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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 and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) >> Installation Procedure

Installation Procedure

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    IMPORTANT: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
  1. Install the ring gear to the differential case.
    2. Fig 1: Ring Gear & Differential Case
    GM866505Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The ring gear bolts on the 8.6 inch and the 9.5 inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads.
  2. Install the new ring gear bolts.

    Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

    3. Fig 2: Identifying Ring Gear Bolts
    GM866503Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

    Tighten: 

    • For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 N.m (89 lb ft).
    • For the 9.5 inch axle, tighten the ring gear bolts in sequence to 140 N.m (103 lb ft).
    • For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 N.m (175 lb ft).

  4. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles) , Drive Pinion Bearings Replacement (9.75 Inch Axle)  or Drive Pinion Bearings Replacement (10.5 Inch Axle) .
  5. Determine the selective shim thickness for the pinion gear. 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) .
  6. Install the selective shim onto the pinion.
  7. Install the inner pinion bearing to the pinion. Refer to Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles) , Drive Pinion Bearings Replacement (9.75 Inch Axle)  or Drive Pinion Bearings Replacement (10.5 Inch Axle) .
  8. Install a new collapsible spacer.
  9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  10. Install the outer pinion bearing into the axle housing.
  11. Install the new pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle)  or Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) .
  12. Install the pinion into the axle housing.
  13. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle)  or Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) .
  14. 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) .
  15. 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) .
  16. Lower the vehicle.
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