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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 >> Front Differential Case Assemble (9.25 Inch 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. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    2. Fig 1: Identifying Differential Side Gears & Thrust Washers
    GM851734Courtesy of GENERAL MOTORS CORP.
  2. 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.

    3. Fig 2: Identifying Differential Pinion Gears & Thrust Washers
    GM851732Courtesy of GENERAL MOTORS CORP.
  3. 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.
  4. Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift.
  5. Install the differential side gear spacers.
    6. Fig 3: View Of Differential & Pinion Shaft
    GM851733Courtesy of GENERAL MOTORS CORP.
  6. Install the pinion gear shaft.
    7. Fig 4: Identifying Differential Pinion Gears & Thrust Washers
    GM851732Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  7. Install the pinion shaft lock bolt and tighten to 53 N.m (39 lb ft).
    8. Fig 5: View Of Ring Gear & Differential Case
    GM866505Courtesy of GENERAL MOTORS CORP.
    NOTE: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
  8. Install the ring gear onto the differential case.
    9. Fig 6: Identifying Ring Gear Bolts
    GM866503Courtesy of GENERAL MOTORS CORP.
    NOTE: The ring gear bolts have left-hand threads.
  9. Install the new ring gear bolts.

    Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

  10. Install the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 138 N.m (102 lb ft).
    11. Fig 7: Installing Differential Side Bearing
    GM680453Courtesy of GENERAL MOTORS CORP.
  11. 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. See Special Tools .
    2. Install the J 29710  (2) and the J 8092  (1) onto the differential case bearing as shown. See Special Tools .
    3. Drive the differential case bearing onto the case using the J 29710  and the J 8092  . See Special Tools .
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