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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 S4WD and 9.25 Lock Tab) >> 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, 9.25 inch axle - right side.
    3. Fig 1: View Of Left Side Differential Bearing Adjuster Nut Lock & Bolt
    GM685960Courtesy of GENERAL MOTORS CORP.
  3. Install the differential adjuster nut lock, 9.25 inch axle - left side.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the differential adjuster nut lock bolt and tighten to 20 N.m (15 lb ft).
  5. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    6. Fig 2: Identifying Clutch Shaft Pilot Bearing - Front Drive Axle
    GM695745Courtesy of GENERAL MOTORS CORP.
  6. Using the J 33842:  installer, install the clutch shaft pilot bearing.
    7. Fig 3: Identifying Differential Carrier Assembly Bolts (9.25 Inch Axle)
    GM205917Courtesy of GENERAL MOTORS CORP.
  7. Install the clutch shaft to the differential carrier case half.
    8. Fig 4: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  8. If servicing the 9.25 inch axle, install the vent hose connector and tighten to 28 N.m (21 lb ft).
    9. Fig 5: View Of Vent Hose & Connector
    GM1690209Courtesy of GENERAL MOTORS CORP.
  9. If servicing the 8.25 inch axle, install the vent hose (1) to the vent connector (2) and tighten to 20 N.m (15 lb ft).
    10. Fig 6: View Of J 45225 & J 8092 Axle Shaft Seal Installation Tools - Front Drive Axle
    GM1486568Courtesy of GENERAL MOTORS CORP.
  10. Using the J 45225:  installer (1) and the J 8092:  handle (2), install the new left side axle shaft seal.
  11. Install the new left side inner axle shaft retainer ring.
    12. Fig 7: View Of Left Side Inner Axle Shaft
    GM1332794Courtesy of GENERAL MOTORS CORP.
  12. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
  13. Hold 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.
  14. 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.
  15. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear
    16. Fig 8: Installing Side Bearing Using J 36609 & J 8092 -- Front Drive Axle
    GM834254Courtesy of GENERAL MOTORS CORP.
  16. Install the inner axle shaft housing into a vise.
  17. Clamp only on the mounting flange of the inner axle shaft housing.
  18. Using the J 36609:  installer (1) and the J 8092:  handle (2), install the bearing.
  19. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
    20. Fig 9: Identifying Axle Shaft Seal Using J 45225 & J 8092 - Front Drive Axle
    GM1486575Courtesy of GENERAL MOTORS CORP.
  20. Using the J 45225:  installer (1) and the J 8092:  handle (2), install the new right side inner axle shaft seal.
    21. Fig 10: Identifying Inner Axle Shaft Housing Components (9.25 Inch)
    GM892812Courtesy of GENERAL MOTORS CORP.
  21. Using a soft faced mallet, install the inner axle shaft (1).
    22. NOTE:
    1. Use chassis grease in order to hold the thrust washer in place.
    2. Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.
  22. Install the thrust washer (with tabs) (5).
  23. Install the thrust washer (without tabs) (6).
  24. Install the new retainer ring (7) onto the inner axle shaft (1).
  25. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
  26. Install the clutch gear shim (9).
  27. Install the clutch sleeve (8).
  28. Install the clutch fork assembly (11).
  29. Install the clutch fork inner spring (10).
  30. Install the inner axle housing gasket.
    31. NOTE: The following service procedure is for the 9.25 inch axle ONLY.
  31. Using the correct sealant, apply sealant to the inner shaft housing to differential carrier sealing surface. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    32. Fig 11: View Of Inner Axle Shaft Housing Assembly To Differential Carrier Assembly
    GM893259Courtesy of GENERAL MOTORS CORP.
  32. Install the inner shaft housing to the differential carrier assembly case.
  33. If servicing the 8.25 inch axle, install the inner shaft housing bolts and tighten to 73 N.m (54 lb ft).
  34. If servicing the 9.25 inch axle, install the inner shaft housing bolts and tighten to 40 N.m (30 lb ft).
  35. Install the drain plug and the washer.
  36. Install the fill plug and the washer and tighten to 33 N.m (24 lb ft).
    37. Fig 12: View Of Front Axle Actuator
    GM893264Courtesy of GENERAL MOTORS CORP.
  37. Apply sealant to the threads of the front axle actuator. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  38. Install the front drive axle actuator and tighten to 20 N.m (15 lb ft).
    39. Fig 13: View Of Lower Differential Carrier Assembly Bushing, J 21474-18, Thrust Bearing, J 36616-2, J 36616-1, & Forcing Screw
    GM892851Courtesy of GENERAL MOTORS CORP.
    NOTE: The following service procedures are for the 9.25 inch axle ONLY.
  39. 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).
  40. 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.
    41. Fig 14: View Of Special Tools J 21474-18, Thrust Bearing, J 36616-2, J 36616-1, & Forcing Screw
    GM893253Courtesy of GENERAL MOTORS CORP.
    NOTE: The following service procedures are for the 9.25 inch axle ONLY.
  41. 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.
  42. 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.
  43. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD)  or Differential Carrier Assembly Replacement (2500 4WD) .
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