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Differential Assembly: Reassembly

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  1. Lubricate the differential side gears and the differential pinion gears with axle lubricant. See LUBRICATION  . Install the differential side gears into the differential case. If the original differential side gears are being used, install the gears in the original location.
  2. Assemble the differential pinion gears and the thrust washers to the differential spider. If the original differential pinion gears, the thrust washers and the differential spider are being used, install the components in the original locations.
    3. CAUTION: The mating surface of the ring gear and each differential case half mating surface must be clean and free of burrs before installing the ring gear or assembling case halves.
  3. Assemble the differential case halves. Assemble the differential case halves. Align the arrow marks in the differential case halves. See Fig 1 .
    4. NOTE: Ring gear bolts on 10.5" ring gear differential assembly are left-hand thread. Ring gear bolts on 11.5" ring gear differential assembly are right-hand thread.
  4. Install the ring gear to the differential case. 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 alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts to specification. See TORQUE SPECIFICATIONS  .
  5. In order to protect the differential case, install the Side Bearing Puller Pilot (J-8107-3) in the case on the side opposite the bearing being installed. Install the side bearing onto the differential case. Using the Differential Side Bearing Installer (J-29710) and the Driver Handle (J-8092), drive side bearing firmly into position on differential case. Repeat procedure for the other side bearing. Install differential case assembly into axle housing. Install and hand tighten retainer caps and cap bolts. DO NOT tighten bolts to specification at this time.
  6. Using Pinion Seal Installer (J-37624) and Driver Handle (J-8092), install the inner pinion bearing race into the pinion gear bearing retainer. Using Pinion Bearing Race Installer (J-8608) and driver handle, install the outer pinion bearing race into the pinion gear bearing retainer. Using Pinion Cone/Side Bearing Installer (J-24433), install the inner pinion bearing. Press the bearing on until the cone seats on the pinion. Install a new collapsible spacer. Lubricate the pinion bearings with axle lubricant.
  7. Install the pinion into the pinion gear bearing retainer. Install the outer pinion bearing onto the pinion. Using Pinion Seal Installer (J-44414), install a new pinion oil seal. Apply sealant, AM P/N 12346004 to the splines of the pinion yoke. Install the pinion yoke. Align the marks made during removal.
    8. NOTE: If pinion rotating torque specification is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
  8. Using Yoke Puller/Holder Set (J-8614), tighten the pinion nut while holding the yoke stationary. Tighten the nut until the pinion end play is just taken up. Rotate the pinion periodically while tightening the nut to evenly seat the bearings.
  9. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten yoke nut in small increments, as needed, until the rotating torque is 3-5 INCH lbs. (0.40-0.57 N.m) greater than the rotating torque recorded during removal. 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. Determine the selective shim thickness for the pinion gear bearing retainer. See DRIVE PINION DEPTH  under ADJUSTMENTS.
  10. Apply sealant, P/N 1052942 (Canadian P/N 10953466) to sealing surface of the pinion gear bearing retainer. Install the selective shim. Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. Apply same sealant to surface of the selective shim. Install the pinion gear bearing retainer. Install the pinion gear bearing retainer bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  11. Measure the rotating torque of the pinion and the ring gear. Compare measurement with the rotating torque recorded during removal. Rotating torque of the pinion and the ring gear should be between 30-55 INCH lbs. (3.9-6.2 N.m) for new bearings or 25-50 INCH lbs. (2.8-5.6 N.m) for used bearings. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. See SIDE BEARING PRELOAD  under ADJUSTMENTS. Adjust backlash as necessary. See RING & PINION GEAR BACKLASH  under ADJUSTMENTS.
  12. Install the drive shaft and drive shaft retaining clamps and the bolts. Tighten the drive shaft retaining clamp bolts to specification. See TORQUE SPECIFICATIONS  . Install the axle shafts. See AXLE SHAFTS  under REMOVAL & INSTALLATION. Fill the axle with axle lubricant. See LUBRICATION  . Lower the vehicle.
Fig 1: Aligning Differential Case Halves
G00173832Courtesy of GENERAL MOTORS CORP.
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