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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 829 (Rear Drive Axle) >> Repair Instructions >> Differential Replacement (8.6 Inch, 9.5 Inch Axles) >> Installation Procedure

Installation Procedure

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  1. Install the ring gear, if necessary. Refer to DRIVE PINION AND RING GEAR REPLACEMENT (8.6 INCH, 9.5 INCH AXLE)  or DRIVE PINION AND RING GEAR REPLACEMENT (9.75 INCH AXLE)  or DRIVE PINION AND RING GEAR REPLACEMENT (10.5 INCH AXLE)  .
  2. Install the differential side bearings, if necessary. Refer to DIFFERENTIAL SIDE BEARINGS REPLACEMENT (ALL EXCEPT 9.75 INCH AXLE)  or DIFFERENTIAL SIDE BEARINGS REPLACEMENT (9.75 INCH AXLE)  .
  3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid.
  4. Place the case, with the bearing cups installed, into the axle housing.

    Support the case in order to keep the case from falling out of the axle housing.

    Fig 1: Installing Differential - 8.6 Inch, 9.5 Inch Axles (1 Of 2)
    G01456193Courtesy of GENERAL MOTORS CORP.
  5. Install the bearing caps and the bolts.

    Do not torque the bearing cap bolts at this time.

  6. Adjust the differential side bearing preload. Refer to DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT (8.6 INCH AXLE)  or DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT (9.5 INCH AXLE)  or DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT (9.75 INCH AXLE)  or DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT (10.5 INCH AXLE)  .
  7. Adjust the backlash. Refer to BACKLASH ADJUSTMENT (ALL EXCEPT 9.75 INCH AXLE)  or BACKLASH ADJUSTMENT (9.75 INCH AXLE)  .
  8. Perform a gear tooth contact pattern check. Refer to GEAR TOOTH CONTACT PATTERN INSPECTION  .
  9. Tighten the bearing cap bolts.

    Tighten: 

    • For the 8.6 inch axle, tighten the bearing cap bolts to 75 N.m (55 lb ft)
    • For the 9.5 inch axle, tighten the bearing cap bolts to 85 N.m (63 lb ft)
  10. Install the axle shafts. Refer to REAR AXLE SHAFT REPLACEMENT (8.6 INCH AXLE W/O JL4, 9.5 INCH AXLE)  or REAR AXLE SHAFT REPLACEMENT (8.6 INCH AXLE W/JL4)  or REAR AXLE SHAFT REPLACEMENT (9.75 INCH AXLE)  .
  11. Fill the axle with lubricant. Use the proper fluid. Refer to LUBRICANT REPLACEMENT - REAR DRIVE AXLE (8.6 INCH AXLE)  or LUBRICANT REPLACEMENT - REAR DRIVE AXLE (9.5, 10.5 INCH AXLE)  or LUBRICANT REPLACEMENT - REAR DRIVE AXLE (9.75 INCH AXLE)  .
  12. Lower the vehicle.
    Fig 2: Installing Differential - 8.6 Inch, 9.5 Inch Axles (2 Of 2)
    G01456194Courtesy of GENERAL MOTORS CORP.
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