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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 inner pinion bearing cup into the pinion gear bearing retainer using the J 37624  (2) and the J 8092  (1).
    Fig 1: Installing Inner Pinion Bearing Cup
    GM739952Courtesy of GENERAL MOTORS CORP.
  2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608  (2) and the J 8092  (1).
    3. Fig 2: Installing Outer Pinion Bearing Cup
    GM739946Courtesy of GENERAL MOTORS CORP.
  3. Install the inner pinion bearing using the J 24433  .

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

    4. Fig 3: Installing The Inner Pinion Bearing Using J 24433
    GM739953Courtesy of GENERAL MOTORS CORP.
  4. Install a new collapsible spacer.
  5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  6. Install the pinion into the pinion gear bearing retainer.
    7. Fig 4: Pinion Retainer
    GM739961Courtesy of GENERAL MOTORS CORP.
  7. Install the outer pinion bearing onto the pinion.
  8. Install a new pinion oil seal using the J 44414  .
    9. Fig 5: Install A New Pinion Oil Seal Using J 44414
    GM739948Courtesy of GENERAL MOTORS CORP.
  9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
  10. Install the pinion yoke.

    Align the marks made during removal.

    11. 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.
  11. 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.
  12. Install the washer and a new pinion nut.
  13. Install the J 8614-01  onto the pinion yoke as shown.
    14. Fig 6: Installing J 8614-01 On Pinion Yoke
    GM694814Courtesy 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.
  14. Tighten the pinion nut while holding the J 8614-01  .

    Tighten:  Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

  15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal.

    Tighten:  Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3-5 lb in) greater than the rotating torque recorded during removal.

    16. Fig 7: Measuring Pinion Rotating Torque
    GM661077Courtesy of GENERAL MOTORS CORP.
  16. 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.
  17. Determine the selective shim thickness for the pinion gear bearing retainer. 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) .
  18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer.
  19. Install the selective shim.

    Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer.

  20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim.
  21. Install the pinion gear bearing retainer.
    22. Fig 8: Pinion Gear Bearing Retainer
    GM739959Courtesy of GENERAL MOTORS CORP.
  22. Install the pinion gear bearing retainer bolts.

    Tighten:  Tighten the pinion gear bearing retainer bolts to 88 N.m (65 lb ft).

  23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal.

    Specification:  The rotating torque of the pinion and the ring gear should be between 3.9-6.2 N.m (30-55 lb in) for new bearings or 2.8-5.6 N.m (25-50 lb in) for used bearings.

    24. Fig 9: Measuring Pinion & Ring Gear Rotating Torque
    GM694807Courtesy of GENERAL MOTORS CORP.
  24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary.
  25. Install the propeller shaft (3) to the pinion yoke (4).

    Align the reference marks made during removal.

    26. Fig 10: Identifying Driveshaft Pinion, Yoke Retainers & Bolts
    GM361391Courtesy of GENERAL MOTORS CORP.
  26. Install the propeller shaft yoke retaining clamps and the bolts.

    Tighten:  Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft).

  27. Install the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
  28. Fill the axle with axle lubricant. 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) .
  29. Lower the vehicle.
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