LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1388 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly Final Assembly (8.25 F4WD Axle) >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
  2. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
  3. Install the differential carrier assembly into a vise.
    4. Fig 1: View Of J 45225 & J 8092 Axle Shaft Seal Installation Tools - Front Drive Axle
    GM1486568Courtesy of GENERAL MOTORS CORP.
  4. Using the J 45225:  installer (1) and the J 8092:  handle (2), install the new left side axle shaft seal.
  5. Install the new left side inner axle shaft retainer ring.
  6. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
    7. Fig 2: View Of Left Side Inner Axle Shaft
    GM1332794Courtesy of GENERAL MOTORS CORP.
  7. Holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear.
  8. Using a soft-faced mallet, drive the inner shaft into the differential case side gear until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  9. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
    10. Fig 3: Installing Side Bearing Using J 36609 & J 8092 -- Front Drive Axle
    GM834254Courtesy of GENERAL MOTORS CORP.
    NOTE: Clamp only on the mounting flange of the inner axle shaft housing.
  10. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
  11. Install the inner axle shaft housing into a vise.
  12. Using the J 36609:  installer (1) and the J 8092:  handle (2), install the bearing with the square shoulder.
    13. Fig 4: Identifying Axle Shaft Seal Using J 45225 & J 8092 - Front Drive Axle
    GM1486575Courtesy of GENERAL MOTORS CORP.
  13. Using the J 45225:  Axle Seal Installer (1) and the J 8092:  handle (2), install the new inner shaft seal.
  14. Install the differential axle housing gasket.
  15. Install the inner shaft housing to the differential carrier assembly case.
    16. CAUTION: Refer to Fastener Caution .
  16. Install the inner shaft housing bolts and tighten to 40 N.m (30 lb ft).
    17. Fig 5: Identifying Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM615683Courtesy of GENERAL MOTORS CORP.
  17. Install the inner shaft (2) into the inner axle shaft housing (1) until the inner shaft is seated against the differential side gear.
  18. While holding the inner shaft (2) against the differential side gear, turn the inner shaft (2) in order to align the splines of the inner shaft (2) with the splines on the differential side gear.
  19. Drive the inner shaft (2) into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft (2) is fully seated within the groove in the differential case side gear.
  20. Pull back on the inner shaft (2) to ensure that the inner shaft is properly retained in the differential case side gear.
  21. Install the drain plug and the washer.
  22. Install the fill plug and the washer and tighten to 33 N.m (24 lb ft).
  23. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD)  or Differential Carrier Assembly Replacement (2500 4WD) .
scientia non olet · About LEMON Manuals