Differential Carrier Assembly - Assemble

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 8092 Universal Driver Handle - 3/4 in - 10
J 33785 Pinion Bearing Installer
J 42211 Axle Bearing Installer
J 8614-01 Flange and Pulley Holding Tool
J 33782 Pinion Oil Seal Installer
J 33788 Output Shaft Bearing Installer
J 33792 Side Bearing Adjuster Wrench
J 33837 Pinion Bearing Cup Remover and Installer
J 23423-A Case Bearing Race Installer
J 42213 Adjuster Sleeve Socket

Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
Install the inner pinion bearing onto the pinion gear using the J 33785 .
Install the new collapsible spacer onto the pinion gear.
Lubricate the inner and the outer pinion bearings with axle lubricant. Use the proper fluid.
Important: Stake the new deflector at 3 new equally spaced positions. You must stake the new deflector in such a way that you do not damage the pinion sealing surface.
Install the new deflector by doing the following:
1. Make sure the sealing surface of the pinion yoke is clean of burrs, if applicable.
2. Install the new deflector onto the pinion yoke by tapping the deflector evenly using a hammer and a brass drift in small increments.
3. Stake the new deflector to the pinion yoke in 3 positions.
Fig 1: Installing Inner Pinion Bearing Onto Pinion Gear
Courtesy of GENERAL MOTORS CORP.
Install the left differential carrier case into the J 33837 .
Tighten the attaching bolts securely.
Install the outer pinion bearing.
Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing.
Install the oil seal by doing the following:
1. Position the oil seal in the bore.
2. Install the J 33782 over the oil seal.
3. Strike the J 33782 with a hammer until the seal flange seats on the axle housing surface.
Install the pinion gear, the selectable shim with inner pinion bearing and the new collapsible spacer, into the left differential carrier case.
Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
Install the pinion yoke.
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.

Fig 2: Installing New Deflector Onto Pinion Yoke
Courtesy of GENERAL MOTORS CORP.
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.
Install the washer and a new pinion nut.
Install the J 8614-01 onto the pinion yoke as shown.
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.
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.
Measure the rotating torque of the pinion using an inch-pound torque wrench.
Specification

The rotating torque of the pinion should be 1.0-2.8 N.m (10-25 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.
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 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.

Fig 3: Installing Washer And A New Pinion Nut
Courtesy of GENERAL MOTORS CORP.
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.
Install the left inner axle shaft bearing into the differential adjuster nut sleeve using the J 8092 (1) and the J 42211 (2).
Install the left inner axle shaft bearing and the differential bearing adjuster nut into the left differential carrier case.
Install the left differential case bearing cup into the left differential carrier assembly case half using the J 23423-A and the J 8092.
Install the right inner axle shaft bearing into the right differential adjuster nut sleeve using the J 8092 (1) and the J 33788 (2).

Fig 4: Installing Right Inner Axle Shaft Bearing Into Right Differential Adjuster Nut Sleeve
Courtesy of GENERAL MOTORS CORP.
Install the right differential bearing adjuster assembly and the right differential case side bearing cup into the right differential carrier case half using the J 23423-A (2) and the J 8092 (1).
Install the differential case assembly into the left differential carrier case half.
Using the J 42213, turn the left differential adjuster nut sleeve in until there is a slight amount of backlash felt between the ring gear and the pinion.
Install the right differential carrier case half to the left differential carrier case half.
Do not use sealer at this time.

If the carrier case halves do not make complete contact, use the J 33792 in order to back out the right differential adjuster nut sleeve.
Install the differential carrier case bolts.
Tighten

Tighten the differential carrier case bolts to 50 N.m (37 lb ft).
Adjust the backlash. Refer to BACKLASH INSPECTION AND ADJUSTMENT .

Fig 5: Installing Differential Case Assembly Into Left Differential Carrier Case Half
Courtesy of GENERAL MOTORS CORP.