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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Front Drive Axle >> Repair Instructions >> Differential Carrier Assembly Assemble >> Assemble

Differential Carrier Assembly Assemble: Assemble

  1. Install the pinion bearing cups into the differential carrier assembly. Refer to Front Differential Drive Pinion Gear Bearing Cup Installation .
  2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
    3. Fig 1: Installing Inner Pinion Bearing Onto Pinion Gear
    GM651742Courtesy of GENERAL MOTORS CORP.
  3. Install the inner pinion bearing onto the pinion gear using the J 36614  . See Special Tools .
  4. Install the new collapsible spacer onto the pinion gear.
  5. Lubricate the pinion bearings with axle lubricant, GM P/N 12378261 (Canadian P/N 10953455) or equivalent meeting GM Specification 9986115.
    6. Fig 2: Installing Outer Pinion Bearing Into Left Differential Carrier Case Half
    GM873374Courtesy of GENERAL MOTORS CORP.
  6. Install the outer pinion bearing into the left differential carrier case half.
    7. Fig 3: Installing Oil Seal Using J 36366
    GM664080Courtesy of GENERAL MOTORS CORP.
  7. Install the pinion oil seal using J 36366  . See Special Tools .
    8. Fig 4: Applying GM P/N 12346004 Sealant To Splines Of Pinion Yoke
    GM873373Courtesy of GENERAL MOTORS CORP.
  8. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
  9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
    10. Fig 5: Pinion Yoke
    GM873377Courtesy of GENERAL MOTORS CORP.
  10. Install the pinion yoke.
    11. NOTE: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
  11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
    12. Fig 6: Pinion Washer
    GM873378Courtesy of GENERAL MOTORS CORP.
  12. Install the washer.
    13. Fig 7: Pinion Nut
    GM873379Courtesy of GENERAL MOTORS CORP.
  13. Install the new pinion nut.
  14. If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and the new pinion nut can be installed:
    1. Remove the pinion nut washer.
    2. Install the old pinion nut.
    3. Tighten the nut until a few of the shaft threads show through the nut so that the washer and the new pinion nut can be installed.
    4. Remove the old pinion nut.
    5. Install the pinion nut washer.
    6. Install the new pinion nut.
    15. Fig 8: Installing J 8614-01 Onto Pinion Yoke
    GM868455Courtesy of GENERAL MOTORS CORP.
  15. Install the J 8614-01  onto the pinion yoke as shown. See Special Tools .
    16. NOTE: Refer to Fastener Notice .
    IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
  16. Tighten the pinion nut while holding the J 8614-01  . See Special Tools .

    Tighten:  Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

  17. Remove the J 8614-01  . See Special Tools .
  18. Measure the rotating torque of the pinion using an inch-pound torque wrench.

    Specification:  The rotating torque of the pinion should be 1.1-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.

  19. 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, re-install the J 8614-01  and continue to tighten the pinion nut. See Special Tools .

    Tighten:  Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.1-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.

  20. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

    Recheck the rotating torque and adjust if necessary.

  21. Remove the J 8614-01  . See Special Tools .
  22. Assemble the right side differential adjuster nut into the differential nut sleeve until fully seated.
  23. Install the right side differential adjuster nut assembly and the new adjuster lock nut tab into the right side differential carrier case half.
    24. Fig 9: Driving Right Side Differential Adjuster Nut Assembly & New Adjuster Lock Nut Tab Into Differential Carrier Case Half Using J 36609 & J8092
    GM873369Courtesy of GENERAL MOTORS CORP.
  24. Drive the right side differential adjuster nut assembly and the new adjuster lock nut tab into the differential carrier case half until seated using the J 36609  (2) and the J 8092  (1). See Special Tools .
    25. Fig 10: Installing Differential Case Side Bearing Cups To Differential Carrier Case Using J 8092 & J 36603
    GM696524Courtesy of GENERAL MOTORS CORP.
  25. Install the right side differential case side bearing cup into the differential carrier case using the J 36603  (2) and the J 8092  (1). See Special Tools .
  26. Install the left side differential adjuster nut assembly into the left side differential carrier case half.
    27. Fig 11: Installing Left Side Axle Shaft Bearing Using J 36609 & J 8092
    GM868358Courtesy of GENERAL MOTORS CORP.
  27. Install the left side axle shaft bearing into the differential adjuster nut sleeve using the J 36609  (2) and the J 8092  (1). See Special Tools .
    28. Fig 12: Differential Case Assembly
    GM868459Courtesy of GENERAL MOTORS CORP.
  28. Install the differential case assembly into the left differential carrier case half.
  29. Install the right differential carrier case half to the left differential carrier case half.

    Do not use sealer at this time.

    If the carrier case halves do not make complete contact, use the J 36599-A  in order to back out the right differential adjuster nut sleeve. See Special Tools .

  30. Install the differential carrier case bolts.

    Tighten:  Tighten the differential carrier case bolts to 78 N.m (58 lb ft).

  31. Install the differential carrier assembly into a vise.
    32. Fig 13: Turning Left Side Differential Adjuster Nut Sleeve Using J 36615
    GM868450Courtesy of GENERAL MOTORS CORP.
  32. Turn the left side differential adjuster nut sleeve in using the J 36615  until the differential adjuster nut contacts the differential side bearing and can no longer be turned. See Special Tools .
  33. Turn the right side differential adjuster nut sleeve in using the J 36599-A  until the differential adjuster nut contacts the differential side bearing and can no longer be turned. See Special Tools .
  34. Rotate the pinion several times in order to seat the bearings.
  35. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

    Specification:  The rotating torque of the pinion and differential assembly should be 2.8-5.1 N.m (25-45 lb in) for used bearings, or 3.4-6.2 N.m (30-55 lb in) for new bearings.

  36. If the rotating torque measurement is below 2.8 N.m (25 lb in) for used bearings, or 3.4 N.m (30 lb in) for new bearings, tighten the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
  37. If the rotating torque measurement is above 5.1 N.m (45 lb in) for used bearings, or 6.2 N.m (55 lb in) for new bearings, loosen the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
  38. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

    Recheck the rotating torque and adjust if necessary.

  39. Measure the drive pinion to ring gear backlash. Refer to Backlash Inspection and Adjustment .
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