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Measurement and Adjustment Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the differential side bearing shims. Refer to Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles)  or Drive Pinion Bearings Replacement (9.75 Inch Axle)  or Drive Pinion Bearings Replacement (10.5 Inch Axle) .
  2. Determine the pinion position shim and the pinion preload shims, if necessary. Refer to Pinion Depth Adjustment (8.6 Inch, 9.5 Inch, 11.5 Inch Axles)  or Pinion Depth Adjustment (9.75 Inch Axle)  or Pinion Depth Adjustment (10.5 Inch Axle) .
  3. Install the differential side bearing without the side bearing shims by doing the following:
    1. In order to protect the differential case, install the J 36597  in the case on the side opposite of the bearing installation.
    2. Install the differential side bearing.
    3. Install the J 24430  or the J 45900  (2) and the J 8092  (1) over the differential side bearing.
    4. Drive the differential side bearing into position using the J 24430  or the J 45900  and the J 8092  .
    4. Fig 1: Driving The Differential Side Bearing Into Position
    GM651740Courtesy of GENERAL MOTORS CORP.
  4. Install the differential assembly into the axle housing.
  5. Move the differential assembly to the left until the left differential side bearing is against the left side bearing bore.
    6. IMPORTANT: Install the bearing caps into the same position from which each was removed.
  6. Install the left side bearing cap.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the left side bearing cap bolts.

    Tighten:  Tighten the bearing cap bolts finger tight. Do not tighten the bolts to specification at this time.

  8. While holding the differential assembly against the left side bearing bore, press the right side bearing cup against the right differential side bearing.
    9. IMPORTANT: In order to accurately measure the differential side bearing shim thickness, the differential side bearing cup must be evenly seated against the differential side bearing.
  9. Using a feeler gage, measure the distance between the right side bearing cup and the right side bearing bore. Use progressively larger feeler gage sizes until a moderate drag is felt. Repeat this step several times while rotating the differential case in order to obtain a consistent reading.

    This measurement, measurement (a), is the total shim pack thickness for the differential assembly without preload.

    10. Fig 2: Measuring Between Right Side Bearing Cup & Right Side Bearing
    GM820553Courtesy of GENERAL MOTORS CORP.
    CAUTION: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.
  10. Remove the left side bearing cap bolts.
  11. Remove the left side bearing cap.
  12. Install the right side bearing cap.
  13. Install the right side bearing cap bolts.

    Tighten:  Tighten the bearing cap bolts finger tight. Do not tighten the bolts to specification at this time.

  14. While holding the differential assembly ring gear against the drive pinion, press the left side bearing cup against the left differential side bearing.
    15. IMPORTANT: In order to accurately measure the differential side bearing shim thickness, the differential side bearing cup must be evenly seated against the differential side bearing.
  15. Using a feeler gage, measure the distance between the left side bearing cup and the left side bearing bore. Use progressively larger feeler gage sizes until a moderate drag is felt. Repeat this step several times while re-positioning the differential case in order to obtain a consistent reading.

    This measurement, measurement (b), is the left side shim thickness for the differential assembly without preload.

    16. Fig 3: Measuring Between Left Side Bearing Cup & Left Side Bearing Bore
    GM820556Courtesy of GENERAL MOTORS CORP.
  16. In order to determine the right side shim thickness, subtract the left side measurement, measurement b, from the total shim measurement, measurement a.

    This measurement is the thickness for the right side shim thickness without preload or setting the initial backlash.

  17. Remove the right side bearing cap bolts.
  18. Remove the right side bearing cap.
  19. Remove the differential assembly.
  20. Remove the differential side bearings by performing the following steps:
    1. Install the J 45711  (2) and the J 36597  (1) as shown.
    2. Remove the differential side bearings using the J 45711  and a hydraulic press.
    21. Fig 4: Removing The Differential Side Bearings Using J 36597 & J 45711
    GM821010Courtesy of GENERAL MOTORS CORP.
  21. Add 0.25 mm (0.010 in) of shim thickness to the right side shim thickness measurement determined in step 16.

    This additional amount will set the differential side bearing preload and the initial backlash.

    22. IMPORTANT: The number of shims required in order to equal the correct thickness may consist of one or more shims.
  22. Install the right side shim thickness onto the differential case.

    Measure the shims one at a time. Add the measurements together in order to obtain the total thickness of the right side shim pack.

  23. Install the right differential side bearing with the side bearing shim thickness by doing the following:
    1. In order to protect the differential case, install the J 8107-3 in the case on the side opposite of the bearing installation.
    2. Place the differential side shim thickness on top of the differential case.
    3. Place the differential side bearing on top of the differential case.
    4. Install the J 24430  or the J 45900  (2) and the J 8092  (1) over the differential side bearing.
    5. Drive the differential side bearing into position using the J 24430  or the J 45900  and the J 8092  .
    24. Fig 5: Driving The Differential Side Bearing Into Position
    GM651740Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The number of shims required in order to equal the correct thickness may consist of one or more shims.
  24. Install the left side bearing shim thickness and differential side bearing using the steps above.
  25. Install the differential assembly into the axle housing. Refer to Differential Replacement (8.6 Inch, 9.5 Inch Axles)  or Differential Replacement (9.75 Inch Axle)  or Differential Replacement (10.5 Inch, 11.5 Inch Axle) .
  26. Adjust the backlash. Refer to Backlash Adjustment (8.6 Inch Axle)  or Backlash Adjustment (9.75 Inch Axle) .

The differential side bearing shims are available in the following sizes:

Shim Sizes: 

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