Tools Required

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

J 22761 Differential Side Bearing Installer
J 33791 Carrier Bushing Remover/Installer
J 36600 Output Shaft Seal Installer
J 36616 Axle Mount Bushing Remover/Installer

Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
Remove the differential carrier assembly bolts.
Remove the right differential carrier case half.
Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly.
The surfaces must be clean of all the grease and the oil.
Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or equivalent to one differential carrier case half sealing surface.
Install the right differential carrier case half.
NOTE: Refer to FASTENER NOTICE .
Install the differential carrier case bolts.
Tighten

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

Fig 1: Install Vent Hose Connector
Courtesy of GENERAL MOTORS CORP.
Install the vent connector.
Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent onto the threads.

Tighten

Tighten the vent connector to 25 N.m (18 lb ft).
Install the left side bearing and the oil seal using the following procedure:
1. 9.1. Install the bearing with the square shoulder in using the J 22761.
2. 9.2. Install the new axle shaft seal using the J 36600.
3. 9.3. Install the inner axle shaft.
  Carefully tap the inner axle shaft into place with a soft-faced mallet.
  
  Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
Install the right side bearing by performing the following steps:
1. 10.1. Install the inner axle shaft housing into a vise.
  Clamp only on the mounting flange of the inner axle shaft housing.
2. 10.2. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
  
  Fig 2: Install Bearing With Square Shoulder Using J 36609
  Courtesy of GENERAL MOTORS CORP.
Install the right side inner axle shaft seal by performing the following steps:
1. 11.1. Install the inner axle shaft housing into a vise.
  Clamp only on the mounting flange of the inner axle shaft housing.
2. 11.2. Install the new axle shaft seal using the J 36600, 8.25 inch axle, or the J 22833, 9.25 inch axle.
Install the inner axle shaft into the inner axle shaft housing.
Carefully tap the inner axle shaft into place with a soft-faced mallet.
Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
Install the inner axle shaft housing to the differential carrier case.

Fig 3: Install Right Side Inner Axle Shaft Seal
Courtesy of GENERAL MOTORS CORP.
Install the inner axle shaft housing bolts.
Tighten

Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
Install the inner axle shaft (2) into the inner axle shaft housing (1) by doing the following:
1. 16.1. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
2. 16.2. Drive the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
  Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
Install the drain plug and the washer.
Install the fill plug and the washer.
Tighten

Tighten the drain plug and the fill plug to 33 N.m (24 lb ft).

Fig 4: Install Inner Axle Shaft Into Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
Install the lower differential carrier assembly bushing by performing the following steps:
1. 19.1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
2. 19.2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
Fig 5: Thrust Bearing, Forcing Screw, J 21474-18, J 36616-2 & J 36616-1
Courtesy of GENERAL MOTORS CORP.
Install the upper differential carrier assembly bushing by performing the following steps:
1. 20.1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
2. 20.2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
Fig 6: Thrust Bearing, Forcing Screw, J 21474-18, J 36616-2 & J 36616-1
Courtesy of GENERAL MOTORS CORP.