Differential Case Assembly Assemble (8.25 Inch Axle)

Tools Required

• J 8092  Universal Driver Handle - 3/4 in - 10. See Special Tools and Equipment .
• J 22761  Differential Side Bearing Installer. See Special Tools and Equipment .
• J 22888-D  Side Bearing Remover Kit. See Special Tools and Equipment .

1. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Sealers, Adhesives, and Lubricants .
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.

Fig 1: Differential Side Gears & Thrust Washers
Courtesy of GENERAL MOTORS CORP.
3. Install the differential pinion gears by performing the following steps:
   1. Position both pinion gears between the differential side gears directly opposite of each other.
   2. 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.

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

Fig 2: Identifying Differential Pinion Gears & Thrust Washers
Courtesy of GENERAL MOTORS CORP.
5. Install the pinion gear shaft.
6. Install the new pinion gear shaft lock pin using a hammer and a brass drift.
Fig 3: View Of Differential And Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
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.
Fig 4: Ring Gear & Differential Case
Courtesy of GENERAL MOTORS CORP.
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 in Cautions and Notices.
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 (89 lb ft).

Fig 5: Identifying Ring Gear Bolts
Courtesy of GENERAL MOTORS CORP.
10. Install the differential side bearings by performing the following steps:
    1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation.
    2. Install the J 22761  (2) and the J 8092  (1) onto the differential case bearing as shown.
    3. Drive the differential case bearing onto the case using the J 22761  and the J 8092  .
Fig 6: Installing Differential Side Bearing
Courtesy of GENERAL MOTORS CORP.