LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1893 (Drive Axles - Front) >> Repair Instructions >> Differential Carrier Assembly - Final Assembly (8.25 S4WD And 9.25 Axles) >> Assembly Procedure

Assembly Procedure

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 GMC Sierra, 2002 Chevrolet Tahoe, and 2002 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.
  1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 8.25 inch axle - both sides, 9.25 inch axle - right side.
  2. Install the differential adjuster nut lock, 9.25 inch axle - left side.
    NOTE: Refer to FASTENER NOTICE .
    Fig 1: Installing Differential Adjuster Nut Lock
    G01455961Courtesy of GENERAL MOTORS CORP.
  3. Install the differential adjuster nut lock bolt.

    Tighten 

    Tighten the differential adjuster lock nut bolt to 20 N.m (15 lb ft).

  4. Remove the differential carrier assembly bolts.
    Fig 2: Differential Carrier Assembly Bolts (8.25 Inch Axles)
    GM1332740
  5. Remove the right differential carrier case half.
    Fig 3: Removing Differential Case Assembly (8.25 Inch Axles)
    GM1332738
  6. 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.

  7. Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or equivalent to one differential carrier case half sealing surface. Refer to Figure.
  8. Install the right differential carrier case half.
  9. Install the differential carrier case bolts.

    Tighten 

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

  10. Lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Figure.
  11. Install the clutch shaft pilot bearing using the J 33842  .
    Fig 4: Installing Clutch Shaft Pilot Bearing
    G01455962Courtesy of GENERAL MOTORS CORP.
  12. Install the clutch shaft to the differential carrier case half.
    Fig 5: Installing Clutch Shaft To Differential Carrier
    G01455963Courtesy of GENERAL MOTORS CORP.
  13. For ratcheting style vent connectors, rotate the pinion yoke until the differential case window can be seen through the vent hose connector opening.
    Fig 6: Locating Differential Case Window
    GM834274
  14. Place the alignment arm of the vent hose connector in the 6 o'clock position.
    NOTE: Refer to COMPONENT FASTENER TIGHTENING NOTICE .
    Fig 7: Aligning Arm Of Vent Hose Connector
    GM834277
  15. Install the vent hose connector with the alignment arm in the 6 o'clock position into the vent hose connector opening.

    Tighten 

    Tighten the vent hose connector to 28 Nm (21 lb ft).

  16. For non-ratcheting style vent connectors, install the vent hose connector.

    Tighten 

    Tighten the vent hose connector to 28 Nm (21 lb ft).

    Fig 8: Installing Vent Hose Connector
    G01455964Courtesy of GENERAL MOTORS CORP.
  17. Install the new left side axle shaft seal using the J 45225  (1), and J 8092  (2).
    Fig 9: Install The New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
    GM1486568
  18. Install the new left side inner axle shaft retainer ring.
  19. Install the left side inner axle shaft by doing the following:
    1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
    2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear.
    3. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.

      Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.

      Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.

      Fig 10: Installing Left Side Inner Axle Shaft
      GM1332794
  20. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
    1. Install the inner axle shaft housing into a vise.

      Clamp only on the mounting flange of the inner axle shaft housing.

    2. Install the bearing with the square shoulder in using the J 36609  (1) and the J 8092  (2).
    Fig 11: Installing Bearing With Square Shoulder
    G01455965Courtesy of GENERAL MOTORS CORP.
  21. Install the new inner shaft seal using the J 45225  (1) and the J 8092  (2).
    Fig 12: Installing New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
    GM1486575
  22. Install the inner axle shaft into the inner shaft housing.

    Carefully tap the inner axle shaft into place with a soft-faced mallet.

  23. For the 8.25 inch axle - 1st design, assemble the following components into the inner shaft housing:
      IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. Install the thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing (4).

    2. Install the new retainer ring (7) into the clutch gear (6).
    3. Install the clutch gear (6) onto the inner axle shaft (1).

      Drive the clutch gear into place with a plastic hammer.

    4. Determine the clutch gear shim thickness. Refer to INNER AXLE SHAFT SHIM ADJUSTMENT .
    5. Install the clutch gear shim (9)
    6. Install the clutch sleeve (8)
    7. Install the clutch fork assembly (14, 13, 12, 11)
    8. Install the clutch fork inner spring (10) into the differential carrier case.
    Fig 13: Inner Axle Shaft Housing Components (8.25 Inch) (1st Design)
    GM695177
  24. For the 8.25 inch S4WD axle - 2nd design, assemble the following components into the inner axle shaft housing:
      IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. Install the thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    2. Install the new retainer ring (7) onto the clutch gear (6).
    3. Install the clutch gear (6) onto the inner axle shaft (1).

      Drive the clutch gear into place with a plastic hammer.

    4. Determine the clutch gear shim thickness. Refer to INNER AXLE SHAFT SHIM ADJUSTMENT .
    5. Install the clutch gear shim (9)
    6. Install the clutch sleeve (8)
    7. Install the clutch fork assembly (11)
    8. Install the clutch fork inner spring (10)
    Fig 14: Inner Axle Shaft Housing Components (8.25 Inch) (2nd Design)
    GM892810
  25. For the 9.25 inch axle - 1st design, install the following components into the inner axle shaft housing:
      IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. The thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slot in the inner axle shaft housing (4).

    2. The second thrust washer (6)
    3. The retainer ring (7) onto the inner axle shaft (1).
    4. Determine the clutch gear shim thickness. Refer to INNER AXLE SHAFT SHIM ADJUSTMENT .
    5. The clutch gear shim (9)
    6. The clutch sleeve (8)
    7. The clutch fork assembly (14, 13, 12, 11)
    8. The clutch fork inner spring (10) into the differential carrier case.
    Fig 15: Inner Axle Shaft Housing Components (9.25 Inch) (1st Design)
    GM695181
  26. For the 9.25 inch axle - 2nd design, install the following components into the inner shaft housing:
      IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. Install the thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.

    2. Install the second thrust washer (6) into the inner axle shaft housing.
    3. Install the new retainer ring (7) onto the inner axle shaft (1).
    4. Determine the clutch gear shim thickness. Refer to INNER AXLE SHAFT SHIM ADJUSTMENT .
    5. Install the clutch gear shim (9)
    6. Install the clutch sleeve (8)
    7. Install the clutch fork assembly (11)
    8. Install the clutch fork inner spring (10)
    Fig 16: Inner Axle Shaft Housing Components (9.25 Inch) (2nd Design)
    GM892812
  27. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealer. Refer to Figure.
  28. Install the inner shaft housing to the differential carrier assembly case.
    Fig 17: Installing Inner Shaft Housing
    G01455969Courtesy of GENERAL MOTORS CORP.
  29. Install the inner shaft housing bolts.

    Tighten 

    Tighten the inner shaft housing bolts to 40 N.m (30 lb ft).

  30. Install the drain plug and the washer.
  31. Install the fill plug and the washer.

    Tighten 

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

    NOTE: Refer to COMPONENT FASTENER TIGHTENING NOTICE .
  32. Install the front drive axle actuator.

    Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealer. Refer to Figure.

    Tighten 

    Tighten the front drive axle actuator to 20 N.m (15 lb ft).

    Fig 18: Installing Front Drive Axle Actuator
    G01455970Courtesy of GENERAL MOTORS CORP.
  33. Install the lower differential carrier assembly bushing by performing the following steps:
    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. 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 19: Installing Lower Differential Carrier Assembly Bushing
    G01455971Courtesy of GENERAL MOTORS CORP.
  34. Install the upper differential carrier assembly bushing by performing the following steps:
    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. 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 with in the differential carrier assembly bushing bore.
    Fig 20: Installing Upper Differential Carrier Assembly Bushing
    G01455972Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals