Drive Axles - Front: Other Chevrolet Silverado 2500

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 the differential case assembly and replace the components as necessary.

Determining the Cause

While most front 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.

Sealing Surfaces

Front axles components are assembled using specific sealers. A leak at a surface sealed with sealant is usually caused by a poor fit of the components but can also be caused by the use of the wrong sealant. When correcting a sealant leak, inspect each component for distortion and for nicks or gouges that may prohibit the sealant from sealing properly and when re-assembling the component, use the proper sealant.

Tools Required

1. J 34011 Pilot Bearing Remover
2. J 33842 Pilot Bearing Installer

Scheme 437

1. Remove the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000) .
2. Remove the clutch shaft from the differential carrier assembly.
3. Remove the clutch shaft pilot bearing using the J 34011 .

Scheme 438

1. Lubricate the bearing with axle lubricant. Use the proper fluid. see scheme 2
2. Install the clutch shaft pilot bearing using the J 33842.
3. Install the clutch shaft to the differential carrier assembly.
4. Install the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000).

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 2619-01 Slide Hammer
3. J 29369-1 Bushing and Bearing Remover
4. J 29369-2 Bushing and Bearing Remover (2-3 inch)
5. J 36609 Axle Tube Bearing Installer
6. J 45225 Axle Seal Installer

Scheme 439

Scheme 440

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095).
2. Drain the differential carrier assembly. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000).
3. If replacing the right side seal and/or bearing, perform the following steps: Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000). Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000) Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01.
4. If only replacing the left side seal, perform the following steps: Place an alignment mark between the inner axle shaft and the wheel drive shaft. Disconnect the wheel drive shaft from the inner axle shaft. Remove the inner axle shaft using a hammer and a brass drift. Remove the inner axle shaft seal using a suitable seal remover tool. (Scheme 441): Removing Inner Axle Shaft Seal/Bearing
5. If replacing the left side seal and/or bearing, perform the following steps: Remove the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000). Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. Remove the inner axle shaft using a hammer and a brass drift. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. (Scheme 442): Removing Inner Axle Shaft Seal/Bearing Install the J 2619-01 to the J 29369-1 or the J 29369-2. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01.

Scheme 441

Scheme 442

Scheme 443

Scheme 444

Scheme 445

Scheme 446

1. If installing the right side bearing, perform the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). (Scheme 444): Installing New Axle Shaft Seal
3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
4. Install the inner axle shaft and clutch fork assembly components into the inner axle housing. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000).
5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000).
6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). (Scheme 445): Install The Left Side Bearing
7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). (Scheme 446): Install The New Axle Shaft Seal
8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000).
10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. see scheme 97: Installing Seal Using
11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. see scheme 98: Axle Shaft Inner Flange
12. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000).
13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft to inner axle shaft bolts to 79 Nm (58 lb ft).
14. Fill the differential carrier assembly. Use the proper fluid. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000).
15. Lower the vehicle.

1. J 34672 Depth Micrometer
2. J34673 Flat Gage Bar
3. J 8001 Dial Indicator Set

1. J 8614-01 Flange and Pulley Holding Tool
2. J 36366 Pinion Oil Seal Installer

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Remove the tire and wheel assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-178243-S06885952862005061300000) .
3. Remove the brake calipers. Refer to «BRAKE CALIPER»(ref-129604-S32254559152004080600000) .
4. Remove the differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
5. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.
6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). NOTE: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint.
7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers.
8. Support the propeller shaft and move out of the way as necessary.
9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: The pinion bearings The pinion seal The carrier bearings The axle bearings The axle seals
10. Scribe an alignment line between the pinion shaft and the pinion yoke.
11. Install the J 8614-01 onto the pinion as shown.
12. Remove the pinion nut while holding the J 8614-01 .
13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
14. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case.
15. Remove the oil seal using a suitable seal removal tool.

Scheme 452

Scheme 453

Scheme 454

1. Install the oil seal by doing the following: Position the oil seal over the seal bore. Install the J 36366 over the oil seal. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke.
3. Install the pinion yoke. Align the reference marks made during removal. NOTE: Refer to «PINION FLANGE/YOKE INSTALLATION NOTICE»(ref-175132-S13969871472005091200000) .
4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
5. Install the washer and a new pinion nut.
6. Install the J 8614-01 onto the pinion yoke as shown. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
7. Tighten the pinion nut while holding the J 8614-01 . Tighten Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement with the rotating torque recorded earlier. Tighten Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal.
9. 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.
10. Install the propeller shaft universal joint (2) to the pinion yoke (1). Align the reference marks made during removal.
11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). Tighten Tighten the yoke retainer bolts to 25 N.m (18 lb ft).
12. Inspect the axle lubricant level, and add, if necessary. Refer to «LUBRICANT LEVEL INSPECTION - FRONT DRIVE AXLE»(ref-304051-S24429850432008110500000) .
13. Install the differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
14. Install the brake calipers. Refer to «BRAKE CALIPER»(ref-129604-S32254559152004080600000) .
15. Install the tire and wheel assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-178243-S06885952862005061300000) .
16. Lower the vehicle.

1. J 33791 Carrier Bushing Remover/Installer
2. J 36616 Axle Mount Bushing Remover/Installer

Scheme 455

Scheme 456

1. Remove the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000) .
2. Remove the upper differential carrier assembly bushing by performing the following steps: Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown . Remove the upper differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18 .
3. Remove the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown. Remove the lower differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18 .

Scheme 457

Scheme 458

1. Install the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
2. Install the upper differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
3. Install the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000) .

Scheme 459

Scheme 460

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

1. Turn the steering wheel all the way to the left.
2. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
3. Place jack or utility stands at the rear end of the vehicle.
4. Remove the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-187666-S17843951582005090100000) .
5. Remove the front differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
6. Drain the differential carrier assembly, if necessary. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000) .
7. Disconnect the front propeller shaft from the differential carrier assembly.
8. Remove the relay rod. Refer to «RELAY ROD REPLACEMENT»(ref-178338-S03851028172005061400000) .
9. Support the differential carrier assembly with a transmission jack or equivalent.
10. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft, both sides.
11. Disconnect the electrical connector from the front axle actuator, S4WD axle only.
12. Disconnect the wire harness from the inner axle shaft housing, S4WD axle only.
13. Disconnect the wire harness from the differential carrier assembly, S4WD axle only.
14. Disconnect the vent hose from the differential carrier assembly.
15. Remove the inner axle housing nuts and washers from the bracket.
16. Remove the differential carrier assembly upper mounting bolt and the nut.
17. Pivot the differential carrier assembly forward and down on the lower mount bolt while it is being supported by the transmission jack.
18. Secure the differential carrier assembly to the jack.
19. Remove the differential carrier assembly lower mounting bolt and the nut.
20. Remove the differential carrier assembly.

Scheme 467

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

1. Install the differential carrier assembly.
2. Install the differential carrier assembly lower mounting bolt and the nut. Do not tighten the bolt at this time.
3. Pivot the differential carrier assembly up and back on the lower mount bolt while it is being supported by the transmission jack.
4. Install the differential carrier assembly upper mounting bolt and the nut. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Install the inner axle housing washers and nuts to the bracket. Tighten Tighten the inner axle housing nuts to 100 N.m (75 lb ft). Tighten the upper and the lower differential carrier assembly bolts to 100 N.m (75 lb ft).
6. Connect the vent hose to the differential carrier assembly.
7. Remove the transmission jack.
8. Connect the wire harness to the differential carrier assembly, S4WD axle only.
9. Connect the wire harness to the inner axle shaft housing, S4WD axle only.
10. Connect the electrical connector to the front axle actuator, S4WD axle only.
11. Install the wheel drive shaft inboard flange to inner axle shaft bolts, both sides. Tighten Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).
12. Install the relay rod. Refer to «RELAY ROD REPLACEMENT»(ref-178338-S03851028172005061400000) .
13. Install the front propeller shaft to the differential carrier assembly.
14. Check the differential carrier assembly fluid level. Refer to «LUBRICANT LEVEL INSPECTION - FRONT DRIVE AXLE»(ref-304051-S24429850432008110500000) .
15. Install the front differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
16. Install the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-187666-S17843951582005090100000) .
17. Remove the utility stands.
18. Lower the vehicle.

Scheme 475

1. Raise the vehicle on a hoist. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Remove the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000) .
3. Remove the nuts and the washers from the bracket.
4. Remove the bolt from the bracket.
5. Remove the bracket from the vehicle.

Scheme 476

1. Install the bracket to the vehicle.
2. Install the bolt to the frame and to the bracket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the washers and the nuts to the bracket. Tighten Tighten the nuts to 90 N.m (70 lb ft).
4. Install the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000) .
5. Lower the vehicle.

Scheme 477

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Remove the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000) .
3. Remove the air conditioning compressor - 4.8 L, 5.3 L and 6.0 L engines. Refer to «COMPRESSOR»(ref-131951-S34250646512003071400000) .
4. Remove the nuts and the washers from the bracket.
5. Remove the bracket from the vehicle.

Scheme 478

1. Install the bracket to the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the washers and the nuts to the bracket. Tighten Tighten the bracket to frame nuts to 90 N.m (67 lb ft).
3. Install the air conditioning compressor -4.8 L, 5.3 L and 6.0 L engines. Refer to «COMPRESSOR»(ref-131951-S34250646512003071400000) .
4. Install the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(ref-304051-S30214223892008110500000) .
5. Lower the vehicle.

1. J 22912-B Split-Plate Bearing Puller
2. J 2619-01 Slide Hammer
3. J 29369-1 Bushing and Bearing Remover
4. J 33791 Carrier Bushing Remover/Installer
5. J 34011 Pilot Bearing Remover
6. J 36598 Holding Fixture
7. J 36599-A Side Bearing Nut Wrench
8. J 36616 Axle Mount Bushing Remover/Installer
9. J 45765 Pinion Remover
10. J 45858 Front Axle Bearing Race Remover/Installer
11. J 8614-01 Flange and Pulley Holding Tool

J 22888-D Side Bearing Remover Kit

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

Scheme 484

1. Remove the differential side bearing by performing the following steps: Place the differential case in a vise. Install the J 22888-20A (2) and the J 8107-2 (1) as shown. Remove the differential side bearings using the J22888-20A .
2. Remove the differential assembly from the vise. Important: The ring gear bolts have left-hand threads.
3. Remove the ring gear bolts. Discard the bolts. NOTE: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.
4. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary.
5. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin.
6. Remove the pinion shaft.
7. Remove the differential pinion gears and the differential side gears by performing the following steps: Roll the differential pinion gears out of the case with the pinion gear thrust washers. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right.

1. J 22888-D Side Bearing Remover Kit
2. J 36597 Side Bearing Puller Pilot - 9.25 in Axle

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

Scheme 491

1. Remove the differential side bearing by performing the following steps: Place the differential case in a vise. Install the J 22888-20A (2) and the J 36597 (1) as shown. Remove the differential side bearings using the J 22888-20A .
2. Remove the differential assembly from the vise. Important: The ring gear bolts have left-hand threads.
3. Remove the ring gear bolts. Discard the bolts. NOTE: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.
4. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary.
5. Remove the pinion shaft lock bolt.
6. Remove the pinion shaft.
7. Remove the differential side gear spacers.
8. Remove the differential pinion gears and thrust washers by performing the following steps: Drive the pinion gear thrust washers out from the differential case using a hammer and a brass drift. Roll the differential pinion gears out of the differential case. Mark the pinion gears and thrust washers top and bottom.
9. Remove the differential side gears and thrust washers. Mark the differential side gears and thrust washers left and right.

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 22761 Differential Side Bearing Installer
3. J 22888-D Side Bearing Remover Kit

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. see scheme 2
2. Install the differential side gears and thrust washers into the differential case. If the same differential side gears and the thrust washers are being used, install the side gears and the thrust washers to their original locations. (Scheme 494): Differential Side Gears & Thrust Washers
3. Install the differential pinion gears by performing the following steps: Position one pinion gear between the differential side gears. Position the second pinion gear between the differential side gear directly opposite of the first gear. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. (Scheme 495): Differential Pinion Gears & Thrust Washers
4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.
5. Install the pinion gear shaft. (Scheme 496): Installing Pinion Shaft
6. Install the new pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
7. Install the ring gear onto the differential case. Important: The ring gear bolts have left-hand threads.
8. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000). (Scheme 498): Ring Gear Bolts
9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft).
10. Install the differential side bearings by performing the following steps: In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. Install the J 22761 (2) and the J 8092 (1) onto the differential case bearing as shown. Drive the differential case bearing onto the case using the J 22761 and the J 8092.

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 29710 Differential Side Bearing Installer
3. J 36597 Side Bearing Puller Pilot - 9.25 in Axle

Scheme 498

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

Scheme 504

1. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. see scheme 2
2. Install the thrust washers and the differential side gears into the differential case. If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations.
3. Install the differential pinion gears by performing the following steps: Position both pinion gears between the differential side gears directly opposite of each other. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening.
4. Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift.
5. Install the differential side gear spacers.
6. Install the pinion gear shaft. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000).
7. Install the pinion shaft lock bolt. Tighten Tighten the pinion shaft lock bolt to 53 N.m (39 lb ft). Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
8. Install the ring gear onto the differential case. Important: The ring gear bolts have left-hand threads.
9. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
10. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 138 N.m (102 lb ft).
11. Install the differential side bearings by performing the following steps: In order to protect the differential case, install the J 36597 in the case on the side opposite the bearing installation. Install the J 29710 (2) and the J 8092 (1) onto the differential case bearing as shown. Drive the differential case bearing onto the case using the J 29710 and the J 8092.

J 45754 Pinion Bearing Race Remover/Installer - 9.25 in Axle

Scheme 505

Scheme 506

Scheme 507

Scheme 508

1. Before assembly, apply axle lubricant to the pinion bearing cups. see scheme 2 The pinion bearings The pinion and the differential gears The thrust washers The pinion bearing cups
2. Install the outer pinion bearing cup into the outer pinion bearing cup bore. (Scheme 507): Installing Outer Pinion Bearing Cup (9.25 Inch Axle)
3. Install the J 45754-1 over the outer pinion bearing cup. (Scheme 508): Installing J 45754-1 Over The Outer Pinion Bearing Cup (9.25 Inch Axle)
4. Install the forcing screw (1), the J 45754-2 (2) into the inner pinion bearing cup bore. see scheme 187: Installing J 45754-2 Over Inner Pinion Bearing Cup Bore (9.25 Inch Axle)
5. Attach the forcing screw to the J 45754-1. Slowly turn the forcing screw until the J 45754-1 is evenly seated over the outer pinion bearing cup bore and the J 45754-2 with the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.
6. Turn the forcing screw clockwise slowly in order to draw the outer pinion bearing cup into the outer pinion bearing cup bore. Inspect the position of the outer pinion bearing cup as it is being drawn into the outer pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45754 and the outer pinion bearing cup and reposition the outer pinion bearing cup.
7. Tighten the forcing screw until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
8. Remove the J 45754.
9. Install the inner pinion bearing cup onto the J 45754-2 (2) and the forcing screw (1). see scheme 188: Installing Inner Pinion Bearing Cup (9.25 Inch Axle)
10. Install the J 45754-2 (2), the forcing screw (1), and the inner pinion bearing cup into the pinion bearing cup bore.
11. Install the J 45754-1 over the outer pinion bearing cup. (Scheme 509): Installing J 45754-1 Over The Outer Pinion Bearing Cup (9.25 Inch Axle)
12. Attach the forcing screw to the J 45754-1. Slowly turn the forcing screw until the J 45754-1 is evenly seated over the outer pinion bearing cup bore and the J 45754-1 with the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.
13. Turn the forcing screw clockwise slowly in order to draw the inner pinion bearing cup into the inner pinion bearing cup bore. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45754 and the inner pinion bearing cup and reposition the inner pinion bearing cup.
14. Tighten the forcing screw clockwise until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
15. Remove the J 45754.
16. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to «PINION DEPTH ADJUSTMENT»(ref-304051-S20233695072008110500000).

J-45858 Pinion Bearing Race Remover/Installer - 8.25 in Axle

Scheme 509

Scheme 510

Scheme 511

1. Before assembly, lubricate the following parts with axle lubricant. Use the proper fluid. see scheme 2 The pinion bearings The pinion and the differential gears The thrust washers The pinion bearing cups
2. Install the J 45858-3 (3), the thrust bearing and the washer (2), and the J 45858-6 (1) over the outer pinion bearing cup bore. (Scheme 510): Installing J 45858-3, Thrust Bearing & Washer, & Forcing Screw (8.25 Inch Axles)
3. Install the inner pinion bearing cup and the J 45858-2 (4) to the J 45858-6 (1). Slowly turn the J 45858-6 until the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore. (Scheme 511): Installing Inner Pinion Bearing Cup (8.25 Inch Axle)
4. Turn the J 45858-6 clockwise slowly in order to draw the inner pinion bearing cup into the inner pinion bearing cup bore. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J-45858 and the inner pinion bearing cup and reposition the inner pinion bearing cup.
5. Tighten the J 45858-6 until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
6. Remove the J-45858.
7. Install the outer pinion bearing cup and the J 45858-1 over the outer pinion bearing cup bore. see scheme 192: Installing Outer Pinion Bearing Cup (8.25 Inch Axle)
8. Install the thrust bearing and the washer (2), the J 45858-6 (1), and the J 45858-2 (3) as shown. see scheme 193: Install The Thrust Bearing And The Washer Using J 45858-6, Thrust Bearing & J 45858-2 (8.25 Inch Axle)
9. Slowly turn the J 45858-6 until the outer pinion bearing cup is evenly seated over the outer pinion bearing cup bore and the J 45858-2 is evenly seated within the inner pinion bearing cup.
10. Turn the J 45858-6 clockwise slowly in order to draw the outer pinion bearing cup into the outer pinion bearing cup bore. Inspect the position of the outer pinion bearing cup as it is being drawn into the outer pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J-45858 and the outer pinion bearing cup and reposition the outer pinion bearing cup.
11. Tighten the forcing screw until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
12. Remove the J-45858.
13. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to «PINION DEPTH ADJUSTMENT»(ref-304051-S20233695072008110500000).

1. J 36601 Pinion Shim Selector
2. J 29763 Static Timing Gage

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 8614-01 Flange and Pulley Holding Tool
3. J 35512 Inner Pinion Bearing Installer
4. J 36366 Pinion Oil Seal Installer
5. J 36599-A Side Bearing Nut Wrench
6. J 36603 Side Bearing Cup Installer
7. J 36609 Axle Tube Bearing Installer
8. J 36612 Output Shaft Bearing Installer
9. J 36614 Inner Pinion Bearing Installer
10. J 36615 Side Bearing Nut Wrench (9.25 inch axle)

Scheme 512

Differential Pinion Gear Shims Sizes. Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

1. Install the pinion bearing cups into the differential carrier assembly. Refer to «PINION BEARING CUP INSTALLATION»(ref-304051-S02920952422008110500000).
2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
3. Install the inner pinion bearing onto the pinion gear using the J 35512, 8.25 inch axle, or the J 36614, 9.25 inch axle.
4. Install the new collapsible spacer onto the pinion gear.
5. Install the outer pinion bearing into the differential carrier case half.
6. Install the pinion oil seal using J 36366.
7. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
8. Lubricate the pinion bearings with axle lubricant. Use the correct sealant. see scheme 2
9. Install the pinion yoke. NOTE: Refer to «PINION FLANGE/YOKE INSTALLATION NOTICE»(ref-175132-S13969871472005091200000).
10. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
11. Install the washer and a new pinion nut. If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed: Remove the pinion nut washer. Install the old pinion nut. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed. Remove the old pinon nut. Install the pinion nut washer. Install the new pinion nut.
12. Install the J 8614-01 onto the pinion yoke as shown. (Scheme 515): Installing The J 8614-01 Onto The Pinion -- Front Axle NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000).
13. Tighten the pinion nut while holding the J 8614-01. Tighten Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order to seat the bearings.
14. Remove the J 8614-01.
15. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.
16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, reinstall the J 8614-01 and continue to tighten the pinion nut. Specification The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.
17. 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.
18. Remove the J 8614-01.
19. Assemble the differential adjuster nut into the differential nut sleeve until fully seated, 8.25 inch axle - left and right sides, 9.25 inch axle, right side.
20. Install the axle shaft bearings into the differential adjuster nut sleeve using the J 36612 (2) and the J 8092 (1), 8.25 inch S4WD axle - left and right sides, 8.25 inch F4WD axle - left side, 9.25 inch axle - right side. see scheme 200: Installing The Axle Shaft Bearings Into The Differential Adjuster Nut Sleeve Using J 8092 & J 36612
21. Install the axle shaft bearing into the differential adjuster nut sleeve using the J 36609 and the J 8092, 9.25 inch axle - left side.
22. Install the differential adjuster nut assembly and new adjuster lock nut tabs into the differential carrier case using the J 36609 and the J 8092, 8.25 inch axle - left and right sides, 9.25 inch axle - right side.
23. Install the differential adjuster nut assembly into the differential carrier case, 9.25 inch axle - left side.
24. Install the differential case side bearing cups to the differential carrier case using the J 36603 (2) and the J 8092 (1), 8.25 inch axle - left and right sides, 9.25 inch axle - right side. see scheme 201: Installing Differential Case Side Bearing Cups To The Differential Carrier Case Using J 8092 & J 36603
25. Install the differential case assembly into the left differential carrier case half. (Scheme 516): Installing Differential Case Assembly Into The Left Differential Carrier Case Half
26. Install the right differential carrier case half to the left differential carrier case half. Do not use sealer at this time. If the carrier case halves do not make complete contact, use the J 36599-A in order to back out the right differential adjuster nut sleeve until the differential carrier case halves make contact. (Scheme 517): Differential Case Assembly (8.25 Inch Axles)
27. Install the differential carrier case bolts. Tighten Tighten the differential carrier case bolts to 47 Nm (35 lb ft).
28. Install the differential carrier assembly into a vise.
29. Turn the right side differential adjuster nut sleeve clockwise 1 revolutions using the J 36599-A. (Scheme 518): Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
30. For the 8.25 inch axle, turn the left side differential adjuster nut sleeve clockwise using the J 36599-A in order to preload the differential side bearings against the differential side bearing cups. Tighten Tighten the differential adjuster nut to 75 Nm (55 lb ft). (Scheme 519): Preloading Differential Side Bearings (8.25 Inch Axle)
31. For the 9.25 inch axle, turn the left side differential adjuster nut clockwise using the J 36615 in order to preload the differential side bearings against the differential side bearing cups. Tighten Tighten the differential adjuster nut to 75 Nm (55 lb ft).
32. Rotate the pinion several times in order to seat the pinion and differential side bearings.
33. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench. Specification The rotating torque of the pinion and differential assembly should be 3.4-6.2 Nm (30-55 lb in) for new bearings or 2.8-5.1 Nm (25-45 lb in) for used bearings.
34. If the rotating torque measurement is below 2.8 Nm (25 lb in) for used bearings, or 3.4 Nm (30 lb in) for new bearings, adjust the differential side bearing preload using the following steps: Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides. Using the J 36599-A or the J 36615, turn the left and the right side differential adjuster nut sleeves in or clockwise one notch. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications. see scheme 206: Alignment Mark Between Differential Adjuster Nut Sleeve & Differential Carrier Case
35. If the rotating torque measurement is above 5.1 Nm (45 lb in) for used bearings, or 6.2 Nm (55 lb in) for new bearings, adjust the differential side bearing preload using the following steps: Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides. Using the J 36599-A or the J 36615, turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
36. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
37. Measure the drive pinion to ring gear backlash. Refer to «BACKLASH INSPECTION AND ADJUSTMENT»(ref-304051-S39600924142008110500000).

1. J 8001 Dial Indicator Set
2. J 36599-A Side Bearing Nut Wrench
3. J 36615 Side Bearing Nut Wrench

Scheme 518

1. Mark the location of the differential adjuster nut sleeves in relation to the differential carrier halves. Ensure that the notches can be counted when turned.
2. Install the J 8001-1 (1, 2), the J 8001-2 (3), and the J 8001-3 (4) as shown. Ensure that the button contacts the outer edge of the pinion yoke and that the plunger is at a right angle to the pinion yoke.
3. Move the pinion yoke back and forth through the pinion yoke's free play while not allowing the ring gear to move.
4. Record the dial indicator reading.
5. To determine the actual backlash, divide the dial indicator reading by 2. An actual dial indicator reading of 0.16 mm (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash. Specification The backlash between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred specification of 0.13-0.18 mm (0.005-0.007 in).
6. If the backlash is too small, increase the backlash by turning the left differential adjuster nut sleeve in one notch using the J 36599-A , 8.25 inch axle, or the J 36615 , 9.25 inch axle, and the right differential adjuster nut sleeve out one notch using the J 36599-A .
7. If the backlash is too large, decrease the backlash by turning the right differential adjuster nut sleeve in one notch using the J 36599-A and the left differential adjuster nut sleeve out one notch using the J 36599-A , 8.25 inch axle, or the J 36615 , 9.25 inch axle.
8. Recheck the backlash and adjust as necessary.
9. Recheck the rotating torque of the pinion and differential assembly and adjust as necessary.
10. Once the backlash and rotating torque of the pinion and differential assembly is correct, perform a gear tooth contact pattern check to ensure proper contact between the pinion and the ring gear. Refer to «GEAR TOOTH CONTACT PATTERN INSPECTION»(ref-304051-S04119770162008110500000) .

1. J 8092 Universal Driver Handle - 3/4 in -10
2. J 33842 Pilot Bearing Installer
3. J 36609 Axle Tube Bearing Installer
4. J 36616 Axle Mount Bushing Remover/Installer
5. J 45225 Axle Seal Installer

Scheme 519

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

Scheme 525

Scheme 526

Scheme 527

Scheme 528

Scheme 529

Scheme 530

1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 8.25 inch axle - both sides, 9.25 inch axle - right side.
2. Install the differential adjuster nut lock, 9.25 inch axle - left side. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000).
3. Install the differential adjuster nut lock bolt. Tighten Tighten the differential adjuster lock nut bolt to 20 N.m (15 lb ft).
4. Remove the differential carrier assembly bolts. (Scheme 521): Differential Carrier Assembly Bolts (8.25 Inch Axles)
5. Remove the right differential carrier case half. see scheme 210: Removing Differential Case Assembly (8.25 Inch Axles)
6. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
7. Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or equivalent to one differential carrier case half sealing surface. see scheme 2
8. Install the right differential carrier case half.
9. Install the differential carrier case bolts. Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft).
10. Lubricate the clutch shaft pilot bearing with axle lubricant. see scheme 2
11. Install the clutch shaft pilot bearing using the J 33842.
12. Install the clutch shaft to the differential carrier case half.
13. For ratcheting style vent connectors, rotate the pinion yoke until the differential case window can be seen through the vent hose connector opening. see scheme 213: Locating Differential Case Window
14. Place the alignment arm of the vent hose connector in the 6 o'clock position. NOTE: Refer to «COMPONENT FASTENER TIGHTENING NOTICE»(ref-175132-S27295026372005041500000). (Scheme 523): Aligning Arm Of Vent Hose Connector
15. Install the vent hose connector with the alignment arm in the 6 o'clock position into the vent hose connector opening. Tighten Tighten the vent hose connector to 28 Nm (21 lb ft).
16. For non-ratcheting style vent connectors, install the vent hose connector. Tighten Tighten the vent hose connector to 28 Nm (21 lb ft).
17. Install the new left side axle shaft seal using the J 45225 (1), and J 8092 (2). see scheme 216: Install The New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
18. Install the new left side inner axle shaft retainer ring.
19. Install the left side inner axle shaft by doing the following: Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. see scheme 217: Installing Left Side Inner Axle Shaft
20. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
21. Install the new inner shaft seal using the J 45225 (1) and the J 8092 (2). see scheme 219: Installing New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
22. Install the inner axle shaft into the inner shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
23. For the 8.25 inch axle - 1st design, assemble the following components into the inner shaft housing: IMPORTANT: Use chassis grease in order to hold the thrust washer in place. Install the thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing (4). Install the new retainer ring (7) into the clutch gear (6). Install the clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). Install the clutch gear shim (9) Install the clutch sleeve (8) Install the clutch fork assembly (14, 13, 12, 11) Install the clutch fork inner spring (10) into the differential carrier case. (Scheme 526): Inner Axle Shaft Housing Components (8.25 Inch) (1st Design)
24. For the 8.25 inch S4WD axle - 2nd design, assemble the following components into the inner axle shaft housing: IMPORTANT: Use chassis grease in order to hold the thrust washer in place. Install the thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). Install the new retainer ring (7) onto the clutch gear (6). Install the clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). Install the clutch gear shim (9) Install the clutch sleeve (8) Install the clutch fork assembly (11) Install the clutch fork inner spring (10) (Scheme 527): Inner Axle Shaft Housing Components (8.25 Inch) (2nd Design)
25. For the 9.25 inch axle - 1st design, install the following components into the inner axle shaft housing: IMPORTANT: Use chassis grease in order to hold the thrust washer in place. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slot in the inner axle shaft housing (4). The second thrust washer (6) The retainer ring (7) onto the inner axle shaft (1). Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (14, 13, 12, 11) The clutch fork inner spring (10) into the differential carrier case. (Scheme 528): Inner Axle Shaft Housing Components (9.25 Inch) (1st Design)
26. For the 9.25 inch axle - 2nd design, install the following components into the inner shaft housing: IMPORTANT: Use chassis grease in order to hold the thrust washer in place. Install the thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. Install the second thrust washer (6) into the inner axle shaft housing. Install the new retainer ring (7) onto the inner axle shaft (1). Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). Install the clutch gear shim (9) Install the clutch sleeve (8) Install the clutch fork assembly (11) Install the clutch fork inner spring (10) (Scheme 529): Inner Axle Shaft Housing Components (9.25 Inch) (2nd Design)
27. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealer. see scheme 2
28. Install the inner shaft housing to the differential carrier assembly case.
29. Install the inner shaft housing bolts. Tighten Tighten the inner shaft housing bolts to 40 N.m (30 lb ft).
30. Install the drain plug and the washer.
31. Install the fill plug and the washer. Tighten Tighten the drain plug and the fill plug to 33 N.m (24 lb ft). NOTE: Refer to «COMPONENT FASTENER TIGHTENING NOTICE»(ref-175132-S27295026372005041500000).
32. Install the front drive axle actuator. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealer. see scheme 2 Tighten Tighten the front drive axle actuator to 20 N.m (15 lb ft).
33. Install the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
34. Install the upper differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered with in the differential carrier assembly bushing bore.

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 33791 Carrier Bushing Remover/Installer
3. J 36609 Axle Tube Bearing Installer
4. J 36616 Axle Mount Bushing Remover/Installer
5. J45225 Axle Seal Installer

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
2. Remove the differential carrier assembly bolts. see scheme 228: Differential Carrier Assembly Bolts (8.25 Inch Axles)
3. Remove the right differential carrier case half. (Scheme 531): Removing Differential Case Assembly (8.25 Inch Axles)
4. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
5. Apply a bead of sealer to one differential carrier case half sealing surface. Use the correct sealer. see scheme 2
6. Install the right differential carrier case half. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000).
7. Install the differential carrier case bolts. Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft).
8. For ratcheting style vent connectors, rotate the pinion yoke until the differential case window can be seen through the vent hose connector opening. see scheme 230: Locating Differential Case Window
9. Place the alignment arm of the vent hose connector in the 6 o'clock position. NOTE: Refer to «COMPONENT FASTENER TIGHTENING NOTICE»(ref-175132-S27295026372005041500000). see scheme 231: Locating Alignment Arm
10. Install the vent hose connector with the alignment arm in the 6 o'clock position into the vent hose connector opening. Tighten Tighten the vent hose connector to 28 Nm (21 lb ft).
11. For non-ratcheting style vent connectors, install the vent hose connector. Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent, onto the threads. Tighten Tighten the vent hose connector to 28 N.m (21 lb ft).
12. Install the differential carrier assembly into a vise.
13. Install the new left side axle shaft seal using the J 45225 (1) and the J 8092 (2). see scheme 233: Install The New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
14. Install the new left side inner axle shaft retainer ring.
15. Install the left side inner axle shaft by doing the following: Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. (Scheme 533): Installing Left Side Inner Axle Shaft
16. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
17. Install the new inner shaft seal using the J 45225 (1) and the J 8092 (2). (Scheme 535): Installing New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
18. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. see scheme 2
19. Install the inner shaft housing to the differential carrier assembly case.
20. Install the inner shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
21. Install the inner shaft (2) into the inner shaft housing (1) by doing the following: Install the inner shaft into the inner axle shaft housing until the inner shaft is seated against the differential side gear. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. (Scheme 536): Axle Shaft & Inner Axle Shaft Housing
22. Install the drain plug and the washer.
23. Install the fill plug and the washer. Tighten Tighten the drain plug and the fill plug to 33 N.m (24 lb ft).
24. Install the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
25. Install the upper differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.

Gear Tooth Nomenclature

The side of the ring gear tooth which curves outward, or is convex, is the drive side (4). The concave side is the coast side (3). The end of the tooth nearest the center of the ring gear is the toe end (2). The end of the tooth farthest away from the center is the heel end (1).

Scheme 536

Condition

The backlash and pinion depth is correct.

Correction

None required.

Service Hints

Loose bearing on the drive pinion or in the differential case may cause patterns that vary. If the contact pattern varies, inspect the following preload settings

1. Total assembly
2. Differential case
3. Drive pinion

If these settings are correct, inspect for damage or incorrectly assembled parts.

Scheme 537

The pinion depth is incorrect. The drive pinion is too far away from the ring gear.

Adjust the pinion depth of drive pinion. Refer to PINION DEPTH ADJUSTMENT .

Scheme 538

The pinion depth is incorrect. The drive pinion is too close to the ring gear.

Adjust the pinion depth of drive pinion. Refer to PINION DEPTH ADJUSTMENT .

Scheme 539

The backlash is incorrect. The ring gear is too far away from the drive pinion.

Decrease the backlash. Move the ring gear closer to the drive pinion by adjusting the side bearing adjuster sleeves. Refer to BACKLASH INSPECTION AND ADJUSTMENT .

Scheme 540

The backlash is incorrect. The ring gear is too close to the drive pinion.

Increase the backlash. Move the ring gear away from the drive pinion by adjusting the side bearing adjuster sleeves. Refer to BACKLASH INSPECTION AND ADJUSTMENT .

Scheme 541