Assembly Procedure

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.

Install the new retaining onto the pinion shaft.
Lubricate the pinion and side gears using axle lubricant. Use the proper fluid.
Install the differential side gear thrust washers to the differential side gears.
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.

Fig 1: Retaining Ring & Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
Install the differential pinion gears and the thrust washers by performing the following steps:
1. 5.1. Install the thrust washers to the pinion gears.
2. 5.2. Position one of the pinion gears with the thrust washer between the differential side gears.
  If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.
3. 5.3. Install the second pinion gear with the thrust washer between the differential side gears directly opposite of the first gear.
4. 5.4. Rotate the differential side gears until the pinion gears and the thrust washers are directly opposite the opening in the differential case.
  
  Fig 2: Differential Pinion Gears & Thrust Washers
  Courtesy of GENERAL MOTORS CORP.
Install the pinion shaft into the differential case by performing the following steps:
1. 6.1. Insert the side of the pinion shaft with the pilot hole into the differential case.
2. 6.2. Slide the pinion shaft through the differential case until the retaining ring is against the differential case.
3. 6.3. Carefully drive the pinion shaft into the differential case using a hammer and a brass drift.
Fig 3: Pinion Shaft & Differential Case
Courtesy of GENERAL MOTORS CORP.

Ensure that the pinion shaft retaining ring is seated in the channel within the differential case.

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.

Fig 4: Ring Gear & Differential Case
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE .

IMPORTANT: The ring gear bolts have right-hand threads.
Install the new ring gear bolts.
Hand start each bolt in ensure the ring gear is properly installed to the differential case.
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 237 N.m (175 lb ft).

Fig 5: Ring Gear Bolts
Courtesy of GENERAL MOTORS CORP.
Install the differential side bearings by performing the following steps:
1. 10.1. In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation.
2. 10.2. Install the J 44420 (2) and the J 8092 (1) onto the differential case bearing as shown.
3. 10.3. Drive the bearing onto the case using the J 44420 and the J 8092.
  
  Fig 6: J 44420 & J 8092
  Courtesy of GENERAL MOTORS CORP.