Differential Carrier Assembly - Final Assembly (8.25 F4WD Axle)

Tools Required

• J 8092  Universal Driver Handle - 3/4 in - 10
• J 33791  Carrier Bushing Remover/Installer. See Special Tools .
• J 36609  Axle Tube Bearing Installer. See Special Tools .
• J 36616  Axle Mount Bushing Remover/Installer
• J 45225  Axle Seal Installer. See Special Tools .

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.
Fig 1: View Of Vent Hose Connector
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
3. Install the vent hose connector.

   Tighten:  Tighten the vent hose connector to 28 N.m (21 lb ft).

4. Install the differential carrier assembly into a vise.
Fig 2: Install The New Axle Shaft Seal Using J 45225 & J 8092 - Front Drive Axle
Courtesy of GENERAL MOTORS CORP.
5. Install the new left side axle shaft seal using the J 45225  (1) and the J 8092  (2). See Special Tools .
6. Install the new left side inner axle shaft retainer ring.
Fig 3: View Of Left Side Inner Axle Shaft
Courtesy of GENERAL MOTORS CORP.
7. Install the left side inner axle shaft by doing the following:
   1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
   2. While holding 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.
   3. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.

      Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.

Fig 4: Installing Side Bearing Using J 36609 & J 8092 - Front Drive Axle
Courtesy of GENERAL MOTORS CORP.
8. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
   1. Install the inner axle shaft housing into a vise.

      Clamp only on the mounting flange of the inner axle shaft housing.

   2. Install the bearing with the square shoulder in using the J 36609  (1) and the J 8092  (2). See Special Tools .
Fig 5: Installing New Axle Shaft Seal Using J 45225 & J 8092 - Front Drive Axle
Courtesy of GENERAL MOTORS CORP.
9. Install the new inner shaft seal using the J 45225  (1) and the J 8092  (2). See Special Tools .
10. Install the differential axle housing gasket.
11. Install the inner shaft housing to the differential carrier assembly case.
NOTE: Refer to Fastener Notice in Cautions and Notices.
12. Install the inner shaft housing bolts.

    Tighten:  Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).

Fig 6: Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
Courtesy of GENERAL MOTORS CORP.
13. Install the inner shaft (2) into the inner shaft housing (1) by doing the following:
    1. Install the inner shaft into the inner axle shaft housing until the inner shaft is seated against the differential side gear.
    2. While holding 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.
    3. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.

       Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.

14. Install the drain plug and the washer.
15. Install the fill plug and the washer.

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

16. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 4WD)  or Differential Carrier Assembly Replacement (2500 4WD) .