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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 >> Rear Axle - Assemble

Rear Axle - Assemble

Tools Required 

  1. Install the outer pinion bearing cup using the J 7818  (7.6 inch axle) or the J 8611-01  (8.6 inch axle) (2) and the J 8092  (1).
  2. Install the inner pinion bearing cup using the J 29609  (7.6 inch axle) or the J 8608  (8.6 inch axle) (1) and the J 8092  (2).
  3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment .
    Fig 2: Installing Inner Pinion Bearing Cup Using J 29609 (7.6 Inch Axle), J 8608 (8.6 Inch Axle) And J 8092
    G01670985Courtesy of GENERAL MOTORS CORP.
  4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
  5. Install the inner pinion bearing using the J 5590  (7.6 inch axle) or the J 24433  (8.6 inch axle).

    Press the bearing on until the cone seats on the pinion shim.

  6. Install a new collapsible spacer.
  7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid.
  8. Install the pinion into the axle housing.
  9. Install the outer pinion bearing onto the pinion.
    Fig 3: Pressing Bearing On Until Cone Seats On Pinion Shim
    G01670986Courtesy of GENERAL MOTORS CORP.
  10. Install the new pinion oil seal using the J 33782  on 7.6 inch axles, or the J 22388  on the 8.6 inch axle.
  11. Apply sealant, GM P/N 12346004 or equivalent, to the splines of the pinion flange/yoke.

    Important:  Install the pinion gear flange/yoke to the pinion gear shaft in the same position as marked during removal in order to maintain correct driveline balance.

  12. Install the pinion flange/yoke.

    Align the marks make during removal.

    NOTE: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
  13. Seat the pinion flange/yoke onto the pinion shaft by tapping it with a soft- faced hammer until a few pinion shaft threads show through the flange/yoke.
    Fig 4: Installing New Pinion Oil Seal Using J 33782 On 7.6 Inch Axles Or J 22388 On 8.6 Inch Axle
    G01670987Courtesy of GENERAL MOTORS CORP.
  14. Install the washer and a new pinion nut.
  15. Install the J8614-01  onto the pinion flange/yoke as shown.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

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

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

    Tighten 

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

    Fig 5: Installing J8614-01 Onto Pinion Flange/Yoke
    G01670988Courtesy of GENERAL MOTORS CORP.
  17. Measure the rotating torque of the pinion.

    Compare this measurement with the rotating torque recorded during removal,

    Tighten 

    Tighten the nut in small increments, as needed, until the rotating torque is 1.1-2.8 N.m (10-25 lb in) (used bearings) or 1.7-3.4 N.m (15-30 lb in) (new bearings).

  18. 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.
    Fig 6: Tightening Nut In Small Increments
    G01670989Courtesy of GENERAL MOTORS CORP.
  19. Lubricate the differential side bearings with axle lubricant. Use the proper fluid.
  20. Place the differential case, with the bearing cups installed, into the axle housing.
    Fig 7: Placing Differential Case, With Bearing Cups Installed, Into Axle Housing
    G01670990Courtesy of GENERAL MOTORS CORP.
  21. Install the bearing caps and the bolts.

    Do not torque the bearing cap bolts at this time.

  22. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment .
    Fig 8: Installing Bearing Caps And Bolts
    G01670991Courtesy of GENERAL MOTORS CORP.
  23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal.

    Specification 

    The rotating torque of the pinion and the ring gear should be 2.8-5.6 N.m (25-50 lb in) (used bearings) or 3.9-6.2 N.m (30-55 lb in) (new bearings).

  24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the differential side bearing preload or the pinion bearing preload as necessary.
  25. 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.
  26. Adjust the backlash. Refer to Backlash Adjustment .
    Fig 9: Measuring Rotating Torque Of Pinion And Ring Gear
    G01670992Courtesy of GENERAL MOTORS CORP.
  27. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
  28. Tighten the bearing cap bolts

    Tighten 

    Tighten the bearing cap bolts to 75 N.m (55 lb ft).

  29. Install the axle shaft bearing using the J 23765  (7.6 inch axle) or the J 23690  (8.6 inch axle) (1) and the J8092  (2).
  30. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.
    Fig 10: Installing Axle Shaft Bearing Using J 23765 (7.6 Inch Axle) Or J 23690 (8.6 Inch Axle) And J8092
    G01670993Courtesy of GENERAL MOTORS CORP.
  31. Install the axle shaft seal using the J 23771  (7.6 inch axle) or the J 21128  (8.6 inch axle).
  32. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube.
    Fig 11: Driving Tool Into Bore Until Axle Shaft Seal Bottoms Flush With Tube
    G01670994Courtesy of GENERAL MOTORS CORP.

    Important:  Carefully insert the axle shaft in order to not damage the seal.

  33. Install the axle shaft (1) into the housing (5).
  34. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
  35. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
  36. On axles with a locking differential, keep the pinion shaft partially withdrawn.
    Fig 12: Installing Axle Shaft Into Housing
    G01670995Courtesy of GENERAL MOTORS CORP.
  37. On axles with a locking differential, place the lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
  38. Pull the shaft flange outward in order to seat the lock in the differential gear.
    Fig 13: Placing Lock On Axle Shaft So Ends Are Flush With Thrust Block
    G01670996Courtesy of GENERAL MOTORS CORP.
  39. Align the hole in the pinion shaft with the bolt hole in the differential case.
  40. Install the new pinion shaft locking bolt.

    Tighten 

    • Tighten the pinion shaft locking bolt to 34 N.m (25 lb ft) (7.6 inch axle).
    • Tighten the pinion shaft locking bolt to 36 N.m (27 lb ft) (8.6 inch axle).
      Fig 14: Installing New Pinion Shaft Locking Bolt
      G01670997Courtesy of GENERAL MOTORS CORP.
  41. Install the rear axle housing cover (2) and a new gasket.
  42. Install the rear axle housing cover bolts (1).

    Tighten 

    • Tighten the rear housing cover bolts in a crosswise pattern to 30 N.m (20 lb ft) (7.6 inch axle).
    • Tighten the rear housing cover bolts in a crosswise pattern to 39 N.m (29 lb ft) (8.6 inch axle).
      Fig 15: Installing Rear Axle Housing Cover, Bolts And Gasket
      G01670998Courtesy of GENERAL MOTORS CORP.
  43. Install the drain plug (8.6 inch axle only).

    Tighten 

    Tighten the drain plug to 33 N.m (24 lb ft).

  44. Fill the axle using the proper fluid.
    Fig 16: Installing Drain Plug
    G01670999Courtesy of GENERAL MOTORS CORP.
  45. Install the fill plug.

    Tighten 

    Tighten the fill plug to 33 N.m (24 lb ft).

    Fig 17: Installing Fill Plug
    G01671000Courtesy of GENERAL MOTORS CORP.
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