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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1611 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly - Assemble >> Tools Required

Tools Required

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  1. Install the pinion bearing cups into the differential carrier assembly. Refer to Pinion Bearing Cup Installation .
    Fig 1: Install Inner Pinion Bearing
    G01480514Courtesy of GENERAL MOTORS CORP.
  2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
  3. Install the inner pinion bearing onto the pinion gear using the J 35512,  8.25 inch axle, or the J 36614,  9.25 inch axle.
  4. Install the new collapsible spacer onto the pinion gear.
  5. Install the J 36598  into a vise.
  6. Install the left differential carrier case half into the J 36598  and the J 36598-6, 8.25 inch axle, or the J 36598,  9.25 inch axle.
  7. Lubricate the pinion bearings with axle lubricant.
  8. Install the outer pinion bearing into the left differential carrier case half.
  9. Install the pinion oil seal using J 36366. 
  10. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
  11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke.
  12. Install the pinion yoke.
    NOTE: Refer to PINION FLANGE/YOKE INSTALLATION NOTICE .
  13. 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.
  14. Install the washer and a new pinion nut.

    If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed:

    1. 14.1. Remove the pinion nut washer.
    2. 14.2. Install the old pinion nut.
      Fig 2: Installing Pinion Oil Seal Using J 36366
      G01480515Courtesy of GENERAL MOTORS CORP.
    3. 14.3. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed.
    4. 14.4. Remove the old pinion nut.
    5. 14.5. Install the pinion nut washer
    6. 14.6. Install the new pinion nut.
  15. Install the J 8614-01  onto the pinion yoke as shown.
    NOTE: Refer to FASTENER NOTICE .
    IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
  16. 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.

  17. Remove the J 8614-01. 
  18. 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.

  19. 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, re-install the J 8614-01  and 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 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal for used bearings or 1.7-3.4 N.m (15-30 lb in) for new bearings.

  20. 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.

  21. Remove the J 8614-01. 
  22. Assemble the differential adjuster nut into the differential nut sleeve until fully seated, 8.25 inch axle-left and right sides, 9.25 inch axle, right side.
    Fig 3: Install J 8614-01 Onto Pinion Yoke
    G01480516Courtesy of GENERAL MOTORS CORP.
  23. Install the axle shaft bearings into the differential adjuster nut sleeves using the J 36612  (2) and the J 8092  (1), 8.25 inch axle-left and right sides, 9.25 inch axle-right side.
  24. Install the axle shaft bearing into the differential adjuster nut sleeve using the J 36609  and the J 8092,  9.25 inch axle-left side.
  25. Install the differential adjuster nut assembly and new adjuster lock nut tabs into the differential carrier case using the J 36609  and the J 8092,  8.25 inch axle-left and right sides, 9.25 inch axle-right side.
  26. Install the differential adjuster nut assembly into the differential carrier case, 9.25 inch axle-left side.
    Fig 4: J 8092 & J 36612
    G01480517Courtesy of GENERAL MOTORS CORP.
  27. Install the differential case side bearing cups to the differential carrier case using the J 36603  (2) and the J 8092  (1), 8.25 inch axle-left and right sides, 9.25 inch axle-right side.
  28. Install the differential case assembly into the left differential carrier case half.
  29. Install the right differential carrier case half to the left differential carrier case half.

    Do not use sealer at this time.

    If the carrier case halves do not make complete contact, use the J 36599-A  in order to back out the right differential adjuster nut sleeve until the differential carrier case halves make contact.

  30. Install the differential carrier case bolts.

    Tighten 

    Tighten the differential carrier case bolts to 47 N.m (35 lb ft).

  31. Install the differential carrier assembly into a vise.
    Fig 5: J 8092 & J 36603
    G01480518Courtesy of GENERAL MOTORS CORP.
  32. For the 8.25 inch axle, turn the left differential adjuster nut sleeve clockwise using the J 36599-A  until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
  33. For the 8.25 inch axle, turn the right differential adjuster nut sleeve clockwise using the J 36599-A  until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
    Fig 6: Turn Right Differential Adjuster Nut Sleeve Clockwise Using J 36599-A
    G01480519Courtesy of GENERAL MOTORS CORP.
  34. For the 9.25 inch axle, turn the differential adjuster nut clockwise using the J 36615  until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
  35. For the 9.25 inch axle, turn the right differential adjuster nut sleeve clockwise using the J 36599-A  until the differential adjuster nut sleeve contacts the differential side bearing and can no longer be turned.
  36. Rotate the pinion several times in order to seat the bearings.
  37. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

    Specification 

    The rotating torque of the pinion and differential assembly should be 2.8-5.1 N.m (25-45 lb in) for used bearings, or 3.4-6.2 N.m (30-55 lb in) for new bearings.

    Fig 7: Measuring Pinion & Differential Assembly Rotating Torque
    G01480520Courtesy of GENERAL MOTORS CORP.
  38. If the rotating torque measurement is below 2.8 N.m (25 lb in) for used bearings, or 3.4 N.m (30 lb in) for new bearings, tighten the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
  39. If the rotating torque measurement is above 5.1 N.m (45 lb in) for used bearings, or 6.2 N.m (55 lb in) for new bearings, loosen the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
  40. 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.

  41. Measure the drive pinion to ring gear backlash. Refer to Backlash Inspection and Adjustment .
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