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Differential Carrier Assembly Assemble (8.25 Inch Axle Lock Ring Style)

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Special Tools

  1. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
    2. Fig 1: Installing Inner Pinion Bearing Onto Pinion Gear
    GM651742Courtesy of GENERAL MOTORS CORP.
  2. Using the J 35512  , install the inner pinion bearing onto the pinion gear. See Special Tools .
  3. Install the new collapsible spacer onto the pinion gear.
  4. Lubricate the inner and the outer pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) .
  5. Install the outer pinion bearing into the differential carrier case half.
    6. Fig 2: Vent Hose Connector
    GM2470603Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  6. Install the vent hose connector (1) and tighten to 28 N.m (21 lb ft)..
  7. Install the differential carrier case half into a vise. Place a shop towel in a vise in order to protect the differential case.
    8. Fig 3: Pinion Seal
    GM2470696Courtesy of GENERAL MOTORS CORP.
  8. Position the pinion seal (1) in the differential case.
    9. Fig 4: View Of Special Tool J 36366 Seal Installer
    GM1865948Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the pinion flange seal is seated on the axle housing surface.
  9. Using the J 36366  , install the pinion flange seal. See Special Tools .
  10. Using the correct sealant, apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  11. Install the pinion gear, with the inner pinion bearing an the new collapsible spacer, into the left differential carrier case half.
    12. Fig 5: Pinion Flange/Yoke Assembly Components
    GM2470739Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Pinion Flange/Yoke Installation Caution .
  12. Position the pinion flange/yoke assembly (2) on the pinion shaft (1).
  13. Using a soft faced mallet, tap the on the pinion flange/yoke assembly (2) until a few pinion shaft by threads show through.
  14. Install the NEW pinion washer (3) and the nut (4).
  15. If the pinion nut cannot be installed, remove the pinion nut washer.
  16. Install the old pinion nut and tighten the nut until a few of the shaft threads show through.
  17. Remove the old pinion nut.
  18. Install the J 8614-01  onto the pinion flange/yoke assembly (2). See Special Tools .
    19. NOTE: If the rotating torque exceeded, the pinion will be removed and a new collapsible spacer installed.
  19. Holding the J 8614-01  , tighten the pinion nut to Tighten the pinion nut until the pinion end play is just taken up. See Special Tools . Rotate the pinion while tightening the nut in order to seat the bearings..
  20. Remove the J 8614-01  . See Special Tools .
  21. Using an inch pound torque wrench, measure the rotating torque of the pinion, which should be 1.0-2.3 N.m (10-20 lb in) for used bearings, 1.7-3.4 N.m (15-30 lb in) for new bearings..
  22. 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, reinstall the J 8614-01  and continue to tighten the pinion nut, which should be 1. See Special Tools .0-2.3 N.m (10-20 lb in) for used bearings, 1.7-3.4 N.m (15-30 lb in) for new bearings..
  23. Once the specified torque is obtained, rotate the pinion several time to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
  24. Remove the J 8614-01  . See Special Tools .
    25. Fig 6: Differential Adjuster Nut & Lock Ring
    GM2470477Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the differential adjuster nut is fully seated in the adjuster nut sleeve.
  25. Position the differential adjuster nut (2) and the lock ring (1) in the differential case half's.
    26. Fig 7: View Of Special Tools J 36614 & J 8092
    GM1891196Courtesy of GENERAL MOTORS CORP.
  26. Using the J 36614  (2) and the J 8092  (1), install the inner shaft bearing onto the differential bearing adjuster for the 8.25 inch S4WD axle left and right side, 8.25 inch F4WD axle left.
    27. Fig 8: Installing Differential Adjuster Nut Assembly Into Differential Carrier Case
    GM696524Courtesy of GENERAL MOTORS CORP.
  27. Using the J 36614  (2) and the J 8092  (1), install the left and right side differential adjuster nut assembly into the differential carrier case.
    28. Fig 9: View Of Special Tool J 8092
    GM1891197Courtesy of GENERAL MOTORS CORP.
  28. Using the J 8092  (1), install the left and right differential case side bearing cups into the differential carrier case.
    29. Fig 10: View Of Differential Case Assembly & Carrier Case Half
    GM1865962Courtesy of GENERAL MOTORS CORP.
  29. Install the differential case assembly into the left differential carrier case half.
    30. Fig 11: View Of Differential Carrier Housing, Gasket & Bolts
    GM1865718Courtesy of GENERAL MOTORS CORP.
    NOTE: The sealing surfaces of the differential carrier halves must be free of grease and oil to ensure that the gasket will seal properly.
  30. Install the differential carrier case gasket (3).
  31. Install the differential carrier case (2) half to the left differential carrier case half. If the carrier case halves do not make complete contact, use the J 36599-A  in order to back out right differential adjuster nut sleeve until the differential carrier case halves make contact. See Special Tools .
  32. Install the differential carrier case bolts (1) and tighten to 73 N.m (54 lb ft)..
  33. Install the differential carrier assembly into a vise.
  34. While rotating the pinion yoke back and forth, turn he right side differential adjuster nut clockwise using the J 36599-A  until 0. See Special Tools .0254-0.072 mm (0.001-0.003 inch) of backlash can be felt between the ring gear and the drive pinion. If the backlash specification cannot be obtained, turn the left side differential adjuster nut sleeve counter clockwise using the J 36599-A  in small equal increments until the backlash specification can be obtained. See Special Tools .
    35. Fig 12: Tightening Differential Adjuster Nut
    GM1865979Courtesy of GENERAL MOTORS CORP.
  35. Using the J 36599-A  turn the left side differential adjuster nut clockwise in order to preload the differential side bearings against the differential side bearings cups and tighten the adjuster nut to 75 N.m (55 lb ft). See Special Tools .
  36. Rotate the pinion several times in order to seat the pinion and differential side bearings.
  37. Using an inch-pound torque wrench, measure the rotating torque of the drive pinion and differential assembly, which should be 0.57-1.13 N.m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier..
  38. If the rotating torque of the drive pinion and differential assembly is not 0.57-1.13 N.m (5-10 lb in) greater than the rotating torque of the drive pinion, adjust the differential side bearing preload using the following steps:
    1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
    2. Using the J 36599-A  , turn the left and right side differential adjuster sleeves in or clockwise in small equal increments. See Special Tools .
    3. Using an inch pound torque wrench, measure the rotating torque of the pinion and differential assembly.
    4. Compare the new measurement to the specification listed in Step 31. If the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves in small equal increments on each side until the rotating torque of the pinion and differential assembly is within specifications.
  39. If the rotating torque of the drive pinion and differential assembly is more than 1.13 N.m (10 lb in) above the rotating torque of the drive pinion measurement, adjust the differential side bearing preload using the following steps:
    1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
    2. Using the J 36599-A  or the J 36615  , turn the left and right side differential adjuster nut sleeve out or clockwise in small equal increments. See Special Tools .
    3. Using a torque wrench, measure the rotating torque of the pinion and differential assembly.
    4. Compare the new measurement to the specification listed in Step 31. If the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeve in small equal increments on each side until the rotating torque of the pinion and differential assembly is within specifications.
  40. Once the specified rotating is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
  41. Measure the drive pinion to the ring gear backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment .
  42. Once the bearing preload and drive pinion to the ring gear backlash is within specifications, perform a gear tooth contact pattern check to ensure proper contact between the pinon and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
  43. Complete the final assembly of the differential carrier. Refer to Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Lock Tab)  or Differential Carrier Assembly Final Assembly (8.25 Inch axle Lock Ring Type) .
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