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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Rear Drive Axle >> Repair Instructions >> Differential Overhaul >> Assembly Procedure

Assembly Procedure

  1. Lubricate the pinion and side gears with axle lubricant. Use the proper fluid.
  2. Install the thrust washers to the differential side gears.

    If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to the original locations.

  3. Install the differential pinion gears by doing the following:
    1. Position one pinion gear between the differential side gears.
    2. Rotate the differential side gears until the pinion gear is directly opposite the opening in the differential case.
      Fig 1: Installing Differential Pinion Gears And Thrust Washers
      G01670963Courtesy of GENERAL MOTORS CORP.
    3. Place the other pinion gear between the differential side gears.

      Line up the hole in both the pinion gears.

  4. Install the thrust washers.

    Rotate the pinion gears toward the opening in order to permit the sliding in of the thrust washers.

  5. Install the pinion shaft.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  6. Install a new pinion shaft lock bolt.

    Tighten 

    • Tighten the new pinion shaft lock bolt to 36 N.m (27 lb ft) (7.6 inch axle).
    • Tighten the new pinion shaft lock bolt to 36 N.m (27 lb ft) (8.6 inch axle).

    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 to the differential case.
  8. Install two threaded studs into the ring gear on opposite sides.
  9. Place the ring gear on the case. Align the studs with the holes in the case.
  10. Install 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 140 N.m (103 lb ft) (7.6 inch axle).
    • Tighten the ring gear bolts in sequence to 120 N.m (90 lb ft) (8.6 inch axle).
      Fig 2: Installing Ring Gear To Differential Case
      G01670964Courtesy of GENERAL MOTORS CORP.
  11. Install the differential side bearings by doing the following:
    • In order to protect the differential case, install the J 8107-2  (7.6 inch axle) or the J 8107-4  (8.6 inch axle) in the case on the side opposite the bearing installation.
    • Install the J 25299  (2) and the J 8092  (1) onto the differential case bearing as shown.
    • Drive the bearing onto the case using the J 25299  (2) and the J 8092  (1).
      Fig 3: Installing J 25299 And J 8092 Onto Differential Case
      G01670965Courtesy of GENERAL MOTORS CORP.
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