Assembly Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Bravada, 2002 GMC Envoy XL, 2002 GMC Envoy, and 2002 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate the pinion and side gears with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
Install the thrust washers to 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 the original locations.
Install the differential pinion gears by doing the following:

Fig 1: Installing Differential Pinion Gears
Courtesy of GENERAL MOTORS CORP.
1. 3.1. Position one pinion gear between the differential side gears.
2. 3.2. Rotate the differential side gears until the pinion gear is directly opposite the opening in the differential case.
3. 3.3. Place the other pinion gear between the differential side gears.
  Line up the hole in both the pinion gears.
Install the thrust washers.
Rotate the pinion gears toward the opening in order to permit the sliding in of the thrust washers.
Install the pinion shaft.
Install a new pinion shaft lock bolt.
NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Tighten

Tighten the new pinion shaft lock bolt to 36 N.m (27 lb ft).

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 2: Installing Ring Gear

Courtesy of GENERAL MOTORS CORP.

Place the ring gear on the case.
Install the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
Tighten

Tighten the ring gear bolts in sequence to 120 N.m (90 lb ft).
Install the differential side bearings by doing the following:
- In order to protect the differential case, install the J 8107-4 in the case on the side opposite the bearing installation.
- Install the J 45231 (2) and the J 8092 (1) onto the differential case bearing as shown.
- Drive the bearing onto the case using the J 45231 (2) and the J 8092 (1).