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Differential Carrier Assembly - Final Assembly

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Tools Required 

  1. Install the right side differential adjuster lock over the differential bearing adjuster.
    Fig 1: Installing Right Side Differential Adjuster Lock
    G01216478Courtesy of GENERAL MOTORS CORP.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  2. Install the right side differential bearing adjuster lock bolt.

    Tighten 

    Tighten the right side differential bearing adjuster lock bolt to 8 N.m (71 lb in).

    Fig 2: Installing Right Side Differential Bearing Adjuster Lock Bolt
    G01216479Courtesy of GENERAL MOTORS CORP.
  3. Install the left side differential bearing adjuster lock over the differential adjuster.
    Fig 3: Installing Left Side Differential Bearing Adjuster Lock
    G01216480Courtesy of GENERAL MOTORS CORP.
  4. Install the left side differential bearing adjuster lock bolt.

    Tighten 

    Tighten the left side differential bearing adjuster lock bolt to 8 N.m (71 lb in).

    Fig 4: Installing Left Side Differential Bearing Adjuster Lock Bolt
    G01216481Courtesy of GENERAL MOTORS CORP.
  5. Remove the differential carrier assembly bolts.
  6. Remove the right differential carrier case half.
  7. Clean the sealing surface of each half of the differential carrier case and the inner shaft housing to differential carrier assembly.

    The surfaces must be clean of all the grease and the oil.

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

    Tighten 

    Tighten the differential carrier case bolts to 48 N.m (35 lb ft).

    Fig 5: Removing Differential Carrier Assembly Bolts
    G01216482Courtesy of GENERAL MOTORS CORP.
  11. Install the lower inner shaft housing bushing by performing the following steps:
    1. Install the inner shaft housing into a vise.
    2. Place the lower inner shaft housing bushing over the bushing bore.
    3. Install the J-45850-2 (2), J-45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown.

      Install the J-45850-3 inside the J-45850-2 (2) in order to gain access to the upper nut.

    4. Install the lower inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
    5. Remove the inner shaft housing from the vise.
    6. Install the inner shaft housing into the vise. Clamp on the inner shaft housing tube.
      Fig 6: Installing J-45850-2, J-45850-1 & Components Over Inner Shaft Housing Bushing
      G01216483Courtesy of GENERAL MOTORS CORP.
  12. Install the upper inner shaft housing bushing by performing the following steps:
    1. Install the inner shaft housing into a vise.
    2. Place the upper inner shaft housing bushing over the bushing bore.
    3. Install the J-45850-2 (2), J-45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown.

      Install the J-45850-3 inside the J-45850-2 (2) in order to gain access to the upper nut.

    4. Install the upper inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
      Fig 7: Installing J-45850-2, J-45850-1 & Components Over Inner Shaft Housing Bushing
      G01216484Courtesy of GENERAL MOTORS CORP.
  13. Install the bearing with the square shoulder in using the J-42211  (2) and the J-8092  (1).
    Fig 8: Installing Bearing Using J-42211 & J-8092
    G01216485Courtesy of GENERAL MOTORS CORP.
  14. Install the new axle shaft seal using the J-42738  .
  15. Remove the inner shaft housing from the vise.
  16. Install the differential carrier assembly into a vise.
    Fig 9: Installing Axle Shaft Seal Using J-42738
    G01216486Courtesy of GENERAL MOTORS CORP.
  17. Apply sealant GM P/N 1052492 (Canadian P/N 10953466) or equivalent to the inner housing to differential carrier assembly sealing surface.
  18. Install the inner shaft housing to the differential carrier assembly.
  19. Install the inner shaft housing to differential carrier assembly bolts.

    Tighten 

    Tighten the inner shaft housing to differential carrier assembly bolts to 48 N.m (35 lb ft).

    Fig 10: Installing Inner Shaft Housing To Differential Carrier Assembly Bolts
    G01216487Courtesy of GENERAL MOTORS CORP.
  20. Install the new inner shaft retaining ring.
    CAUTION: Do not nick or cut the inner shaft oil seal.
  21. Install the inner shaft into the inner shaft housing by performing the following steps:
    1. Carefully guide the inner shaft through the inner shaft housing until the retaining ring on the inner shaft contacts the differential case side gear.
    2. Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
    3. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
      Fig 11: Installing Inner Shaft Into Inner Shaft Housing
      G01216488Courtesy of GENERAL MOTORS CORP.
  22. Install the inner shaft seal cover.
    Fig 12: Installing Inner Shaft Seal Cover
    G01216489Courtesy of GENERAL MOTORS CORP.
  23. Install the inner shaft seal cover bolts.

    Tighten 

    Tighten the inner shaft seal cover bolts to 18 N.m (13 lb ft).

    Fig 13: Installing Inner Shaft Seal Cover Bolts
    G01216490Courtesy of GENERAL MOTORS CORP.
  24. Install the new inner shaft retaining ring.
    CAUTION: Do not nick or cut the inner shaft oil seal.
  25. Install the left inner shaft into the differential carrier assembly by performing the following steps:
    1. Carefully guide the inner shaft through the oil seal until the retaining ring on the inner shaft contacts the differential case side gear.
    2. Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
    3. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
      Fig 14: Installing Left Inner Shaft Into Differential Carrier Assembly
      G01216491Courtesy of GENERAL MOTORS CORP.
  26. Install the lower differential carrier assembly bushing by performing the following steps:
    1. Install the differential carrier assembly bushing into the differential carrier assembly bushing bore.
    2. Install the J-45850-2 (3), the J-45850-3 (2), the forcing screw, the thrust bearing, and the nuts (1, 4-5) over the differential carrier assembly bushing as shown.
    3. Install the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J-45850  .
      Fig 15: Installing J-45850-2, J-45850-3 & Components Over Differential Carrier Assembly Bushing
      G01216492Courtesy of GENERAL MOTORS CORP.
  27. Install the upper differential carrier assembly bushing by performing the following steps:
    1. Install the differential carrier assembly bushing into the differential carrier assembly bushing bore.
    2. Install the J-45850-2 (2), the J-45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown.
    3. Install the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J-45850  .
    Fig 16: Installing J-45850-2, J-45850-3 & Components Over Differential Carrier Assembly Bushing
    G01216493Courtesy of GENERAL MOTORS CORP.
  28. Install the drain plug and the washer.

    Tighten 

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

  29. Fill the axle with lubricant with the proper fluid. Refer to Lubricant Replacement - Front Drive Axle .
  30. Install the fill plug and the washer.

    Tighten 

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

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