Assembly Procedure

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 GMC Sierra, 2002 Chevrolet Tahoe, and 2002 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Figure.
Install the thrust washers and the differential side gears into the differential case.
If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations.

Fig 1: Installing Thrust Washers And Differential Side Gears Into Differential Case (9.25 Inch Axle)
Courtesy of GENERAL MOTORS CORP.
Install the differential pinion gears by performing the following steps:
1. Position both pinion gears between the differential side gears directly opposite of each other.
2. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening.
Fig 2: Installing Differential Pinion Gears
Courtesy of GENERAL MOTORS CORP.
Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift.
Install the differential side gear spacers.
Install the pinion gear shaft.

Fig 3: Installing Pinion Gear Shaft
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE .
Install the pinion shaft lock bolt.
Tighten

Tighten the pinion shaft lock bolt to 53 N.m (39 lb ft).

Fig 4: Installing Pinion Shaft Lock Bolt
Courtesy of GENERAL MOTORS CORP.

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
Install the ring gear onto the differential case.

Fig 5: Installing Ring Gear Onto Differential Case
Courtesy of GENERAL MOTORS CORP.

Important: The ring gear bolts have left-hand threads.
Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

Fig 6: Installing New Ring Gear Bolts
Courtesy of GENERAL MOTORS CORP.
Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
Tighten

Tighten the ring gear bolts in sequence to 138 N.m (102 lb ft).
Install the differential side bearings by performing the following steps:
1. In order to protect the differential case, install the J 36597 in the case on the side opposite the bearing installation.
2. Install the J 29710 (2) and the J 8092 (1) onto the differential case bearing as shown.
3. Drive the differential case bearing onto the case using the J 29710 and the J 8092 .
Fig 7: Installing Differential Side Bearings
Courtesy of GENERAL MOTORS CORP.