Differential Carrier Assembly - Final Assembly (8.25 F4WD Axle)

Tools Required

• J 8092  Universal Driver Handle - 3/4 in - 10. See Special Tools and Equipment .
• J 33791  Carrier Bushing Remover/Installer. See Special Tools and Equipment .
• J 36609  Axle Tube Bearing Installer. See Special Tools and Equipment .
• J 36616 Axle Mount Bushing Remover/Installer
• J 45225  Axle Seal Installer. See Special Tools and Equipment .

1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
2. Remove the differential carrier assembly bolts.
Fig 1: Differential Carrier Assembly Bolts (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
3. Remove the right differential carrier case half.
Fig 2: Right Differential Carrier Case Half (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
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. Refer to Sealers, Adhesives, and Lubricants .
6. Install the right differential carrier case half.
NOTE: Refer to Fastener Notice in Cautions and Notices.
7. Install the differential carrier case bolts.

   Tighten:  Tighten the differential carrier case bolts to 47 N.m (35 lb ft).

NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
8. Install the vent hose connector.

   Tighten:  Tighten the vent hose connector to 28 N.m (21 lb ft).

Fig 3: View Of Vent Hose Connector
Courtesy of GENERAL MOTORS CORP.
9. Install the differential carrier assembly into a vise.
10. Install the new left side axle shaft seal using the J 45225  (1) and the J 8092  (2).
Fig 4: Installing The New Left Side Axle Shaft Seal Using J 45225 & J 8092 (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
11. Install the new left side inner axle shaft retainer ring.
12. Install the left side inner axle shaft by doing the following:
    1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
    2. 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.
    3. 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.

    Fig 5: Installing Left Side Inner Axle Shaft (8.25 F4WD Axle)
    Courtesy of GENERAL MOTORS CORP.
13. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
    1. Install the inner axle shaft housing into a vise.

       Clamp only on the mounting flange of the inner axle shaft housing.

    2. Install the bearing with the square shoulder in using the J 36609  (1) and the J 8092  (2).
Fig 6: Install The Bearing Using J 36609 & J 8092 (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
14. Install the new inner shaft seal using the J 45225  (1) and the J 8092  (2).
Fig 7: Installing The New Inner Shaft Seal Using J 45225 & J 8092 (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
15. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
16. Install the inner shaft housing to the differential carrier assembly case.
17. Install the inner shaft housing bolts.

    Tighten:  Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).

18. Install the inner shaft (2) into the inner shaft housing (1) by doing the following:
    1. Install the inner shaft into the inner axle shaft housing until the inner shaft is seated against the differential side gear.
    2. 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.
    3. 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.

Fig 8: Inner Shaft & Housing (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
19. Install the drain plug and the washer.
20. Install the fill plug and the washer.

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

21. Install the lower differential carrier assembly bushing by performing the following steps:
    1. 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.
    2. 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.
Fig 9: Installing Lower Differential Carrier Assembly Bushing (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.
22. Install the upper differential carrier assembly bushing by performing the following steps:
    1. 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.
    2. 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.
Fig 10: Installing Upper Differential Carrier Assembly Bushing (8.25 F4WD Axle)
Courtesy of GENERAL MOTORS CORP.