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Differential Carrier Assembly - Final Assembly

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 

  1. Install the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Install the differential adjuster nut lock tab bolts.

    Tighten 

    Tighten the differential adjuster nut lock tab bolt to 8 N.m (71 lb in).

  3. Remove the differential carrier assembly bolts.
  4. Remove the right differential carrier case half.
  5. 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.

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

    Tighten 

    Tighten the differential carrier case bolts to 50 N.m (37 lb ft).

  9. Lubricate the clutch shaft pilot bearing with axle lubricant. Use the proper fluid.
    Fig 1: Installing Differential Adjuster Nut Lock Tab Bolts
    G01468063Courtesy of GENERAL MOTORS CORP.
  10. Install the clutch shaft pilot bearing using the J 33842. 
  11. Install the clutch shaft thrust washer into the differential carrier assembly.
  12. Install the clutch shaft to the differential carrier assembly.
  13. Install the inner shaft seal cover.
  14. Install the inner shaft seal cover bolts.

    Tighten 

    Tighten the inner axle shaft seal cover bolts to 25 N.m (18 lb ft).

  15. Install the new left side axle shaft seal using the J 42738. 
    Fig 2: Installing Clutch Shaft Pilot Bearing
    G01468064Courtesy of GENERAL MOTORS CORP.
  16. Install the differential carrier bushings using the J 33791. 
    Fig 3: Installing Differential Carrier Bushings
    G01468065Courtesy of GENERAL MOTORS CORP.
  17. Install the right side inner axle shaft housing bearing and the seal using the following procedure:
    1. Install the bearing with the square shoulder in using the J 42211. 
    2. Install the new axle shaft seal using the J 42738. 
    Fig 4: Installing Right Side Inner Axle Shaft Housing Bearing And Seal
    G01468066Courtesy of GENERAL MOTORS CORP.
  18. Install the clutch cable housing seal using the J 33799. 
  19. Install the inner axle shaft into the inner axle shaft housing.
  20. Install the thrust washer into the inner axle shaft housing. Use chassis grease in order to hold the thrust washer in place.

    Ensure the tabs on the thrust washer align with the slot in the inner axle shaft housing.

    Fig 5: Installing Clutch Cable Housing Seal
    G01468067Courtesy of GENERAL MOTORS CORP.
  21. Install the new retaining ring into the clutch gear.
  22. Install the clutch gear onto the inner axle shaft.

    Drive the clutch gear into place with a plastic hammer.

    Fig 6: Installing Thrust Washer Into Inner Axle Shaft Housing
    G01468068Courtesy of GENERAL MOTORS CORP.
  23. Install the following components into the inner axle shaft housing:
    • The thrust washer (9)
    • The clutch fork inner spring (16)
    • The clutch fork (17)
    • The clutch fork sleeve (11)
  24. Apply sealant, GM P/N 1052492 or equivalent, to the inner axle housing to differential carrier sealing surface.
  25. Install the inner axle shaft housing to the differential carrier assembly.
  26. Install the 2 upper inner axle shaft housing bolts. Tighten the bolts finger tight.
    Fig 7: Identifying Inner Axle Shaft Housing Components
    G01468069Courtesy of GENERAL MOTORS CORP.
  27. The clutch cable retainer spring to the clutch fork.
  28. Install the clutch cable housing.
  29. Install the clutch cable housing bolts.

    Tighten 

    Tighten the inner axle shaft housing and the clutch cable housing bolts to 48 N.m (36 lb ft).

  30. Install the drain plug and the washer.
  31. Install the fill plug and the washer.

    Tighten 

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

  32. Install the four-wheel drive indicator switch.

    Tighten 

    Tighten the four-wheel drive indicator switch to 5 N.m (44 lb in).

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