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.

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 by performing the following steps:
1. Position one of the pinion gears between the differential side gears.
2. Install the second pinion gear directly opposite of the first gear between the differential side gears.
3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.
4. Install the pinion gear thrust washers using a hammer and a brass drift.

Fig 1: Exploded View Of Differential Case

Courtesy of GENERAL MOTORS CORP.

Install the pinion shaft.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Install a new pinion shaft lock bolt.
Tighten: Tighten the new pinion shaft lock bolt to 50 N.m (37 lb ft).

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 2: Ring Gear & Differential Case

Courtesy of GENERAL MOTORS CORP.

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

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

Fig 3: 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 140 N.m (103 lb ft).
Install the differential side bearings by performing the following steps:
1. In order to protect the differential case, install the J 36597 in the case on the side opposite the bearing installation.
2. Install the J 29710 (2) and the J 8092 (1) onto the differential case bearing as shown.
3. Drive the bearing onto the case using the J 29710 and the J 8092 .

Fig 4: Driving The Differential Side Bearing Into Position

Courtesy of GENERAL MOTORS CORP.