pinion and differential assembly. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the J 25025: pins and the J 8001: indicator to the axle housing.
3. Set the J 8001: indicator so that the stem is aligned with the gear rotation and square to the tooth angle.
4. Hold the drive pinion stationary, move the ring gear back and forth.
5. Repeat the measuring procedure at eight points around the ring gear.
6. The difference between the backlash at all of the measuring points should not vary by more than 0.05 mm (0.002 in).
7. If the difference between the backlash at all of the measuring points varies by more than 0.05 mm (0.002 in), inspect for burrs, a distorted case flange or uneven bolting.
8. If the difference between all the measuring points is within specifications, the backlash at the minimum lash point measured should be 0.08-0.25 mm (0.003-0.010 in) with a preferred backlash of 0.13-0.18 mm (0.005-0.007 in).
9. If the backlash is too small, increase the backlash using the following procedure: NOTE: Mark the bearing caps left or right. Remove the bearing cap bolts and the bearing caps. NOTE: Mark the bearing cups and the shims left or right. Remove the differential case assembly with the bearing cups and the shims. NOTE: Measure the production shim or the shim and service spacer in 3 locations. Measure each shim separately. Measure the thickness of left side shim pack. NOTE: Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the left side shim pack. Calculate the average of the 3 measurements for each shim. NOTE: If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to increase the backlash by 0.05 mm (0.002 in), remove 0.10 mm (0.004 in) of thickness from the left side shim pack. Assemble a new left side shim pack by decreasing the appropriate amount of thickness from the original left side shim pack. NOTE: Measure each shim separately. Measure the thickness of right side shim or the shim and service spacer in 3 locations. NOTE: Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the right side shim pack. Calculate the average of the 3 measurements for each shim. Assemble a new right side shim pack by increasing the appropriate amount of thickness to the original right side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to increase the backlash by 0.05 mm (0.002 in), add 0.10 mm (0.004 in) of thickness to the right side shim pack.
10. Use the following procedure to decrease the backlash if the backlash is too large: NOTE: Mark the bearing caps left or right. Remove the bearing cap bolts and the bearing caps. NOTE: Mark the bearing cups and the shims left or right. Remove the differential case assembly with the bearing cups and the shims. NOTE: Measure the production shim or the shim and service spacer in 3 locations. Measure each shim separately. Measure the thickness of left side shim pack. NOTE: Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the left side shim pack. Calculate the average of the 3 measurements for each shim. Assemble a new left side shim pack by increasing the appropriate amount of thickness to the original left side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to increase the backlash by 0.05 mm (0.002 in), add 0.10 mm (0.004 in) of thickness to the left side shim pack. NOTE: Measure the shim or the shim and service spacer in 3 locations. Measure each shim separately. Measure the thickness of right side shim pack. NOTE: Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the right side shim pack. Calculate the average of the 3 measurements for each shim. Assemble a new right side shim pack by decreasing the appropriate amount of thickness to the original right side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to decrease the backlash by 0.05 mm (0.002 in), remove 0.10 mm (0.004 in) of thickness to the right side shim pack.
11. Install the differential case assembly with the bearing cups.
12. Install the left side service spacer between the axle housing and the differential case.
13. Install the right side service spacer between the axle housing and the differential case.
14. Using the J 25588: installer, install the left side service shim or shims.
15. Using the J 25588: installer, install the right side service shim or shims.
16. Install the bearing caps and bolts and tighten to 75 N.m (55 lb ft).
17. Recheck the backlash and adjust, if necessary.
18. Once backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Backlash Adjustment (9.5 LD Axle)

Special Tools

1. J 8001: Dial Indicator Set
2. J 24429: Side Bearing Backlash Spanner
3. J 25025: Guide Pins

Note. Ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used. The differential side bearings must be initially preloaded in order to determine the backlash of the gear set. After the backlash is set, the final bearing preload is set.

1. Measure the rotating torque of the drive pinion and differential assembly. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle)
2. Install the J 25025: pins and the J 8001: indicator to the axle housing.
3. Set the J 8001-3 so that the stem is aligned with the gear rotation and square to the tooth angle.
4. Hold the drive pinion stationary, move the ring gear back and forth.
5. Repeat the measuring procedure at eight points around the ring gear.
6. The difference between the backlash at all of the measuring points should not vary by more than 0.05 mm (0.002 in).
7. If the difference between the backlash at all of the measuring points varies by more than 0.05 mm (0.002 in), inspect for burrs, a distorted case flange or uneven bolting.
8. If the difference between all the measuring points is within specifications, the backlash at the minimum lash point measured should be 0.08-0.25 mm (0.003-0.010 in) with a preferred backlash of 0.13-0.18 mm (0.005-0.007 in).
9. If the backlash is not within specifications, remove the differential bearing adjuster nut retainer bolt and retainer.
10. Loosen, but DO NOT remove the bearing cap bolts.
11. Using the J 24429: spanner, loosen the differential bearing adjuster nut.
12. Remove the differential side bearing shim and measure the thickness of the shim.
13. Calculate the average of the 3 measurements.
14. Install the selected shim.
15. Using the J 24429: spanner, tighten the differential bearing adjuster nut until the differential bearing adjuster nut is seated against the bearing cup.
16. With the differential bearing adjuster nut is seated against the differential bearing, use the J 24429: spanner tighten the differential bearing adjuster nut the following additional amounts. For used bearings, turn the differential adjuster nut an additional 2 slots. For new bearings, turn the differential adjuster nut an additional 3 slots.
17. Tighten the differential bearing cap bolts to 85 N.m (63 lb ft).
18. Install the differential bearing adjuster nut retainer.
19. Install the differential bearing adjuster nut retainer bolt and tighten to 26 N.m (19 lb ft).
20. Measure the drive pinion and differential case side bearing preload and adjust, if necessary following the steps above.
21. Once the backlash and bearing preload is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Backlash Adjustment (10.5 Inch Axle)

Special Tools

1. J 8001: Dial Indicator Set
2. J 24429: Side Bearing Backlash Spanner
3. J 25025: Guide Pins

Note. Ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used. The differential side bearings must be initially preloaded in order to determine the backlash of the gear set. After the backlash is set, the final bearing preload is set.

1. Measure the rotating torque of the drive pinion and differential assembly. Refer to «Drive Pinion Bearings Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion Bearings Replacement (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Install the J 8001: indicator and the J 25025: pins to the axle housing.
3. Place the indicator stem of the J 8001: indicator at the heel end of a gear tooth.
4. Set the J 8001: indicator so that the stem is aligned with the gear rotation and square to the tooth angle.
5. Hold the drive pinion stationary, move the ring gear back and forth.
6. Repeat the measuring procedure at eight points around the ring gear.
7. The difference between the backlash at all of the measuring points should not vary by more than 0.05 mm (0.002 in).
8. If the difference between the backlash at all of the measuring points varies by more than 0.05 mm (0.002 in)., inspect for burrs, distorted case flange or uneven bolting.
9. If the difference between all the measuring points is within specifications, the backlash at the between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred backlash of 0.13-0.18 mm (0.005-0.007 in) at the minimum lash point.
10. If the backlash is not within specifications, remove the differential bearing adjuster nut retainers bolts.
11. Remove the differential bearing adjuster nut retainers.
12. Remove the bearing cap bolts.
13. Remove the bearing caps.
14. If the backlash is less than, use the J 24429: spanner to increase the backlash by turning the left differential bearing adjuster in one slot and the right differential bearing adjuster out one slot until the correct backlash is obtained.
15. If the backlash is greater than, use the J 24429: spanner to decrease the backlash by turning the right differential bearing adjuster in one slot and the left differential bearing adjuster out one slot until the correct backlash is obtained.
16. Install the bearing caps.
17. Install the bearing cap bolts and tighten to 185 N.m (136 lb ft).
18. Recheck the backlash following the steps above to verify that the backlash is within specifications.
19. Install the differential bearing adjuster nut retainers.
20. Install the differential bearing adjuster nut retainer bolts to tighten to 27 N.m (20 lb ft).
21. Measure the drive pinion and differential case side bearing preload and adjust, if necessary following the steps above.
22. Once the backlash and bearing preload is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Gear Tooth Contact Pattern Inspection

Pattern Evaluation (Ring Gear) Drive Side Coast Side Pattern Condition Corrective Action Heel Toe Toe Heel If the pinion depth needs to be adjusted, refer to Pinion Depth Adjustment (8.6 Inch Axle) or Pinion Depth Adjustment (9.5LD Inch Axle) or Pinion Depth Adjustment (10.5 Inch Axle) . If the backlash needs to be adjusted, refer to Backlash Adjustment (8.6 Inch Axle) or Backlash Adjustment (9.5 LD Axle) or Backlash Adjustment (10.5 Inch Axle) . For the ring gear to pinion gear wear pattern test and the proper identification of the 2-Cut and 5-Cut, refer to Differential Drive Pinion Gear and Ring Gear Description and Operation . Drive Side Centered - Coast Side Centered No correction required. Drive Pinion Issue - 2-Cut Gearset Drive Side Low Heel Contact - Coast Side High Heel Contact Inspect the backlash to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in) If backlash is correct, move the drive pinion closer to the ring gear by increasing the thickness of the pinion shim on a one-piece axle housing or by decreasing the thickness of the pinion shim on the 10.5 inch two-piece axle housing. Drive Side Low Heel Contact - Coast Side Low Toe Contact Inspect the backlash to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in) If backlash is correct, move the drive pinion away from the ring gear by decreasing the thickness of the pinion shim on a one-piece axle housing or by increasing the thickness of the pinion shim on the 10.5 inch two-piece axle housing. Backlash Issue Drive Side High Heel Contact - Coast Side High Toe Contact Backlash incorrect. The ring gear is too far away from the drive pinion. Inspect and adjust the backlash as necessary to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in). Drive Side Low Toe Contact - Coast Side Low Heel Contact Backlash incorrect. The ring gear is too close to the drive pinion. Inspect and adjust the backlash as necessary to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in). Drive Side Centered - Coast Side Centered No correction required. Drive Pinion Issue - 5-Cut Gearset Drive Side High and Slightly Heel Contact - Coast Side High and Slightly Toe Contact Inspect the backlash to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in) If backlash is correct, move the drive pinion closer to the ring gear by increasing the thickness of the pinion shim on a one-piece axle housing or by decreasing the thickness of the pinion shim on the 10.5 inch two-piece axle housing. Drive Side Low and Slightly Heel Contact - Coast Side High and Slightly Toe Contact Inspect the backlash to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in) If backlash is correct, move the drive pinion away from the ring gear by decreasing the thickness of the pinion shim on a one-piece axle housing or by increasing the thickness of the pinion shim on the 10.5 inch two-piece axle housing. Backlash Issue Drive Side Heel Contact - Coast Side Toe Contact Backlash incorrect. The ring gear is too far away from the drive pinion. Inspect and adjust the backlash as necessary to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in). Drive Side Toe Contact - Coast Side Heel Contact Backlash incorrect. The ring gear is too close to the drive pinion. Inspect and adjust the backlash as necessary to ensure that it is approximately 0.08-0.13 mm (0.003-0.005 in)

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Drive Side Heel Toe Pattern Condition Coast Side Toe Heel Pattern Condition Corrective Action Face Hobbing Toe Contact Heel Contact Pinion shim correct. Increase backlash. Desirable Pattern - Drive pattern should be centered on tooth Desirable Pattern - Coast pattern should be center to slightly toe on tooth No correction required. Top Toe Contact Top Heel Contact Backlash correct. Increase in pinion shim. Root Heel Contact Root Toe Contact Backlash correct. Decrease in pinion shim. Top Heel Contact Top Toe Contact Pinion shim correct. Decrease backlash. Root Toe Contact Root Heel Contact Pinion shim correct. Increase backlash. Face Milling Desirable Pattern - Drive pattern should be centered on tooth Desirable Pattern - Coast pattern should be center to slightly toe on tooth No correction required. Top and Slightly Heel Contact Top and Slightly Toe Contact Backlash correct. Increase in pinion shim. Root and Slightly Toe Contact Root and Slightly Heel Contact Backlash correct. Decrease in pinion shim. Heel Contact Toe Contact Pinion shim correct. Decrease backlash

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Locking Differential Disassemble (10.5 Inch Axle)

1. Remove the differential case assembly. Refer to «Differential Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Remove the differential ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the differential case screws.
5. Use the yoke hole location to pry and separate the differential case halves.
6. Hold the locking differential cam, side gear, and the clutch plate assembly in the right side case half.
7. Remove the differential governor.
8. Remove the differential governor lock.
9. Remove the locking differential thrust block.
10. Remove the locking differential spider, pinion gears and the thrust washers.
11. Remove the locking differential side gear.
12. Remove the left side clutch plates and the guide clips.
13. Remove the left side gear thrust washer.
14. Remove the right side cam unit and clutch plate assembly.
15. Remove the right side locking differential clutch disc thrust washer.
16. Disassemble the left side differential side gear and clutch disc assembly. Refer to «Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-clutch-disc-assembly-disassemble) or «Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-clutch-disc-assembly-disassemble) or «Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-clutch-disc-assembly-disassemble) .
17. Disassemble the right side locking differential side gear cam unit and clutch disc assembly. Refer to «Locking Differential Cam Unit Disassemble (8.6 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-cam-unit-disassemble-86) or «Locking Differential Cam Unit Disassemble (9.5 INch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Locking Differential Cam Unit Disassemble (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

J 26252: Positraction Bushing Remover

Disassemble

1. Remove the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
2. Using the J 26252: remover, remove the governor bushing.
3. Using the J 26252: remover, remove the latching bracket assembly bushing.
4. Remove the pinion shaft lock bolt.
5. Remove the pinion shaft.
6. Remove the differential pinion gears and the thrust washers by rotate the pinion gears and roll the pinion gears and the thrust washers out of the case through the differential opening.
7. Remove the thrust block, right side gear and clutch discs assembly and the right side shim..
8. Remove the left side gear cam unit and clutch disc assembly.
9. Remove the left side gear thrust washer.

Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle)

1. Remove the guide clips (3).
2. Remove the clutch discs and the splined discs (2, 4-6) from the locking differential side gear (1).

Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle)

1. Remove the guide clips (2).
2. Remove the clutch discs and the splined discs (3-7) from the locking differential side gear (1).

Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle)

1. Remove the guide clips (6).
2. Remove the clutch discs and the splined discs (2-5, 7) from the locking differential side gear (1).

Locking Differential Cam Unit Disassemble (8.6 Inch Axle)

1. Remove the locking differential clutch disc thrust washer.
2. Using the appropriate tool, remove the external snap ring retainer.
3. Remove and disassemble the locking differential clutch disc set (1).
4. Remove the locking differential clutch disc thrust washer (4).
5. Remove the locking differential clutch disc guide (5).
6. Remove the locking differential cam (3).

1. J 22912-01: Split Plate Bearing Puller
2. J 45232: Adjuster Bearing Replacer (Left Side)

1. Measure and record the overall length of the locking differential side gear assembly from the front of the locking differential side locking differential side gear to thrust washer.
2. Remove the guide clips.
3. Using the J 22912-01: puller (2), J 45232: replacer (1) and a hydraulic press, remove the locking differential side gear thrust sleeve.
4. Remove the locking differential clutch disc thrust washer (7).
5. Remove the locking differential side gear thrust sleeve (6).
6. Remove the locking differential clutch disc set (1).
7. Remove the locking differential clutch disc guide.
8. Disassemble the locking differential clutch disc assembly (1).

1. J 22912-01: Split Plate Bearing Puller
2. J 45232: Adjuster Bearing Replacer (left Side)

1. Measure and record the overall length of the locking differential cam, side gear and clutch plate assembly from the front of the gear to the back of the thrust sleeve, including the locking differential clutch disc thrust washer.
2. Remove the guide clips.
3. Using a hydraulic press, the J 22912-01: puller (2) and the J 45232: replacer (1), remove the thrust sleeve.
4. Remove the differential side gear shim (6).
5. Remove the locking differential side gear thrust sleeve (5).
6. Remove and disassemble the locking differential clutch disc set (7).
7. Remove the locking differential clutch disc thrust washer (3).
8. Remove the locking differential clutch disc guide (4).
9. Remove the locking differential cam (2).

Locking Differential Cleaning and Inspection

1. Clean all the parts with an approved solvent.
2. Visually inspect all the parts for excessive wear or breakage. Replace the parts if necessary.
3. Inspect the pinion gear and the side gear teeth for any the following conditions: Wear Cracks Scoring Spalling
4. Inspect the thrust washers for wear.
5. Inspect the fit of the side gears on the axle shafts.
6. Inspect the differential case for cracks and scoring.
7. Inspect the thrust sleeve for excessive wear.
8. Inspect the side gear bore for scoring. If scoring is present, replace the entire differential.
9. Replace the differential if you find any damage to the case.

Locking Differential Cam Unit Assemble (8.6 Inch Axle)

1. Apply axle lubricant to the locking differential clutch (friction disc) contact area. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
2. Install the locking differential cam (3) on the locking differential side gear (2).
3. Install the locking differential clutch disc set (1) on the locking differential side gear (2).
4. Compress the locking differential clutch disc set assembly.
5. Using the appropriate tool, install the external span ring retainer.
6. Apply a small amount of chassis grease to hold the locking differential clutch disc guide (5). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .

J 29710: Differential Side Bearing Installer

Assemble

1. Apply axle lubricant to each of the locking differential clutch (friction disc) contact area. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
2. Install the locking differential cam (3) on the locking differential side gear (2).
3. Install the locking differential clutch disc set (1) on the locking differential side gear (2).
4. Position the locking differential side gear thrust sleeve (5).
5. Using the J 29710: installer and a hydraulic press, install the locking differential side gear thrust sleeve until it is fully seated on the locking differential side gear.
6. If the locking differential cam side gear or the locking differential thrust sleeve has been replaced, measure the overall length of the gear assembly by doing the following: Place the locking differential clutch disc thrust washer on top of the thrust sleeve. Measure the overall length of the gear assembly from the front of the cam side gear to the back of the locking differential clutch disc thrust washer. Compare this measurement to the measurement obtained during disassembly. If the new reading is more than 0.762 mm (0.003 in) higher or lower than the original, select a locking differential clutch disc thrust washer that will return the reading closest to the original reading.
7. Align the ears of all the clutch discs.
8. Install the guide clips to the clutch disc assembly and apply chassis grease to the locking differential guides. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .

J 29710: Differential Side Bearing Installer Differential Side Bearing Installer

1. Apply axle lubricant to each of the locking differential clutch (friction disc) contact area. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers)
2. Install the locking differential cam (2) on the locking differential side gear (1).
3. Install the locking differential clutch disc set (7).
4. Position the locking differential side gear thrust sleeve (5) on the locking differential side gear (1).
5. Using the J 29710: installer and a hydraulic press, install the locking differential side gear thrust sleeve until it is fully seated on the locking differential side gear.
6. If the cam side gear or the thrust sleeve has been replaced, measure the overall length of the gear assembly by doing the following: Place the locking differential clutch disc thrust washer on top of the thrust sleeve. Measure the overall length of the gear assembly from the front of the cam side gear to the back of the locking differential clutch disc thrust washer. Compare this measurement to the measurement obtained during disassembly. If the new reading is more than 0.762 mm (0.003 in) greater than or less than the original, select a locking differential clutch disc thrust washer that will return the reading closest to the original reading.
7. Align the locking differential clutch disc set.
8. Install the and apply a small amount of chassis grease to the locking differential guides. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .

Locking Differential Clutch Disc Assembly Assemble (8.6 Inch Axle)

1. Apply the correct axle lubricant to the surface of each disc. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
2. Assemble the right side or bell-end side clutch disc assembly as follows: Install the two-sided carbon eared disc (2) to the side gear (1). Install the 1st splined disc (4). Install the 2nd splined disc (5). Install the one-sided carbon eared disc (6). Install the guide clips (3) to the clutch discs (2, 4-6). Apply chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .

Locking Differential Clutch Disc Assembly Assemble (9.5LD Axle)

1. Apply proper axle lubricant to the surface of each disc. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
2. Assemble the right side or bell-end side clutch disc assembly as follows: Install the 1st non-carbon eared disc (3) to the side gear (1). Install the 1st splined disc (4). Install the 2nd non-carbon eared disc (5). Install the 2nd splined disc (6). Install the 3rd non-carbon eared disc (7). Install the guide clips (2) to the clutch discs (2-7). Apply chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .

Locking Differential Clutch Disc Assembly Assemble (10.5 Inch Axle)

1. Apply the proper axle lubricant to the surface of each disc. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
2. Assemble the left side clutch disc assembly as follows: Install the 1st non-carbon eared disc (2) to the side gear (1). Install the 1st splined disc (3). Install the 2nd non-carbon eared disc (4). Install the 2nd splined disc (5). Install the 3rd non-carbon eared disc (7). Align the ears of all the clutch discs. Install the guide clips (6) to the clutch discs (2-5, 7). Apply the proper chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .

1. J 7872: Magnetic Base Indicator Set
2. J 8001: Dial Indicator Set

Adjustment of the Differential

Note. If it is necessary to replace the left side locking differential side gear cam unit and clutch disc assembly, the right side locking differential side gear and clutch disc assembly, or the thrust block, the entire differential must be adjusted. The differential is adjusted using selective thickness thrust washers between the clutch disc assemblies and the case and/or different selective thickness thrust blocks. When adjusting the differential, note the following

1. Assemble the clutch disc assemblies properly.
2. Adjust the backlash and thrust block clearance in the following order: The left side gear backlash The right side gear backlash The thrust block clearance

Left Side Gear Backlash Adjustment

1. Install the new locking differential clutch disc thrust washer.
2. Install the locking differential side gear cam unit and clutch disc assembly.
3. Install the differential pinion gears with the differential pinion gear thrust washers into the differential case.
4. Install the pinion shaft and the bolt.
5. Rotate the pinion gear closest to the lock bolt so that one of the teeth is pointing downward, square to the ring gear flange.
6. Install a brass drift between the locking differential side gear cam unit and the pinion shaft.
7. Press the brass drift in far enough in order to compress the clutch discs.
8. Measure the backlash of the differential pinion gear and the locking differential side gear cam unit by doing the following: Install the J 7872: base (1) and the J 8001: indicator (2) to the ring gear flange. Place the contact pad of the J 8001: indicator (2) on one of the teeth of the pinion gear closest to the pinion shaft lock bolt and zero the gauge. Pull the pinion gear firmly into the differential case seat. Rotate the pinion gear back and forth. NOTE: If the backlash is greater than, install a thicker locking differential clutch disc thrust washer and recheck the backlash. If the backlash is less than, install a thinner locking differential clutch disc thrust washer and recheck the backlash The backlash between the differential pinion gear and the locking differential side gear cam unit should be: For the 8.6 inch axle, 0.254-0.406 mm (0.010-0.016 in). For the 9.5 LD axle, 0.279-0.432 mm (0.011-0.017 in).
9. Locking differential clutch disc thrust washers are available in the following sizes: Washer Sizes: 0.559 mm (0.022 in) 0.686 mm (0.027 in) 0.813 mm (0.032 in) 0.914 mm (0.036 in) 1.016 mm (0.040 in) 1.118 mm (0.044 in) 1.219 mm (0.048 in) 1.321 mm (0.052 in)

Right Side Gear Backlash Adjustment

1. If necessary, remove the following from the differential case: The pinion lock shaft bolt The pinion shaft The differential pinion gears The differential pinion gear thrust washers The left side locking differential side gear cam unit and clutch disc assembly
2. Install the differential side gear shim into the right side of the differential case.
3. Install the locking differential side gear and clutch disc assembly.
4. Align the openings of the differential pinion gears and the differential pinion gear thrust washers to the pinion shaft opening in the differential case.
5. Install the differential pinion gears with the differential pinion thrust washers into the differential case.
6. Install the pinion shaft lock and the bolt.
7. Rotate the differential pinion gear so that one of the teeth is pointing downward, square to the ring gear flange.
8. Install a brass drift between the locking differential side gear and the pinion shaft.
9. Press the brass drift in enough in order to compress the clutch discs.
10. Measure the backlash of the pinion gear and the right side gear by doing the following: Install the J 7872: base (1)and the J 8001: indicator (2) to the ring gear flange. Place the contact pad of the J 8001: indicator (2) on one of the teeth of the pinion gear closest to the pinion shaft lock bolt and zero the gauge. Pull the pinion gear firmly into the differential case seat. Rotate the pinion gear back and forth. NOTE: If the backlash is greater than, install a thicker locking differential clutch disc thrust washer and recheck the backlash. If the backlash is less than, install a thinner locking differential clutch disc thrust washer and recheck the backlash The backlash between the differential pinion gear and the locking differential side gear cam unit should be: For the 8.6 inch axle 0.076-0.229 mm (0.003-0.009 in). For the 9.5 LD axle 0.051-0.203 mm (0.002-0.008 in).

Differential side gear shims are available in the following sizes

Shim Sizes

1. 0.254 mm (0.010 in)
2. 0.381 mm (0.015 in)
3. 0.508 mm (0.020 in)
4. 0.635 mm (0.025 in)
5. 0.762 mm (0.030 in)
6. 0.889 mm (0.035 in)
7. 1.016 mm (0.040 in)
8. 1.143 mm (0.045 in)

Thrust Block Clearance Adjustment

1. Install the locking differential clutch disc thrust washer into the left side or flange-end of the differential case.
2. Install the locking differential side gear cam unit and clutch disc assembly into the left side or flange-end of the differential case.
3. Install the differential side gear shim into the right side of the differential case.
4. Install the locking differential side gear and clutch disc assembly into the right side of the differential case.
5. Install the pinion shaft and the bolt.
6. Install a brass drift between the left locking differential side gear cam unit and the pinion shaft.
7. Press the brass drift in far enough in order to compress the clutch disc assembly and hold the left side gear assembly in place.
8. Install a brass drift between the right side locking differential side gear and the pinion shaft.
9. Press the brass drift in far enough in order to hold the right side gear assembly in place.
10. Using a 25.4-50.8 mm (1-2 in) telescoping gage, measure the distance between the side gear faces.
11. Measure the telescoping gage with a micrometer and record the measurement.
12. Compare the measurement obtained in step 11 to the thrust block sizes available.
13. If the measurement obtained in step 11 is not equal to one of the thrust blocks sizes available, then select the thrust block that is smaller than the measurement.
14. If the measurement obtained in step 11 is less than 33.578 mm (1.322 in) for the 8.6 inch axle or 40.488 mm (1.622 in) for the 9.5LD axle, then reduce the left side gear thrust washer or the right side gear shim thickness in order to increase the thrust block opening.
15. If the measurement obtained in step 11 is greater than 34.290 mm (1.350 in) for the 8.6 inch axle or 41.120 mm (1.622 in) for the 9.5LD axle, then increase the left side gear thrust washer or the right side gear shim thickness in order to decrease the thrust block opening.
16. Recheck the left and/or right side gear backlash and adjust as necessary.
17. Recheck the thrust block clearance and adjust as necessary.
18. Assemble the differential. Refer to «Locking Differential Assemble (8.6, 9.5LD Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-assemble-86-95ld-axles) or «Locking Differential Assemble (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__locking-differential-assemble-105-inch-axle) .

1. J 7872: Magnetic Base Indicator
2. J 8001: Dial Indicator
3. J 34672: Depth Micrometer
4. J 34673: Flat Gage Bar

Note. If it is necessary to replace the right side cam gear and clutch disc assembly, the left hand side gear and clutch disc assembly, or the thrust block, the entire differential must be adjusted. The differential is adjusted using selective thickness thrust washers between the clutch pack assemblies and case and/or different selective thickness thrust blocks.

When adjusting the differential, note the following

1. Assemble the clutch disc sets properly.
2. Adjust the backlash and thrust block clearance in the following order: The left side gear backlash The right side gear backlash The thrust block clearance

1. Install the locking differential clutch disc thrust washer.
2. Install the locking differential clutch disc set.
3. Install the differential side gear.
4. Install the long bolt, washers and nut
5. Install the differential case half into a vise.
6. Clamp on the nut on the bottom of the differential case.
7. Install the differential pinion gears, thrust washers and the locking differential spider into the case half.
8. Install the J 7872: base and the J 8001: indicator on the differential case.
9. Adjust the J 8001: indicator on the tooth that is square to the differential side gear and set the J 8001: indicator to zero
10. Measure the differential pinion gear to locking differential side gear backlash by performing the following steps: Pull the pinion gear firmly into the seat. Rotate the pinion gear back and forth. Record the measurement.
11. The backlash between the differential pinon gear and locking differential side gear should be between 0.051-0.203 mm (0.002-0.008 in).
12. Differential side gear shims are available in the following sizes

Shim Sizes

1. 0.254 mm (0.010 in)
2. 0.381 mm (0.015 in)
3. 0.508 mm (0.020 in)
4. 0.635 mm (0.025 in)
5. 0.762 mm (0.030 in)
6. 0.899 mm (0.035 in)
7. 1.016 mm (0.040 in)
8. 1.143 mm (0.045 in)
9. 1.270 mm (0.050 in)
10. 1.397 mm (0.055 in)
11. 1.524 mm (0.060 in)

1. Install the locking differential clutch disc thrust washer.
2. Install the locking differential cam unit.
3. Install the long bolt, washers and nut
4. Install the differential case half into a vise.
5. Clamp on the nut on the bottom of the differential case.
6. Install the differential pinion gears, thrust washers and the locking differential spider into the case half.
7. Install the J 7872: base and the J 8001: indicator on the differential case.
8. Adjust the J 8001: indicator on the tooth that is square to the differential side gear and set the J 8001: indicator to zero
9. Measure the differential pinion gear to locking differential side gear backlash by performing the following steps: Pull the pinion gear firmly into the seat. Rotate the pinion gear back and forth. Record the measurement.
10. The backlash between the differential pinon gear and locking differential side gear should be between 0.279-0.432 mm (0.011-0.017 in).
11. Differential side gear shims are available in the following sizes: Washer Sizes 0.559 mm (0.022 in) 0.686 mm (0.027 in) 0.813 mm (0.032 in) 0.914 mm (0.036 in) 1.016 mm (0.040 in) 1.067 mm (0.042 in) 1.118 mm (0.044 in) 1.219 mm (0.048 in) 1.321 mm (0.052 in)

Note. The left and right side gear backlash measurements must be done before the thrust block measurement can be completed.

1. Install the differential side gear shim.
2. Install the clutch pack assembly.
3. Install the differential side gear.
4. Assemble a set of washers, a nut, and a bolt long enough in order to hold the side gear in place.
5. Install the bolt and washer assembly through the differential case half.
6. Install a second set of washers and the nut onto the bolt extending through the differential case half.
7. Install the differential case half into a vise.
8. Clamp on the nut on the bottom of the differential case.
9. Tighten the bolt until the clutch plates are compressed.
10. Install the J 34673: bar (2) and the J 34672: micrometer (1) onto the differential case as shown.
11. Install the J 34673 onto the face of the differential case, not the ridge of the differential case, or an inaccurate measurement will result.
12. Using the J 34672: micrometer and the J 34673: bar, measure and record the depth from the face of the to the face of the differential side gear.
13. Measure the thickness of the J 34673: bar subtract from the measurement obtained in step 10 and record the measurement. This measurement is equal to one-half of the thrust block thickness.
14. Remove the differential case half from the vise.
15. Install the locking differential clutch disc thrust washer.
16. Install the differential side gear cam unit.
17. Assemble a set of washers, a nut, and a bolt long enough in order to hold the side gear in place.
18. Install the long bolt, washers and nut
19. Install the differential case half into a vise.
20. Clamp on the nut on the bottom of the differential case.
21. Install the J 34673: bar (2) and the J 34672: micrometer (1) onto the differential case.
22. Using the J 34673: bar and the J 34672: micrometer, measure and record the depth from the face of the to the face of the differential side gear.
23. Measure the thickness of the J 34673: bar subtract from the measurement obtained in step 23.
24. Add the measurements in step 12 and step 25 together. This is the thickness for the thrust block.
25. Compare the measurement obtain in step 25 to the thrust block sizes available.
26. If the measurement obtained in step 25 is less then 40.488 mm (1.594 in), then reduce the left differential side gear shim or the right locking differential clutch disc thrust washer thickness in order to increase the thrust block opening.
27. If the measurement obtained in step 25 is greater then 41.120 mm (1.622 in), then increase the left differential side gear shim or the right locking differential clutch disc thrust washer thickness in order to decrease the thrust block opening.
28. Recheck the left and/or right side gear backlash and adjust as necessary.
29. Recheck the thrust block clearance and adjust as necessary.

Locking Differential Assemble (8.6, 9.5LD Axles)

Note. The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the locking differential can be assembled.

1. Install the left side gear thrust washer.
2. Install the left side gear cam unit and clutch disc assembly.
3. Install the right side gear thrust washer.
4. Install the right side clutch disc assembly.
5. Install the right side gear.
6. Install the pinion gear and the pinion thrust washers.
7. Rotate the pinion gears and the pinion thrust washers 90 degrees and align the pinion gears with the pinion shaft opening in the differential case.
8. Install the thrust block.
9. Install the pinion shaft and the NEW lock bolt.
10. Install the governor assembly.
11. Using a hammer and a brass drift, install the governor bushing until there is 0.25-1.27 mm (0.010-0.050 in) of shaft end play.
12. Install the latching bracket assembly.
13. Using a hammer and a brass drift, install the latching bracket bushing until there is 0.000-0.051 mm (0.000-0.002 in) of shaft end play.
14. Tighten the pinion shaft lock bolt to. For the 8.6 inch axle, tighten the bolt to 36 N.m (27 lb ft). For the 9.5LD axle, tighten the bolt to 50 N.m (37 lb ft).
15. Install the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

Locking Differential Assemble (10.5 Inch Axle)

Note. The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the differential can be assembled.

1. Install the right side differential side gear shim into the right differential case half.
2. Install the locking differential side gear cam unit and clutch disc assembly.
3. Install the latching bracket and spring assembly.
4. Install the governor assembly.
5. Position the straight end of the latching bracket spring over the governor assembly shaft.
6. Install the locking differential spider, the differential pinion gears, and the differential pinion gear thrust washers into the differential case.
7. Install the thrust block.
8. Install the left side differential side gear shim into the left differential case half.
9. Install the left side clutch disc assembly.
10. Install the locking differential side gear.
11. Install the left case half to the right case half. Hold the left side locking differential side gear and clutch disc assembly in the left side case half. Align the governor and latching bracket assembly shaft with the holes in the left case half.
12. Turn the differential case over onto the left case half.
13. Install the differential case screws. Tighten: Tighten the differential case screws to 17 N.m (13 lb ft).
14. Install the ring gear. Refer to «Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) or «Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .
15. Install the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle) .

Drive Pinion and Ring Gear Identification

Production drive pinion and ring gears are manufactured by using a 2 cut or a 5 cut method. The 2 cut drive pinions and ring gears can be identified by having a groove cut into the outside edge of the ring gear and a ring on the stem of the drive pinion. The gear tooth contact patterns that are produced from each style of gear set differ slightly. A 2 cut gear will produce a pattern that is bias from the toe to the heel of the tooth (drive side), while a 5 cut gear will produce a square pattern from the toe to the heel of the (drive side). When diagnosing the gear tooth contact pattern, regardless of what type of gear set it is, a correct pattern will be centered within the area of the tooth, from the toe to the heel and from the top to the bottom. For the proper gear tooth wear pattern, refer to Gear Tooth Contact Pattern Inspection .

Test Procedure

1. Using the appropriate cleaning solvent, remove the lubricant from the differential housing and from the teeth of the ring gear.
2. Using a medium stiff brush, sparingly apply gear marking compound to all of the ring gear teeth. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__adhesives-fluids-lubricants-and-sealers) .
3. Torque the differential bearing caps. Tighten the differential bearing caps. For the 8.6 inch axle, tighten the bearing caps to 75 N.m (55 lb ft) For the 9.5 inch LD axle, tighten the bearing caps to 95 N.m (63 lb ft) For the 10.5 inch axle, tighten the bearing caps to 185 N.m (136 lb ft)
4. Apply the park brake until the torque load is 14 N.m (10 lb ft) is required to rotate the pinion.
5. Using the appropriate size wrench, slowly rotate the drive pinion flange/yoke 3 complete revolutions clockwise.
6. Slowly rotate the drive pinion flange/yoke 3 complete revolutions counter-clockwise.
7. Observe the contact pattern on the teeth. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/avalanche/ii-2006-2013/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Locking Differential Description and Operation

The locking differential consists of the following components

1. Differential case - 1 or 2 piece
2. Locking differential spider - 2 piece case only
3. Pinion gear shaft - 1 piece case only
4. Differential pinion gear shaft lock bolt - 1 piece case only
5. Two clutch discs sets
6. Locking differential side gear
7. Thrust block
8. Locking differential clutch disc guides
9. Differential side gear shim
10. Locking differential clutch disc thrust washer
11. Locking differential governor
12. Latching bracket
13. Cam plate assembly
14. Differential pinion gears
15. Differential pinion gear thrust washers

The optional locking differential (RPO G80) enhances the traction capability of the rear axle by combining the characteristics of a limited-slip differential and the ability of the axle shafts to "lock" together when uneven traction surfaces exist. The differential accomplishes this in 2 ways. First by having a series of clutch plates at each side of the differential case to limit the amount of slippage between each wheel. Second, by using a mechanical locking mechanism to stop the rotation of the right differential side gear, in order to transfer the rotating torque of the wheel without traction to the wheel with traction. Each of these functions occur under different conditions.

Limited-Slip Function

Under normal conditions, when the differential is not locked, a small amount of limited-slip action occurs. The gear separating force developed in the right-hand clutch pack is primarily responsible for this.

The operation of how the limited-slip function of the unit works can be explained when the vehicle makes a right-hand turn. Since the left wheel travels farther than the right wheel, it must rotate faster than the ring gear and differential case assembly. This results in the left axle and left side gear rotating faster than the differential case. The faster rotation of the left-side gear causes the pinion gears to rotate on the pinion shaft. This causes the right-side gear to rotate slower than the differential case.

Although the side gear spreading force produced by the pinion gears compresses the clutch packs, primarily the right side, the friction between the tires and the road surface is sufficient to overcome the friction of the clutch packs. This prevents the side gears from being held to the differential case.

Locking Function

Locking action occurs through the use of some special parts

1. A governor mechanism with 2 flyweights
2. A latching bracket
3. The left side cam plate and cam side gear

When the wheel-to-wheel speed difference is 100 RPM or more, the flyweights of the governor will fling out and one of them will contact an edge of the latching bracket. This happens because the left cam side gear and cam plate are rotating at a speed different, either slower or faster, than that of the ring gear and differential case assembly. The cam plate has teeth on its outer diameter surface in mesh with teeth on the shaft of the governor.

As the side gear rotates at a speed different than that of the differential case, the shaft of the governor rotates with enough speed to force the flyweights outward against spring tension. One of the flyweights catches its edge on the closest edge of the latching bracket, which is stationary in the differential case. This latching process triggers a chain of events.

When the governor latches, it stops rotating. A small friction clutch inside the governor allows rotation, with resistance, of the governor shaft while one flyweight is held to the differential case through the latching bracket. The purpose of the governor's latching action is to slow the rotation of the cam plate as compared to the cam side gear. This will cause the cam plate to move out of its detent position.

The cam plate normally is held in its detent position by a small wave spring and detent humps resting in matching notches of the cam side gear. At this point, the ramps of the cam plate ride up on the ramps of the cam side gear, and the cam plate compresses the left clutch pack with a self-energizing action.

As the left clutch pack is compressed, it pushes the cam plate and cam side gear slightly toward the right side of the differential case. This movement of the cam side gear pushes the thrust block which compresses the right-hand side gear clutch pack.

At this point, the force of the self-energizing clutches and the side gear separating force combine to hold the side gears to the differential case in the locking stage.

The entire locking process occurs in less than 1 second. The process works with either the left or right wheel spinning, due to the design of the governor and cam mechanism. A torque reversal of any kind will unlatch the governor, causing the cam plate to ride back down to its detent position. Cornering or deceleration during a transmission shift will cause a torque reversal of this type. The differential unit returns to its limited-slip function.

The self-energizing process would not occur if it were not for the action of one of the left clutch discs. This energizing disc provides the holding force of the ramping action to occur. It is the only disc which is splined to the cam plate itself. The other splined discs fit on the cam side gear.

If the rotating speed of the ring gear and differential case assembly is high enough, the latching bracket will pivot due to centrifugal force. This will move the flyweights so that no locking is permitted. During vehicle driving, this happens at approximately 32 km/h (20 mph) and continues at faster speeds.

When comparing the effectiveness of the locking differential, in terms of percent-of-grade capability to open and limited-slip units, the locking differential has nearly 3 times the potential of the limited-slip unit under the same conditions.

Locking Differential Torque-Limiting Disc

The locking differential design was modified in mid-1986 to include a load-limiting feature to reduce the chance of breaking an axle shaft under abusive driving conditions. The number of tangs on the energizing disc in the left-hand clutch pack was reduced allowing these tangs to shear in the event of a high-torque engagement of the differential locking mechanism.

At the time of failure of the load-limiting disc, there will be a loud bang in the rear axle and the differential will operate as a standard differential with some limited-slip action of the clutch packs at low torques.

The service procedure, when the disc tangs shear, involves replacing the left-hand clutch plates and the wave spring. It is also necessary to examine the axle shafts for twisting because at high torques it is possible to not only shear the load-limiting disc, but to also twist the axle shafts.

Rear Axles for this vehicle consist of the following components

1. Differential Axle Housing
2. Differential Carrier
3. Right and left Axle tubes
4. Right and left axle shafts

The 900 series utility vehicles use either the 8.60 or the 9.50 inch axles. The type of the axle can be identified by the stamping on the right side axle tube. They may also be identified by the ring gear size. The ring gear sizes include the 8.60 and the 9.50 inch axles. The locking differential information for these rear axles can be located in the locking differential section.

A open differential has a set of 4 gears. 2 are side gears and 2 are pinion gears. Each side gear is splined to an axle shaft so each axle shaft ; so each axle shaft turns when its side gear rotates. The pinion gears are mounted on a differential pinion shaft, and the gears are free to rotate on this shaft. The pinion shaft is fitted into a bore in the differential case and is at right angles to the axle shafts. Power is transmitted through the differential as follows: The drive pinion rotates the ring gear which is bolted to the differential case assembly. The differential pinion, as it rotates with the case, forces the pinion gears against the side gears. When both wheels have equal traction, the pinion gears do not rotate on the pinion shaft because the input force on the pinion gear is equally divided between the 2 side gears. Therefore the pinion gears revolve with the pinion shaft; but do not rotate around the shaft itself. The side gears; being splined to the axle shafts, and in mesh with the pinion gears rotate the axle shafts. When the vehicle turns a corner the inner wheel turns slower than the outer wheel which slows the rear axles' side gear (as the shaft is splined to the side gear). The rear axle pinion gears will roll around the slower moving rear axle side gear; driving the rear axle side gear wheel faster.

Illustration Tool Number/Description J 2222-C Wheel Bearing Race Installer Outer J 2619-01 Slide Hammer J 7872 Magnetic Base Dial Indicator J 8001 Dial Indicator Set J 8092 Driver Handle J 8107-4 Side Bearing Puller Pilot J 8614-01 Flange and Pulley Holding Tool J 21128 Axle Pinion Oil Seal Installer J 21777-B Pinion Setting Gage Kit J 21784 Side Bearing Installer J 22306 Pinion Cup Bearing Installer-Rear J 22536 Pinion Driver J 22779 Side Bearing Backlash Gage J 22888-D Side Bearing Remover Kit J 22912-B Bearing Puller J 24426 Wheel Bearing Race Installer - Outer J 24427 Hub Outer Bearing Race Installer J 24429 Side Bearing Backlash Spanner J 25025 Guide Pins J 25588 Side Bearing Shim Installer J 26252 Locking Differential Governor Remover J 29710 Differential Side Bearing Installer J 34672 Depth Micrometer J 34673 Flat Gage Bar J 44419 Hub Outer Bearing Race Installer J 44420 Differential Bearing and Hub Seal Installer J 44685 Rear Axle Seal and Bearing Remover J 45108 Pinion Setting Gage Block J 45232 Differential Side Bearing Adjuster Needle Bearing Installer J 45857 Tone Wheel and/or Bearing Remover J 45859 Axle Remover

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

See also:
• Wheel Stud Replacement
• Lifting and Jacking the Vehicle
• Fluid and Lubricant Recommendations
• Fastener Caution
• Approximate Fluid Capacities
• Tire and Wheel Removal and Installation
• Rear Brake Caliper Bracket Replacement (1500 Series)
• Rear Brake Caliper Bracket Replacement (2500 Series)
• Rear Wheel Speed Sensor Ring Replacement
• Rear Wheel Speed Sensor Ring Replacement
• Rear Brake Rotor Replacement (1500 Series)
• Rear Propeller Shaft Replacement
• Pinion Flange/Yoke Installation Caution
• Ring Gear Removal Caution
• Differential Case Removal Warning
• Differential Housing Cover and Gasket Removal Caution
• Electronic Suspension Rear Position Sensor Replacement - Left Side
• Rear Brake Caliper Replacement (1500 Series)
• Rear Brake Caliper Replacement (2500 Series)
• Suspension Position Calibration (Without Z95)
• Parking Brake Rear Cable Replacement - Left Side
• Rear Brake Shield Replacement
• Symptoms - Locking/Limited Slip Rear Axle
• Locking Differential Description and Operation
• Locking Differential Diagnosis
• Locking Rear Drive Axle Chatters in Turns
• Noise in Addition to Normal Clutch Engagement
• Noisy in Drive
• Noisy When Coasting
• Intermittent Noise
• Constant Noise
• Noisy on Turns
• Backlash Adjustment (9.5 LD Axle)
• Backlash Adjustment (10.5 Inch Axle)
• Pinion Depth Adjustment (10.5 Inch Axle)
• Rear Axle Lubricant Level Inspection (10.5 Inch Axle)
• Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle)
• Fastener Tightening Specifications
• Locking Differential Disassemble (10.5 Inch Axle)
• Locking Differential Assemble (8.6, 9.5LD Axles)
• Locking Differential Assemble (10.5 Inch Axle)
• Locking Differential Cam Unit Disassemble (8.6 Inch Axle)
• Locking Differential Cleaning and Inspection
• Locking Differential Cam Unit Assemble (8.6 Inch Axle)
• Adhesives, Fluids, Lubricants, and Sealers
• Gear Tooth Contact Pattern Inspection
• Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle)