Locking Differential Assemble (8.6, 9.5, 11.5 Inch Axles)

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.

IMPORTANT: The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the locking differential can be assembled.

Install the left side gear thrust washer.

Fig 1: View Of Left Side Gear Thrust Washer

Courtesy of GENERAL MOTORS CORP.

Install the left side gear cam unit and clutch disc assembly.

Fig 2: View Of Left Side Gear Cam Unit & Clutch Disc Assembly

Courtesy of GENERAL MOTORS CORP.

Install the right side gear thrust washer.
Install the right side clutch disc assembly.
Install the right side gear.

IMPORTANT: If the original pinion gears and thrust washers are being re-used, install the pinion gears and thrust washers on the same side as when removed.

Install the pinion gear and the pinion thrust washers.
Place the pinion gears and the pinion thrust washers 180 degrees apart.
Rotate the pinion gears and the pinion thrust washers 90 degrees and align the pinion gears with the pinion shaft opening in the differential case.
Install the thrust block.
The open side of the thrust block must face the window opening.
Install the pinion shaft.
For the 8.6 inch, 9.5 inch axles, install the new pinion shaft lock bolt.
Tighten the pinion shaft lock bolt finger tight.
For the 11.5 inch axle, install the new pinion shaft retaining pin.
Drive the retaining pin into the differential case using a hammer and drift pin.
Install the governor assembly.

Fig 3: Installing Governor Assembly

Courtesy of GENERAL MOTORS CORP.

Install the governor bushing using a hammer and a brass drift.
Specification: Press the bushing into place until there is 0.025-0.076 mm (0.010-0.030 in) of shaft end play.
Install the latching bracket assembly.
The straight end of the latching bracket spring must be over and outside the governor assembly shaft.
Install the latching bracket bushing using a hammer and a brass drift.
Specification: Press the bushing into place until there is 0.000-0.051 mm (0.000-0.002 in) of shaft end play.

Fig 4: Installing Latching Bracket Busing

Courtesy of GENERAL MOTORS CORP.

For the 8.6, 9.5 inch axles, tighten the pinion shaft lock bolt.
Tighten:
- For the 8.6 inch axle, tighten the pinion shaft lock bolt to 36 N.m (27 lb ft).
- For the 9.5 inch axle, tighten the pinion shaft lock bolt to 50 N.m (37 lb ft).
Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) or Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) or Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) in Rear Drive Axle.