Tools Required

• J 22536  Pinion Driver
• J 24433  Pinion Cone and Side Bearing Installer
• J 34925  Pinion Setting Gage and Components
• J 45692  Pinion Shim Selector Kit - Dana Axles
• J 45710  Pinion Bearing Oil Seal Installer
• J 8001  Dial Indicator Set
• J 8614-01  Flange and Pulley Holding Tool

Important: 

Fig 1: Adjusting Pinion Depth - 9.75 Inch Axles (1 Of 13)

Courtesy of GENERAL MOTORS CORP.

• Make sure all of the tools, the differential side bearing bores, and the pinion bearing cups are clean before proceeding.
• The oil deflector must be installed behind the inner pinion bearing cup in order to obtain the correct pinion depth measurement

1. Lubricate the pinion bearings with axle lubricant.
2. Assemble the J 45692-5 (2) and the outer pinion bearing onto the J 21777-43 (1) as shown.
3. Install the J 45692-5, the outer pinion bearing, and the J 21777-43 into the axle housing.
4. Install the inner pinion bearing into the axle housing.
   Fig 2: Adjusting Pinion Depth - 9.75 Inch Axles (2 Of 13)

   Courtesy of GENERAL MOTORS CORP.
5. Install the J 21777-35 into the inner pinion bearing as shown.
   Fig 3: Adjusting Pinion Depth - 9.75 Inch Axles (3 Of 13)

   Courtesy of GENERAL MOTORS CORP.
6. Install the J 45692-1 into the axle housing as shown.
7. While holding the J 21777-43 stationary, tighten the nut on the J 21777-43 just until the end play between the pinion bearings is removed.
8. Rotate the assembly several times in both directions in order to seat the pinion bearings.
9. Measure the rotating torque of the assembly using an inch-pound torque wrench.

   Specification 

   The rotating torque of the assembly should be between 2.3-5.1 N.m (20-45 lb in).

10. If the rotating torque of the assembly is less than 2.3 N.m (20 lb in), continue to tighten the nut of the J 21777-43 until a rotating torque of 2.3-5.1 N.m (20-45 lb in) is obtained.
    Fig 4: Adjusting Pinion Depth - 9.75 Inch Axles (4 Of 13)

    Courtesy of GENERAL MOTORS CORP.
11. Assemble the J 45692-2 (1) and the J 21777-1 (2) as shown.
    Fig 5: Adjusting Pinion Depth - 9.75 Inch Axles (5 Of 13)

    Courtesy of GENERAL MOTORS CORP.
12. Install the J 45692-2 (1) and the J 21777-1 (2) into the axle housing. Place the stem of the J 21777-1 onto the bottom step of the J 45692-1.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

    Important:  Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.

13. Install the bearing caps and bearing cap bolts.

    Tighten: 

    Tighten the bearing cap bolts to 75 N.m (55 lb ft).

14. Rotate the J 21777-1 within the J 45692-2. The J 21777-1 must rotate back and forth freely with the discs. If the J 21777-1 does not rotate freely, disassemble the components, inspect for proper seating and/or mis-aligned components and re-assemble.
    Fig 6: Adjusting Pinion Depth - 9.75 Inch Axles (6 Of 13)

    Courtesy of GENERAL MOTORS CORP.
15. Install the J 8001  to the J 21777-1 as follows:
    1. Loosely clamp the J 8001  onto the stem on the J 21777-1.
    2. Place the contact pad of the J 8001  onto the mounting post of the J 21777-1.
    3. With the contact pad of the J 8001  touching the mounting post of the J 21777-1, loosen the lock nut on the J 8001  and push down on the J 8001  until the needle the J 8001  has turned 3/4 of a turn clockwise.
    4. Tighten the clamp on the J 8001  finger tight.
16. Move the plunger of the J 21777-1 (1) back and forth on the bottom step of the J 45692-1 (2) until the needle of the J 8001  indicates the greatest deflection.

    The deflection is the point where the needle changes direction.

17. At the greatest point of deflection, move the indicator housing of the J 8001  until the needle indicates ZERO.
18. Move the plunger of the J 21777-1 back and forth again to verify the ZERO setting. Adjust the housing of the J 8001  as necessary to set the needle to ZERO.
    Fig 7: Adjusting Pinion Depth - 9.75 Inch Axles (7 Of 13)

    Courtesy of GENERAL MOTORS CORP.
19. Rotate the plunger of the J 21777-1 (1) away from the J 45692-1 (2).

    The value indicated is the amount of pinion shim thickness required for a nominal pinion setting.

    Fig 8: Adjusting Pinion Depth - 9.75 Inch Axles (8 Of 13)

    Courtesy of GENERAL MOTORS CORP.
20. In order to adjust the pinion shim thickness for the drive pinion that is to be installed, do the following:
    1. Read the number on the button end of the pinion.

       If the number on the button end of the pinion is "0", no adjustment of the pinion preload shim pack is necessary.

    2. If the number is not "0", the number will also have a corresponding "+" or "-" in front of it.

       The "+" or "-" indicates the amount of pinion preload shim thickness that either needs to be added to or subtracted from the amount determined in step 19 in order to the drive pinion gear to be positioned properly within the axle housing.

       • For example, if the number on the button end of the pinion is a "+3", this indicates that 0.0762 mm (0.003 in) of shim thickness will need to be subtracted from the value determined in step 19 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Refer to the table.
       • If the number on the button end of the pinion is a "-3", this indicates that 0.0762 mm (0.003 in) of shim thickness will need to be added to the value determined in step 19 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Refer to the table.
21. Remove the pinion depth setting tools.
22. Remove the pinion bearings.
23. Install the pinion position shim onto the drive pinion.

    Measure the thickness of the shim with a micrometer in order to verify the thickness.

24. Install the inner pinion bearing onto the drive pinion using the J 24433  .
25. Install the original pinion preload shims onto the drive pinion. If the original shims are not available, assemble 1.52 mm (0.060 in) of pinion preload shims to install.

    Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.

26. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
27. Install the outer pinion bearing.
28. Install the thrust washer.
29. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
30. Install the pinion yoke nut washer.
31. Install the pinion yoke nut.

    Tighten: 

    Tighten the pinion yoke nut to 252 N.m (186 lb ft).

32. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

    Specification 

    The rotating torque of the drive pinion should be between 2.3-5.1 N.m (20-45 lb in).

    Fig 9: Adjusting Pinion Depth - 9.75 Inch Axles (9 Of 13)

    Courtesy of GENERAL MOTORS CORP.
33. If the rotating torque of the drive pinion is not within specifications, adjust the pinion preload shim thickness by doing the following:
    1. Install the J 8614-01  to the pinion yoke.
    2. Remove the pinion nut while holding the J 8614-01  .
    3. Remove the washer.
    4. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
    5. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
    6. Remove the thrust washer.
    7. Install the J 22536  .

       Ensure that the J 22536  is firmly seated on the drive pinion.

    8. Drive the pinion out using the J 22536  and a hammer.
    9. Remove the outer pinion bearing.
    10. Remove the pinion preload shim(s).
    11. Adjust the amount of pinion preload shim thickness by doing the following:
    Fig 10: Adjusting Pinion Depth - 9.75 Inch Axles (10 Of 13)

    Courtesy of GENERAL MOTORS CORP.

    Important:  Removing approximately 0.0254 mm (0.001 in) of shim thickness will increase the rotating torque by approximately 71-89 N.m (8-10 lb in).

    • If the rotating torque is too low, remove the appropriate amount of shim thickness from the shim thickness pack using the guideline above.

      Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.

    Important:  Adding approximately 0.0254 mm (0.001 in) of shim thickness will decrease the rotating torque by approximately 71-89 N.m (8-10 lb in).

    • If the rotating torque is too high, add the appropriate amount of shim thickness to the shim thickness pack using the guideline above.

      Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.

34. Install the new pinion preload shim pack onto the drive pinion.
35. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
36. Install the outer pinion bearing.
37. Install the thrust washer.
38. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
39. Install the pinion yoke nut washer.
40. Install the pinion yoke nut.

    Tighten: 

    Tighten the pinion yoke nut to 252 N.m (186 lb ft).

41. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

    Specification 

    The rotating torque of the drive pinion should be between 2.3-5.1 N.m (20-45 lb in).

42. If the rotating torque of the drive pinion is not within specification, adjust the pinion bearing preload shim pack as necessary following the steps above.
43. If the rotating torque is within specifications, install the J 8614-01  to the pinion yoke.
44. Remove the pinion nut while holding the J 8614-01  .
45. Remove the washer.
    Fig 11: Adjusting Pinion Depth - 9.75 Inch Axles (11 Of 13)

    Courtesy of GENERAL MOTORS CORP.
46. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
47. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
48. Apply a light coat of axle lubricant,

    GM P/N 12378557 or equivalent meeting GM Specification 9986207, to lip of the pinion seal.

    Fig 12: Adjusting Pinion Depth - 9.75 Inch Axles (12 Of 13)

    Courtesy of GENERAL MOTORS CORP.
49. Install the new pinion oil seal using the J 45710  .
50. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
51. Install the pinion yoke nut washer.
52. Install the new pinion yoke nut.

    Tighten: 

    Tighten the pinion yoke nut to 370 N.m (272 lb ft).

53. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

    Specification 

    The rotating torque of the drive pinion should be between 2.3-5.1 N.m (20-45 lb in).

    Fig 13: Adjusting Pinion Depth - 9.75 Inch Axles (13 Of 13)

    Courtesy of GENERAL MOTORS CORP.
    Fig 14: Pinion Marking Table

    Courtesy of GENERAL MOTORS CORP.