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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1040 (Rear Drive Axle) >> Repair Instructions >> Differential Replacement (8.6 Inch, 9.5 Inch Axles) >> Installation Procedure

Installation 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.
  1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) , Drive Pinion and Ring Gear Replacement (9.75 Inch Axle)  or Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) .
  2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement (All Except 9.75 Inch Axle)  or Differential Side Bearings Replacement (9.75 Inch Axle) .
  3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  4. Place the case, with the bearing cups installed, into the axle housing.

    Support the case in order to keep the case from falling out of the axle housing.

    5. Fig 1: View Of Differential Case And Axle Housing
    GM667660Courtesy of GENERAL MOTORS CORP.
  5. Install the bearing caps and the bolts. Do not torque the bearing cap bolts at this time.
    6. Fig 2: Removing/Installing Bearing Cap Bolt
    GM667502Courtesy of GENERAL MOTORS CORP.
  6. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment (8.6 Inch Axle) , Differential Side Bearing Preload Adjustment (9.5 Inch Axle) , Differential Side Bearing Preload Adjustment (9.75 Inch Axle)  or Differential Side Bearing Preload Adjustment (10.5 Inch, 11.5 Inch Axles) .
  7. Adjust the backlash. Refer to Backlash Adjustment (8.6 Inch Axle)  or Backlash Adjustment (9.75 Inch Axle) .
  8. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
  9. Tighten the bearing cap bolts.

    Tighten: 

    • For the 8.6 inch axle, tighten the bearing cap bolts to 75 N.m (55 lb ft)
    • For the 9.5 inch axle, tighten the bearing cap bolts to 85 N.m (63 lb ft)

  10. Install the axle shafts. Refer to Rear Axle Shaft Replacement (8.6 Inch, 9.5 Inch Axles)  or Rear Axle Shaft Replacement (9.75 Inch Axle) .
  11. Fill the axle with the proper lubricant. Refer to Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) , Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) .
  12. Lower the vehicle.
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