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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1014 (Rear Drive Axle) >> Repair Instructions >> Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles) >> Installation Procedure

Installation 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. Install the outer pinion bearing cup using the J 8611-01  , 8.6 inch axle, or the J 7818  , 9.5 inch axle, or the J 8608  (11.5 inch axle) (2) and the J 8092  (1).
    2. Fig 1: Install The Outer Pinion Bearing Cup Using J 8611-01, J 7818 Or J 8608 & J 8092
    GM889101Courtesy of GENERAL MOTORS CORP.
  2. Install the inner pinion bearing cup using the J 45900  , 8.6 inch axle, or the J 22306  , 9.5 inch axle, or the J 44417  , 11.5 inch axle (2) and the J 8092  (1).
    3. Fig 2: Install The Inner Pinion Bearing Cup Using J 45900, J 22306 Or J 44417 & J 8092
    GM651743Courtesy of GENERAL MOTORS CORP.
  3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) , Pinion Depth Adjustment (9.75 Inch Axle)  or Pinion Depth Adjustment (10.5 Inch Axle) .
  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  , 8.6 inch axle, or the J 36614  , 9.5 inch axle, or the J 44412  , 11.5 inch axle.

    Press the bearing on until the cone seats on the pinion shim.

    6. Fig 3: Installing Inner Pinion Bearing Onto Pinion Gear
    GM651742Courtesy 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 outer pinion bearing into the axle housing.
  9. Install a new pinion oil seal using the J 22388  , 8.6 inch, 9.5 inch axles, or the J 44414  , 11.5 inch axle.
    10. Fig 4: Installing New Pinion Oil Seal
    GM889108Courtesy of GENERAL MOTORS CORP.
  10. Install the pinion into the axle housing.
  11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
  12. Install the pinion yoke.

    Align the marks made during removal.

    13. Fig 5: View Of Pinion Shaft & Pinion Yoke Alignment Marks
    GM788905Courtesy 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 8614-01  onto the pinion yoke as shown.
    16. Fig 6: Holding Pinion Yoke With Special Tool
    GM788482Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
  16. Tighten the pinion nut while holding the J 8614-01  .

    Tighten:  Tighten the pinion 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 between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.

    18. Fig 7: Measuring Pinion Rotating Torque
    GM661077Courtesy of GENERAL MOTORS CORP.
  18. If the rotating torque measurement is below 1.0 N.m (10 lb in) for used bearings, or 1.7 N.m (15 lb in) for 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 between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.

  19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

    Inspect the rotating torque and adjust if necessary.

  20. Install the differential assembly. Refer to Differential Replacement (8.6 Inch, 9.5 Inch Axles) , Differential Replacement (9.75 Inch Axle)  or Differential Replacement (10.5 Inch, 11.5 Inch Axle) .
  21. Fill the axle with lubricant. Use the proper fluid. Refer to Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) , Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) .
  22. Lower the vehicle.
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