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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1288 (Rear Drive Axle) >> Repair Instructions >> Differential Overhaul >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the following components into the differential carrier:
    • The side gear thrust washers
    • The differential side gears
    • The pinion gear thrust washers
    • The pinion gears
    • The pinion shaft
  2. Use a J 8001  in order to measure the differential side gear backlash.
    Fig 1: Measuring Differential Side Gear Backlash
    G01545930Courtesy of GENERAL MOTORS CORP.
    1. Place the J 8001  plunger between the teeth of the left side gear.
    2. Hold 1 pinion gear against the differential case, then move the side gear up and down while observing the J 8001. 
    3. The standard differential side gear backlash should be between 0.05 to 0.20 mm (0.002 to 0.0079 in).
    4. If the differential side gear backlash is not between 0.05 - 0.20 mm (0.002 - 0.0079 in), replace the side gear thrust washers with different thicknesses in order to obtain the proper backlash. Refer to Spacer and Shim Specifications 
  3. Use a standard drift punch and hammer in order to install the pinion shaft roll pin into the differential carrier and the pinion shaft.
  4. Stake the outside of the differential case roll pin hole using a hammer and chisel.
    Fig 2: Staking Outside Of Differential Case Roll Pin Hole
    G01545931Courtesy of GENERAL MOTORS CORP.
  5. Heat the ring gear in boiling water (1).
    Fig 3: Heating Ring Gear In Boiling Water
    G01545932Courtesy of GENERAL MOTORS CORP.
  6. Clean the contact surfaces of the differential case and the ring gear.
  7. Carefully remove the ring gear from the boiling water.
  8. After the moisture as completely evaporated, quickly install the ring gear on the differential case.
  9. Align the reference marks (1) on the differential case and the ring gear.
    Fig 4: Aligning Reference Marks On Differential Case And Ring Gear
    G01545933Courtesy of GENERAL MOTORS CORP.
  10. Temporarily install 10 new bolts.
    NOTE: Refer to FASTENER NOTICE .
  11. Allow the ring gear to cool, then tighten the bolts in a star pattern.
    1. Tighten 
    2. Tighten the ring gear bolts to 78 N.m (58 lb ft).
  12. Install the differential case side bearings using a press.
  13. Install the drive pinion rear bearing shim that was removed in disassembly.
  14. Install the drive pinion rear bearing (1) using a press.
    Fig 5: Installing Drive Pinion Rear Bearing
    G01545934Courtesy of GENERAL MOTORS CORP.
  15. Temporarily install the drive pinion and front bearing.
  16. Lightly coat the drive pinion threads with multi-purpose grease.
  17. Temporarily adjust the drive pinion preload by tightening the pinion nut.
    1. Tighten 
    2. Tighten the pinion nut to no more than 223 N.m (164 lb ft).
  18. Measure and record the pinion preload using a torque wrench (1) and J 46004. 
    • Starting drive pinion preload with a new set of bearings should be 0.69 - 1.27 N.m (6 - 11 lb in).
    • Starting drive pinion preload with a reused set of bearings should be 0.39 - 0.69 N.m (3 - 6 lb in).
      Fig 6: Measuring Pinion Preload
      G01545935Courtesy of GENERAL MOTORS CORP.
  19. Temporarily install the differential case into the differential carrier.
  20. Temporarily install the differential side cover.
  21. Measure the ring gear backlash using the J 8001  and J 35405. 
  22. Ring gear backlash should be between 0.10 - 0.15 mm (0.0039 - 0.059 in).

    Important:  If the backlash measurement is not within the specifications given, increase or decrease the thickness of the shims on both sides in equal amounts. Refer to Spacer and Shim Specifications 

    • When the backlash measurement is smaller than the specified value, select a thicker shim for the right side and a thinner shim for the left side.
    • When the backlash measurement is larger than the specified value, select a thinner shim for the right side and a thicker shim for the left side.
      Fig 7: Measuring Ring Gear Backlash
      G01545936Courtesy of GENERAL MOTORS CORP.
  23. Measure the differential total preload. This measurement should be the drive pinion preload recorded in the previous step plus 0.3 - 0.5 N.m (2.6 - 4.31 lb in).

    Adjust total preload by changing the right-hand shim thickness.

  24. Remove the 10 differential side cover bolts.
  25. Remove the differential side cover from the differential carrier.
  26. Remove the differential case from the differential carrier.
  27. Coat the ring gear teeth with Gear Marking Compound GM P/N 1052351 (Canadian P/N 10953497).
  28. Temporarily install the differential case in the differential carrier.
  29. Temporarily install the differential side cover to the differential carrier.
  30. Install the 10 differential side cover bolts.
  31. Rotate the drive pinion several times.
  32. Remove the 10 bolts and the differential side cover.
  33. Check the ring gear tooth contact pattern.

    Important:  When changing the thickness of the side gear shim, adjust the drive pinion preload, ring gear backlash and total preload before adjusting the ring gear tooth contact pattern.

  34. Adjust the contact pattern as necessary.
  35. Remove the differential case from the differential carrier.
  36. Remove the drive pinion from the differential carrier.
  37. Install a new bearing spacer and the oil slinger on the drive pinion.
  38. Install the drive pinion.
  39. Using J 46002  and J 46004  , install the drive pinion nut.
    1. Tighten 
    2. Adjust the drive pinion preload by tightening the nut NO MORE THAN 223 N.m (164 lb ft).
  40. Check the pinion preload using a torque wrench (1) and J 46004. 
    • Starting drive pinion preload with a new set of bearings should be 0.69 - 1.27 N.m (6 - 11 lb in).
    • Starting drive pinion preload with a reused set of bearings should be 0.39 - 0.69 N.m (3 - 6 lb in).
    • If the preload is greater than specified, replace the collapsible spacer.
    • If the preload is less than specified, tighten the drive pinion nut an additional 13 N.m (9 lb ft) of torque at a time until a maximum of 245 N.m (181 lb ft) is reached.
    Fig 8: Checking Pinion Preload
    G01545937Courtesy of GENERAL MOTORS CORP.
  41. Clean the mating surfaces of the differential side cover and the differential carrier.
  42. Install the differential case in the differential carrier.

    Important:  Do not add gear oil or drive the vehicle immediately after cover installation. Allow silicone to cure for 1 hour or more. Avoid rapid acceleration or deceleration for 12 hours or more.

  43. Apply a 2 - 3 mm (0.08 - 0.12 in) bead of Red Silicone Sealant GM P/N 1052366 to the differential side cover. Begin and end the application in area (a).
    Fig 9: Identifying Area (a)
    G01545938Courtesy of GENERAL MOTORS CORP.
  44. Install the differential side cover on the differential carrier.
  45. Install the 10 side cover bolts.
    1. Tighten 
    2. Tighten the 10 bolts to 42 N.m (31 lb ft).
  46. Check the ring gear backlash, then check the total preload.
  47. Align the elbow reference marks, then install elbows into the differential carrier.
    Fig 10: Aligning Elbow Reference Marks
    G01545939Courtesy of GENERAL MOTORS CORP.
  48. Install the breather hose.
  49. Install the new front oil seal.
  50. Install the side gear oil seals.
  51. Install the coupling into the coupling cover, then install the assembly on the differential carrier.
  52. Install the 4 coupling cover bolts.
    1. Tighten 
    2. Tighten the bolts to 19 N.m (14 lb ft).
  53. Install the differential carrier into the vehicle. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT  .
  54. Install the drain plug.
    1. Tighten 
    2. Tighten the drain plug to 39 N.m (29 lb ft).
  55. Fill the differential carrier with 0.5 L (1.05 Pints) of GL-5 80W -90W gear oil or equivalent.
  56. Install the fill plug.
    1. Tighten 
    2. Tighten the fill plug to 39 N.m (29 lb ft).
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