Assembly Procedure

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.

Install the new retaining onto the pinion shaft.

Fig 1: Installing Pinion Shaft Retaining Ring

Courtesy of GENERAL MOTORS CORP.

Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
Install the differential side gear thrust washers to the differential side gears.
Install the differential side gears and thrust washers into the differential case.
If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.
Install the differential pinion gears and the thrust washers by performing the following steps:
1. Install the thrust washers to the pinion gears.
2. Position one of the pinion gears with the thrust washer between 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 their original locations.
3. Install the second pinion gear with the thrust washer between the differential side gears directly opposite of the first gear.
4. Rotate the differential side gears until the pinion gears and the thrust washers are directly opposite the opening in the differential case.

Fig 2: Installing Differential Side Gears & Thrust Washers

Courtesy of GENERAL MOTORS CORP.

Install the pinion shaft into the differential case by performing the following steps:
1. Insert the side of the pinion shaft with the pilot hole into the differential case.
2. Slide the pinion shaft through the differential case until the retaining ring is against the differential case.
3. Carefully drive the pinion shaft into the differential case using a hammer and a brass drift.
  Ensure that the pinion shaft retaining ring is seated in the channel within the differential case.

IMPORTANT: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

Install the ring gear to the differential case.

Fig 4: Ring Gear & Differential Case

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: The ring gear bolts have right-hand threads.

Install the new ring gear bolts.
Hand start each bolt in ensure the ring gear is properly installed to the differential case.

Fig 5: Identifying Ring Gear Bolts

Courtesy of GENERAL MOTORS CORP.

Tighten the ring gear bolts. Tighten the bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
Tighten: Tighten the ring gear bolts in sequence to 237 N.m (175 lb ft).
Install the differential side bearings by performing the following steps:
1. In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation.
2. Install the J 44420 (2) and the J 8092 (1) onto the differential case bearing as shown.
3. Drive the bearing onto the case using the J 44420 and the J 8092 .

Fig 6: Driving The Differential Side Bearing Into Position

Courtesy of GENERAL MOTORS CORP.