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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1459 (Rear Drive Axle) >> Repair Instructions >> Differential Overhaul >> Assembly Procedure

Assembly Procedure

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  1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  2. Install the differential side gear thrust washers to the differential side gears.
  3. 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.

    4. Fig 1: Exploded View Of Differential Case
    GM680404Courtesy of GENERAL MOTORS CORP.
  4. Install the differential pinion gears and pinion gear thrust washers by performing the following steps:
    1. Position one pinion gear between the differential side gears.
    2. Position the second pinion gear between the differential side gears directly opposite the of the first gear.
    3. Rotate the differential side gears until the pinion gears is directly opposite the opening in the differential case.
    4. Install the thrust washers.

      Rotate the pinion gears toward the differential opening in order to permit the sliding in of the thrust washers.

  5. Install the pinion shaft.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install a new pinion shaft lock bolt.

    Tighten:  Tighten the new pinion shaft lock bolt to 36 N.m (27 lb ft).

    7. IMPORTANT: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
    Fig 2: Ring Gear & Differential Case
    GM866505Courtesy of GENERAL MOTORS CORP.
  7. Install the ring gear to the differential case.
    8. Fig 3: Identifying Ring Gear Bolts
    GM866503Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The ring gear bolts have left-hand threads.
  8. Install the new ring gear bolts.

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

  9. 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 120 N.m (89 lb ft).

  10. Install the differential side bearings. Refer to Differential Side Bearings Replacement  .
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