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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1562 (Rear Drive Axle) >> Repair Instructions >> Differential Replacement (Manual Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: When tilting down the rear of the driveline, insert a putty knife or similar tool between the shift control bracket on the driveline support assembly and the brake pipe retainer on the driveline tunnel wall to prevent damage.
NOTE: Ensure that the clutch hydraulic hoses are positioned away from nearby vehicle components or vehicle damage may result.
    Fig 1: Differential, Transmission Bolts & Nuts
    GM71507Courtesy of GENERAL MOTORS CORP.
  1. SLOWLY slide the differential to the transmission.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the differential to transmission bolts and nuts.

    Tighten:  Tighten the differential to transmission bolts and nuts to 50 N.m (37 lb ft).

    3. Fig 2: Rubber Band & Transmission Shift Rod
    GM180809Courtesy of GENERAL MOTORS CORP.
  3. Loosely install a rubber band onto the transmission shift rod and position just behind the shift rod clamp.

    The rubber band will be used to aid in installing the shift control assembly after the driveline has been installed.

  4. Using a piece of masking tape, or similar tape which can be easily broken, affix the transmission shift rod to the driveline support assembly and position the rod just to the outside of the mounting boss used for the shift control.

    The tape is intended to keep the shift rod in position to aid in shift control installation after the driveline has been installed.

    5. Fig 3: J 42055 & Transmission Jack
    GM180744Courtesy of GENERAL MOTORS CORP.
  5. Position the chainfall, or equivalent lifting device, in a way which will protect the rear exhaust hangers located on the driveline support assembly.
    6. IMPORTANT: The aid of an assistant will be necessary for the following steps until the driveline is installed into the vehicle.
  6. Using the lifting device, raise the driveline off the workbench and position the driveline with the J 42055  onto a transmission jack.
  7. Connect the J 42055  to the transmission jack.
    8. Fig 4: Propeller Input Shaft
    GM71467Courtesy of GENERAL MOTORS CORP.
  8. Remove the lifting device from the driveline.
  9. Position the driveline under the vehicle.
  10. Begin to raise the driveline at the approximate angle used during removal.
  11. Position the wiring harness along the driveline support assembly and LOOSELY install the harness into the harness retaining slots.
  12. Have an assistant guide the front of the driveline so the propeller input shaft is just to the rear of the engine flywheel housing, then raise the driveline to the PROPER HEIGHT and the PROPER ANGLE to install to the engine.
  13. Have an assistant begin to insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle of the driveline; if necessary, use a screwdriver to rotate the shaft slightly to bring the splines into alignment.
    14. Fig 5: Edge Of Shifter Bracket
    GM180656Courtesy of GENERAL MOTORS CORP.
  14. Insert a putty knife, or similar tool, between the edge of the shifter bracket on the side of the driveline support assembly and the brake pipe retainer on the wall of the driveline tunnel.
    15. Fig 6: Supporting Transmission Using Jackstand
    GM180740Courtesy of GENERAL MOTORS CORP.
  15. SLOWLY seat the driveline to the engine flywheel housing while maintaining the proper angle of the driveline.
  16. Reposition the wiring harness bracket from near the driveline tunnel wall to align with the appropriate driveline support assembly bolt hole.
    17. Fig 7: Driveline Support Assembly To Engine Flywheel Housing Bolts
    GM180741Courtesy of GENERAL MOTORS CORP.
  17. Install the driveline support assembly to engine flywheel housing bolts.

    Tighten:  Tighten the driveline support assembly to engine flywheel housing bolts to 50 N.m (37 lb ft).

  18. Install the wiring harness to the wiring harness retainer along the top of the transmission.
  19. SLOWLY raise the driveline to approximately 5 cm (2 in) BELOW the final installed height.
    20. Fig 8: Transmission Fluid Temperature Sensor Electrical Connector
    GM315711Courtesy of GENERAL MOTORS CORP.
  20. Connect the transmission fluid temperature sensor electrical connector, if equipped.
    21. Fig 9: Gear Select (Skip Shift) Solenoid Electrical Connector
    GM180654Courtesy of GENERAL MOTORS CORP.
  21. Connect the gear select (skip shift) solenoid electrical connector.
    22. Fig 10: Reverse Lockout Solenoid Electrical Connector
    GM180652Courtesy of GENERAL MOTORS CORP.
  22. Connect the reverse lockout solenoid electrical connector.
    23. Fig 11: Backup Lamp Switch Electrical Connector
    GM180651Courtesy of GENERAL MOTORS CORP.
  23. Connect the backup lamp switch electrical connector.
    24. Fig 12: Wiring Harness Retainer To Stud At Differential Rear Cover
    GM71409Courtesy of GENERAL MOTORS CORP.
  24. Connect the wiring harness clip to the top of the differential.
  25. Connect the wiring harness retainer to the stud at the differential rear cover.
    26. Fig 13: Vehicle Speed Sensor (VSS) Electrical Connector
    GM180649Courtesy of GENERAL MOTORS CORP.
  26. Connect the vehicle speed sensor (VSS) electrical connector.
    27. Fig 14: View Of Transaxle Mount Bracket & Bolts
    GM71501Courtesy of GENERAL MOTORS CORP.
  27. Slowly raise the driveline to final installation height.
  28. Remove the putty knife, if still in position.
  29. Remove the jack which supported the rear of the engine.
  30. Remove the tie-off retainers from the axle shafts.
  31. CAREFULLY align and seat the axle shafts to the differential.
  32. Install the transaxle mount with bracket to the differential.
  33. Install the transaxle mount bracket to differential bolts.

    Tighten:  Tighten the transaxle mount bracket to differential bolts to 50 N.m (37 lb ft).

    34. Fig 15: View Of Rear Suspension Crossmember
    GM180638Courtesy of GENERAL MOTORS CORP.
  34. With the aid of an assistant, begin to raise the rear suspension crossmember (still firmly attached to a transmission jack), to the vehicle frame rails.
  35. Guide the rear suspension crossmember alignment pins into the alignment holes in the vehicle frame rails, and guide the transaxle mount studs into the mounting holes in the crossmember, then raise the crossmember to seat to the frame rails.
    36. Fig 16: View Of Jack Supports
    GM180637Courtesy of GENERAL MOTORS CORP.
  36. Using ONLY HAND TOOLS, install NEW rear suspension crossmember mounting nuts.

    Tighten:  Tighten the rear suspension crossmember mounting nuts to 110 N.m (81 lb ft).

    37. Fig 17: View Of Transaxle Mount-To-Rear Crossmember Nuts
    GM180633Courtesy of GENERAL MOTORS CORP.
  37. Remove the transmission jack from the rear suspension crossmember.
  38. Release the J 42055  from the transmission, then remove the J 42055  and transmission jack.
  39. Install the transaxle mount to rear suspension crossmember nuts.

    Tighten:  Tighten the transaxle mount to rear suspension crossmember nuts to 50 N.m (37 lb ft).

  40. Install the differential to transmission lower nut.

    Tighten:  Tighten the differential to transmission lower nut to 50 N.m (37 lb ft).

  41. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
    42. Fig 18: View Of Shock Absorber Mounting To Control Arm
    GM180606Courtesy of GENERAL MOTORS CORP.
  42. Support the lower control arm with a jack.
  43. Connect the lower ball joint to the suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  44. Install the shock absorber lower mounting bolt.

    Tighten:  Tighten the rear shock absorber lower mounting bolt to 220 N.m (162 lb ft).

  45. Connect the outer tie rod end to the suspension knuckle. Refer to Tie Rod Replacement (Outer End) or Tie Rod Replacement (Suspension Link) in Rear Suspension.
  46. Remove the straight jack from the suspension control arm.
  47. Repeat steps 41 through 46 for the other side of the vehicle.
  48. Install the rear transverse spring. Refer to Rear Transverse Spring Replacement in Rear Suspension.
    49. Fig 19: Wiring Harness & Driveline Support Assembly
    GM321406Courtesy of GENERAL MOTORS CORP.
  49. Carefully pull the wiring harness down into the L-shaped brackets along the driveline support assembly, align the harness retainer (locator) (1) to the hole in the forward bracket, then secure in place.
    50. Fig 20: Identifying White Circular Release Ring
    GM71472Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.
  50. Connect the clutch actuator cylinder hose to the clutch master cylinder hose.

    Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.

  51. Check the clutch hydraulic hoses for twists or kinks.
    52. Fig 21: Clutch Actuator Cylinder Hose
    GM71473Courtesy of GENERAL MOTORS CORP.
  52. Install the clutch actuator cylinder hose to the hose retaining clip (at the rear of the engine).
  53. Install the driveline tunnel closeout panel. Refer to Driveline Tunnel Closeout Panel Replacement in Propeller Shaft.
  54. Remove the tie-off retainers from the muffler assemblies.
  55. Install the catalytic converters. Refer to Catalytic Converter Replacement in Engine Exhaust.
  56. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    57. Fig 22: View Of Master Cylinder Push Rod To Clutch Pedal
    GM71474Courtesy of GENERAL MOTORS CORP.
  57. Lower the vehicle.
  58. Connect the clutch master cylinder pushrod to the clutch pedal.
  59. Install the clutch master cylinder pushrod retainer.
  60. Install the left IP lower insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Console.
    61. Fig 23: Rubber Band & Rear Stud On Top Of Driveline Tunnel
    GM180851Courtesy of GENERAL MOTORS CORP.
  61. Grasp the transmission shift rod and pull up to break the masking tape installed earlier to maintain position during installation.
  62. Stretch the rubber band, while still installed onto the transmission shift rod, over the rear stud on top of the driveline tunnel to aid in shift control installation.
  63. Install the shift control assembly. Refer to Shift Control Assembly Replacement in Manual Transmission.
  64. Break and remove the rubber band.
    65. Fig 24: Control Closeout Boot & Retaining Nuts
    GM71523Courtesy of GENERAL MOTORS CORP.
  65. Install the shift control closeout boot.

    Check that the closeout boot fully seats to the shift control lever seal and the base of the shift control assembly (1).

  66. Install the shift control closeout boot retaining nuts.

    Tighten:  Tighten the shift control closeout boot retaining nuts to 12 N.m (106 lb in).

    67. Fig 25: IP Accessory Trim Plate & Boot
    GM71519Courtesy of GENERAL MOTORS CORP.
  67. Install the IP accessory trim plate. Refer to Trim Plate Replacement - Instrument Panel (I/P) Accessory in Instrument Panel, Gauges and Console.
  68. Install the shift control boot over the shift control lever.
    69. Fig 26: Shift Control Boot, IP Accessory Trim Plate & Boot Retaining Tabs
    GM180589Courtesy of GENERAL MOTORS CORP.
  69. Align the shift control boot to the IP accessory trim plate opening, then press to lock the boot retaining tabs.
  70. Adjust the shape of the boot for appearance, if necessary.
    71. Fig 27: Gear Shift Knob Removed
    GM71520Courtesy of GENERAL MOTORS CORP.
  71. Screw the shift control knob onto the shift control lever until the knob bottoms out.
    72. Fig 28: Shift Control Knob Button
    GM71521Courtesy of GENERAL MOTORS CORP.
  72. Unscrew the shift control knob just enough to align the retainer slot with the slot on the shift control lever.
  73. Install the shift control knob retainer (1) into the slots and seat fully.
  74. Install the shift control knob button.
  75. Install the console. Refer to Console Replacement in Instrument Panel, Gauges and Console.
  76. Connect the negative battery cable.

    Tighten:  Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

  77. Program the transmitters. Refer to Transmitter Programming in Keyless Entry.
  78. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding in Clutch.
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