Installation Procedure

WARNING: This page is about a different car, the 2003 Oldsmobile Bravada, 2003 GMC Envoy XL, 2003 GMC Envoy, and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

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

NOTE: Refer to Fastener Notice in Cautions and Notices.
Tighten the new ring gear 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).
Install the drive pinion bearing cups. Refer to DRIVE PINION BEARINGS REPLACEMENT .

Fig 1: Installing Ring Gear To Differential Case
Courtesy of GENERAL MOTORS CORP.
Determine the selective shim thickness for the pinion gear. Refer to PINION DEPTH ADJUSTMENT .
Install the selective shim onto the pinion.
Install the inner pinion bearing onto the pinion. Refer to DRIVE PINION BEARINGS REPLACEMENT .
Install a new collapsible spacer.
Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
Install the pinion to the axle housing.
Install the outer pinion bearing.
Install a new pinion oil seal using the J 38694 .
Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.

Fig 2: Installing New Pinion Oil Seal Using J38694
Courtesy of GENERAL MOTORS CORP.
Install the pinion yoke.
Align the marks made during removal.
Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
Install the washer and a new pinion nut.

Fig 3: Aligning Marks
Courtesy of GENERAL MOTORS CORP.
Install the J 8614-01 onto the pinion yoke as shown.
IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
Tighten the pinion nut while holding the J 8614-01 .
Tighten

Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

Fig 4: Installing J 8614-01 Onto Pinion Yoke
Courtesy of GENERAL MOTORS CORP.
Measure the rotating torque of the pinion using an inch-pound torque wrench.
Specification

The rotating torque of the pinion should be 1.0-2.3 N.m (10-20 lb in) for used bearings or 1.7-3.4 N.m (15-30 lb in) for new bearings.
If the rotating torque measurement is below 1.0 N.m (10 lb in) for used bearings, or 1.7 N.m (15 lb in) for new bearings, continue to tighten the pinion nut.
Tighten

Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.3 N.m (10-20 lb in) for used bearings or 1.7-3.4 N.m (15-30 lb in) for new bearings.

Fig 5: Measuring Rotating Torque Of Pinion Using Inch-Pound Torque Wrench
Courtesy of GENERAL MOTORS CORP.
Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.
Recheck the rotating torque and adjust if necessary.
Install the differential. Refer to DIFFERENTIAL REPLACEMENT .
Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to GEAR TOOTH CONTACT PATTERN INSPECTION .
Install the axle shafts. Refer to REAR AXLE SHAFT REPLACEMENT .
Install the brake rotors. Refer to Brake Rotor Replacement - Rear in Disc Brakes.
Install the brake calipers. Refer to Brake Caliper Replacement - Rear in Disc Brakes.
Install the tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
Fill the axle with axle lubricant. Use the proper fluid. Refer to LUBRICANT REPLACEMENT - REAR DRIVE AXLE .
Lower the vehicle.