LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1013 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly - Final Assembly (8.25 S4WD and 9.25 Axles)

Differential Carrier Assembly - Final Assembly (8.25 S4WD and 9.25 Axles)

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

  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.
    3. Fig 1: Differential Adjuster Nut Lock (9.25 Inch Axle)
    GM685960Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  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.
    5. Fig 2: Differential Carrier Assembly Bolts
    GM1332740Courtesy of GENERAL MOTORS CORP.
  5. Remove the right differential carrier case half.
    6. Fig 3: Right Differential Carrier Case Half
    GM1332738Courtesy of GENERAL MOTORS CORP.
  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 to 1 differential carrier case half sealing surface. Use the correct sealer. Refer to Sealers, Adhesives, and Lubricants .
  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. Use the correct fluid. Refer toSealers, Adhesives, and Lubricants .
  11. Install the clutch shaft pilot bearing using the J 33842  .
    12. Fig 4: Clutch Shaft Pilot Bearing
    GM695745Courtesy of GENERAL MOTORS CORP.
  12. Install the clutch shaft to the differential carrier case half.
    13. Fig 5: Installing Clutch Shaft To Differential Carrier Case Half
    GM205917Courtesy of GENERAL MOTORS CORP.
  13. Install the vent hose connector.

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

    14. Fig 6: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  14. Install the new left side axle shaft seal using the J 45225  (1) and the J 8092  (2).
    15. Fig 7: Installing The New Left Side Axle Shaft Seal Using J 45225 & J 8092
    GM1486568Courtesy of GENERAL MOTORS CORP.
  15. Install the new left side inner axle shaft retainer ring.
  16. 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.

    17. Fig 8: Installing Left Side Inner Axle Shaft
    GM1332794Courtesy of GENERAL MOTORS CORP.
  17. 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).
    18. Fig 9: Installing The Bearing With The Square Shoulder In Using J 36609 & J 8092
    GM834254Courtesy of GENERAL MOTORS CORP.
  18. Install the new right side inner axle shaft seal using the J 45225  (1) and the J 8092  (2).
    19. Fig 10: Installing Right Side Inner Axle Shaft Seal
    GM1486575Courtesy of GENERAL MOTORS CORP.
  19. Install the inner axle shaft into the inner shaft housing.

    Carefully tap the inner axle shaft into place with a soft-faced mallet.

  20. For the 8.25 inch axle, assemble the following components into the inner shaft housing:
    1. Install the inner axle shaft (1).
    2. Place the inner axle housing on end so that the splines of the inner axle shaft are facing up.
      3. IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    3. Install the thrust washer (5).

      Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing (4).

    4. Install the new retainer ring (7) into the clutch gear (6).
    5. Install the clutch gear (6) onto the inner axle shaft (1).

      Drive the clutch gear into place with a plastic hammer.

    6. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    7. Install the clutch gear shim (9).
    8. Install the clutch sleeve (8).
    9. Install the clutch fork assembly (11).
    10. Install the clutch fork inner spring (10).
    21. Fig 11: Inner Shaft Housing Components (8.25 Inch Axle)
    GM892810Courtesy of GENERAL MOTORS CORP.
  21. For the 9.25 inch axle, install the following components into the inner shaft housing:
    1. Install the inner axle shaft (1).
    2. Place the inner axle housing on end so that the splines of the inner axle shaft are facing up.
      3. IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    3. 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 second thrust washer (6) into the inner axle shaft housing.
    5. Install the new retainer ring (7) onto the inner axle shaft (1).
    6. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    7. Install the clutch gear shim (9).
    8. Install the clutch sleeve (8).
    9. Install the clutch fork assembly (11).
    10. Install the clutch fork inner spring (10).
    22. Fig 12: Inner Shaft Housing Components (9.25 Inch Axle)
    GM892812Courtesy of GENERAL MOTORS CORP.
  22. Apply sealant to the inner shaft housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
  23. Install the inner shaft housing to the differential carrier assembly case.
    24. Fig 13: Installing Inner Shaft Housing
    GM893259Courtesy of GENERAL MOTORS CORP.
  24. Install the inner shaft housing bolts.

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

  25. Install the drain plug and the washer.
  26. Install the fill plug and the washer.

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

    27. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  27. Install the front drive axle actuator.

    Apply sealant to the threads of the front axle actuator. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .

    Tighten:  Tighten the front drive axle actuator to 20 N.m (15 lb ft).

    28. Fig 14: Installing Front Drive Axle Actuator
    GM893264Courtesy of GENERAL MOTORS CORP.
  28. 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.
    29. Fig 15: Install The Lower Differential Carrier Assembly Bushing Using J 21474-18, Thrust Bearing, J 36616-2, J 36616-1 & Forcing Screw
    GM892851Courtesy of GENERAL MOTORS CORP.
  29. 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.
    30. Fig 16: Installing Upper Differential Carrier Assembly Bushing
    GM893253Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals