Rear Axle - Assemble

Tools Required

• J 8001  Dial Indicator Set
• J 8092  Universal Driver Handle-3/4 in - 10
• J 8608  Rear Pinion Bearing Race Installer
• J 8611-O1  Rear Pinion Bearing Race Installer
• J 8614-O1  Flange and Pulley Holding Tool
• J 21128  Axle Pinion Oil Seal Installer
• J 23690  Bearing Installer
• J 24433  Pinion Cone and Side Bearing Installer
• J 34178  Spreader Gage Adapter
• J 44685  Rear Axle Seal and Bearing Remover
• J 45222  Axle Housing Spreader

1. Install the outer pinion bearing cup using the J 8611-O1 (2) and the J 8092 (1).
Fig 1: Installing Outer Pinion Bearing Cup
Courtesy of GENERAL MOTORS CORP.
2. Install the inner pinion bearing cup using the J 8608 (1) and the J 8092 (2).
Fig 2: Installing Inner Pinion Bearing Cup
Courtesy of GENERAL MOTORS CORP.
3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment .
4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion shim.
Fig 3: Installing Inner Pinion Bearing Using J 24433
Courtesy of GENERAL MOTORS CORP.
6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
8. Install the pinion into the axle housing.
9. Install the outer pinion bearing onto the pinion.
10. Install a new seal using the J 22388.
Fig 4: Installing A New Seal Using J 22388
Courtesy of GENERAL MOTORS CORP.
11. Apply sealant (GM P/N 12346004 or equivalent) to the splines of the pinion yoke.
12. Install the pinion yoke.

    Align the marks make during removal.

    NOTE: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
Fig 5: Installing Pinion Yoke And Aligning Removal Marks
Courtesy of GENERAL MOTORS CORP.
13. 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.
14. Install the washer and a new pinion nut.
15. Install the J 8614-O1 onto the pinion yoke as shown.
    IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
Fig 6: Installing J 8614-O1 Onto Pinion Yoke
Courtesy of GENERAL MOTORS CORP.
16. Tighten the pinion nut while holding the J 8614-O1.
    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 nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

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

    Specification 

    The rotating torque of the pinion should be 1.0-2.8 N.m (10-25 lb in) (used bearings) or 1.7-3.4 N.m (15-30 lb in) (new bearings).

Fig 7: Measuring Rotating Torque Of Pinion
Courtesy of GENERAL MOTORS CORP.
18. If the rotating torque measurement is below 1.0 N.m (10 lb in) (used bearings) or 1.7 N.m (15 lb in) (new bearings), continue to tighten the pinion nut.

    Tighten 

    Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.8 N.m (10-25 lb in) (used bearings) or 1.7-3.4 N.m (15-30 lb in) (new bearings).

19. 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.

20. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
21. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
22. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
23. Install the J 45222 to the axle housing as shown.
Fig 8: Installing J 45222 To Axle Housing
Courtesy of GENERAL MOTORS CORP.
24. Install the J 8001-1 (2), the J 8001-2 (3), the J 34178 (4, 6), and the J 8001-1 (5) as shown.
Fig 9: Installing J 8001-1, J 8001-2, J 34178, And 8001-1
Courtesy of GENERAL MOTORS CORP.
25. Preload the J 8001-1 (5) approximately 1 revolution.
26. Move the housing of the J 8001-1 (5) until the needle indicates zero.
27. Spread the axle housing by turning the clevis screw of the J 34178 until the needle of the J 8001-1 indicates 1.02 mm (0.040 in).
Fig 10: Spreading Axle Housing
Courtesy of GENERAL MOTORS CORP.
28. Place the differential case, with the bearing cups installed, into the axle housing.
29. Install the bearing caps and the bolts.

    Do not torque the bearing cap bolts at this time.

30. Remove the J 8001-1, the J 8001-2, the J 34178, and the J 8001-1.
31. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment .
32. Adjust the backlash. Refer to Backlash Adjustment (All Except 9.75 Inch Axle) .
33. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
34. Tighten the bearing cap bolts.

    Tighten 

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

Fig 11: Tightening Bearing Cap Bolts
Courtesy of GENERAL MOTORS CORP.
35. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2).
Fig 12: Installing Axle Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
36. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.
37. Install the axle shaft seal using the J 21128.
Fig 13: Installing Axle Shaft Seal
Courtesy of GENERAL MOTORS CORP.
38. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube.
    IMPORTANT: Carefully insert the axle shaft in order to not damage the seal.
39. Install the axle shaft (1) into the housing (5).
Fig 14: Installing Axle Shaft Into Housing
Courtesy of GENERAL MOTORS CORP.
40. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
41. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
42. On axles with a locking differential, keep the pinion shaft partially withdrawn.
43. On axles with a locking differential, place the lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
Fig 15: Placing Lock On Axle Shaft So That Ends Are Flush With Thrust Block
Courtesy of GENERAL MOTORS CORP.
44. Pull the shaft flange outward in order to seat the lock in the differential gear.
45. Align the hole in the pinion shaft with the bolt hole in the differential case.
46. Install the new pinion shaft locking bolt.

    Tighten 

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

Fig 16: Installing New Pinion Shaft Locking Bolt
Courtesy of GENERAL MOTORS CORP.
47. Install the rear axle housing cover (2) and a new gasket.
Fig 17: Installing Rear Axle Housing Cover
Courtesy of GENERAL MOTORS CORP.
48. Install the rear axle housing cover bolts (1).

    Tighten 

    Tighten the rear housing cover bolts in a crosswise pattern to 30 N.m (20 lb ft).

49. Install the drain plug.

    Tighten 

    Tighten the drain plug to 48 N.m (35 lb ft).

Fig 18: Installing Drain Plug
Courtesy of GENERAL MOTORS CORP.
50. Fill the axle using the proper fluid. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
51. Install the fill plug.

    Tighten 

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

Fig 19: Installing Fill Plug
Courtesy of GENERAL MOTORS CORP.