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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1346 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly - Final Assembly (8.25 S4WD and 9.25 Axles) >> Tools Required

Tools Required

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  1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 8.25 inch axle-both side, 9.25 inch axle-right side.
  2. Install the differential adjuster nut lock, 9.25 inch axle-left side.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the differential adjuster nut lock bolt.

    Tighten 

    Tighten the differential adjuster lock nut bolt to 20 N.m (15 lb ft).

  4. Remove the differential carrier assembly bolts.
  5. Remove the right differential carrier case half.
  6. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly.

    The surfaces must be clean of all the grease and the oil.

  7. Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or equivalent to one differential carrier case half sealing surface.
  8. Install the right differential carrier case half.
  9. Install the differential carrier case bolts.

    Tighten 

    Tighten the differential carrier case bolts to 47 N.m (35 lb ft).

  10. Lubricate the clutch shaft pilot bearing with axle lubricant.
    Fig 1: Remove Differential Carrier Assembly Bolt
    G01480522Courtesy of GENERAL MOTORS CORP.
  11. Install the clutch shaft pilot bearing using the J 33842. 
    Fig 2: Install Clutch Shaft Pilot Bearing
    G01480523Courtesy of GENERAL MOTORS CORP.
  12. Install the clutch shaft to the differential carrier.
    Fig 3: Install Clutch Shaft To Differential Carrier
    G01480524Courtesy of GENERAL MOTORS CORP.
  13. Install the vent connector.

    Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) or equivalent onto the threads.

    Tighten 

    Tighten the vent connector to 25 N.m (18 lb ft).

  14. Install the new axle shaft seal using the J 36600,  8.25 inch axle, or the J 22833,  9.25 inch axle.
  15. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
  16. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    Fig 4: Install Vent Hose Connector
    G01480525Courtesy of GENERAL MOTORS CORP.
  17. Install the right side bearing by performing the following steps:
    1. 17.1. Install the inner axle shaft housing into a vise.

      Clamp only on the mounting flange of the inner axle shaft housing.

    2. 17.2. Install the bearing with the square shoulder in using the J 36609  (1) and the J 8092  (2).
    Fig 5: J 36609 & J 8092
    G01480526Courtesy of GENERAL MOTORS CORP.
  18. Install the right side inner axle shaft seal by performing the following steps:
    1. 18.1. Install the inner axle shaft housing into a vise.

      Clamp only on the mounting flange of the inner axle shaft housing.

    2. 18.2. Install the new axle shaft seal using the J 36600,  8.25 inch axle, or the J 22833,  9.25 inch axle.
  19. Install the inner axle shaft into the inner axle shaft housing.

    Carefully tap the inner axle shaft into place with a soft-faced mallet.

    Fig 6: Install Right Side Inner Axle Shaft Seal
    G01480527Courtesy of GENERAL MOTORS CORP.
  20. For the 8.25 inch axle, assemble the following components into the inner axle shaft housing:
    IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. 20.1. Install the thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    2. 20.2. Install the new retainer ring (7) onto the clutch gear (6).
    3. 20.3. Install the clutch gear (6) onto the inner axle shaft (1).

      Drive the clutch gear into place with a plastic hammer.

      Fig 7: Install Inner Axle Shaft Inner Axle Shaft Housing & Components
      G01480528Courtesy of GENERAL MOTORS CORP.
    4. 20.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5. 20.5. Install the clutch gear shim (9)
    6. 20.6. Install the clutch sleeve (8)
    7. 20.7. Install the clutch fork assembly (11)
    8. 20.8. Install the clutch fork inner spring (10)
  21. For the 9.25 inch axle, install the following components into the inner axle shaft housing:
    IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. 21.1. Install the thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing.

    2. 21.2. Install the second thrust washer (6) into the inner axle shaft housing.
    3. 21.3. Install the new retainer ring (7) onto the inner axle shaft (1).
    4. 21.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5. 21.5. Install the clutch gear shim (9)
    6. 21.6. Install the clutch sleeve (8)
    7. 21.7. Install the clutch fork assembly (11)
    8. 21.8. Install the clutch fork inner spring (10)
  22. Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
    23. Fig 8: Install Inner Axle Shaft Inner Axle Shaft Housing & Components
    G01480529Courtesy of GENERAL MOTORS CORP.
  23. Install the inner axle shaft housing to the differential carrier case.
  24. Install the inner axle shaft housing bolts.

    Tighten 

    Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).

  25. Install the drain plug and the washer.
  26. Install the fill plug and the washer.

    Tighten 

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

    Fig 9: Install Inner Axle Shaft Housing
    G01480530Courtesy of GENERAL MOTORS CORP.
  27. Install the front drive axle actuator.

    Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the front axle actuator.

    Tighten 

    Tighten the front drive axle actuator to 20 N.m (15 lb ft).

    Fig 10: Install Front Drive Axle Actuator
    G01480531Courtesy of GENERAL MOTORS CORP.
  28. Install the lower differential carrier assembly bushing by performing the following steps:
    1. 28.1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
    2. 28.2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
    Fig 11: Thrust Bearing, Forcing Screw, J 21474-18 & J 36616-2
    G01480532Courtesy of GENERAL MOTORS CORP.
  29. Install the upper differential carrier assembly bushing by performing the following steps:
    1. 29.1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
    2. 29.2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
    Fig 12: Thrust Bearing, Forcing Screw, J 21474-18, J 36616-2 & J 36616-1
    G01480533Courtesy of GENERAL MOTORS CORP.
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