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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 (9.75 Inch Axle) >> 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. 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. Determine the total shim pack size for the differential assembly. Refer to Determining Total Shim Pack Size .
  3. 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) .
  4. Install the J 24385-C  onto the axle housing.
  5. Install the J 25025-B  (4), the J 8001-1 and the J 8001-2 (5, 1), the J 34178  (2), and the J 8001-3 and the J 8001-4 (3) onto the axle housing as shown.
    6. Fig 1: Installing J 8001-2, J 34178, J 8001-4 & J 25025-B Onto The Axle Housing
    GM815592Courtesy of GENERAL MOTORS CORP.
  6. Preload the dial of the J 8001-3 by pushing the J 8001-3 against the edge of the J 24385-C  until the needle of the J 8001-3 has moved approximately 3/4 of a turn clockwise.
  7. Rotate the indicator housing to align the indicator needle of the J 8001-3 and the dial indicator face to ZERO.
    8. NOTE: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.
  8. Spread the axle housing by turning the clevis screw of the J 24385-C  clockwise while observing theJ 8001  .

    Spread the housing just enough to install the differential assembly.

  9. Remove the J 25025-B  , the J 8001-1, the J 8001-2, the J 34178  , the J 8001-3 and the J 8001-4 from the axle housing.
  10. Install the differential assembly.
  11. Remove the J 24385-C  .
    12. IMPORTANT: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.
  12. Install the bearing caps.
    13. NOTE: Refer to Fastener Notice in Cautions and Notices.
  13. Install the bearing cap bolts.

    Tighten:  Tighten the bearing cap bolts to 109 N.m (80 lb ft).

  14. 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) .
  15. 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) .
  16. Lower the vehicle.
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