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Differential Carrier Assembly Final Assembly (8.25 F4WD): Assembly

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  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, 9.25 inch axle - right side.
    3. Fig 1: Left Side Differential Bearing Adjuster Nut Lock & Bolt (9.25 Inch Axle)
    GM685960Courtesy of GENERAL MOTORS CORP.
  3. Install the differential adjuster nut lock, 9.25 inch axle - left side.
    4. NOTE: Refer to Fastener Notice .
  4. Install the differential adjuster nut lock bolt.

    Tighten:  Tighten the differential adjuster lock nut bolt to 20 N.m (15 lb ft).

  5. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    6. Fig 2: Identifying Differential Carrier Assembly Bolts
    GM205917Courtesy of GENERAL MOTORS CORP.
  6. Install the clutch shaft to the differential carrier case half.
    7. Fig 3: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The following service procedure is for the 9.25 inch axle.
  7. Install the vent hose connector.

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

    8. IMPORTANT: The following service procedure is for the 8.25 inch axle.
    Fig 4: View Of Vent Hose & Connector
    GM1690209Courtesy of GENERAL MOTORS CORP.
  8. Install the vent hose (1) to the vent connector (2).

    Tighten:  Tighten the vent hose connector (2) to 20 N.m (15 lb ft).

    9. Fig 5: Install New Axle Shaft Seal Using J 45225 & J 8092 - Front Drive Axle
    GM1486568Courtesy of GENERAL MOTORS CORP.
  9. Using the J 45225  (1) and the J 8092  (2), install the new left side axle shaft seal.
  10. Install the new left side inner axle shaft retainer ring.
    11. Fig 6: Left Side Inner Axle Shaft
    GM1332794Courtesy of GENERAL MOTORS CORP.
  11. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
  12. 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
  13. Using a soft faced mallet, drive the inner shaft into the differential case side gear until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  14. Ensure that the inner shaft is properly retained in the differential case side gear by pulling back on the inner shaft.
    15. Fig 7: Installing Side Bearing Using J 36609 & J 8092 - Front Drive Axle
    GM834254Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Clamp only on the mounting flange of the inner axle shaft housing.
  15. Install the inner axle shaft housing into a vise.
    16. IMPORTANT: When installing the bearing, ensure that the square shoulder of the bearing is facing inward.
  16. Using the J 36609  (1) and the J 8092  (2), install the bearing. See Special Tools .
    17. Fig 8: Installing New Axle Shaft Seal Using J 45225 & J 8092 - Front Drive Axle
    GM1486575Courtesy of GENERAL MOTORS CORP.
  17. Using the J 45225  (1) and the J 8092  (2), install the new right side inner axle shaft seal.
    18. Fig 9: Inner Shaft Housing Components
    GM2047154Courtesy of GENERAL MOTORS CORP.
  18. Install the following components into the inner shaft housing:
    1. The inner axle shaft (1)-Carefully tap the inner axle shaft into place with a soft-faced mallet.
      2. IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    2. The thrust washer, with tabs (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.
    3. The new retainer ring (6) onto the inner axle shaft (1)
    4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment  .
    5. The clutch gear shim (8)
    6. The clutch sleeve (9)
    7. The clutch fork assembly (10)
    8. The clutch fork inner spring (9)
    9. The inner axle housing gasket
    19. IMPORTANT: The following service procedure is for the 9.25 inch axle ONLY.
  19. Apply sealant to the inner shaft housing to differential carrier sealing surface. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    20. Fig 10: View Of Inner Axle Shaft Housing Assembly To Differential Carrier Assembly
    GM893259Courtesy of GENERAL MOTORS CORP.
  20. Install the inner shaft housing to the differential carrier assembly case.
  21. If servicing the 8.25 inch axle, install the inner shaft housing bolts.

    Tighten:  Tighten the inner shaft housing bolts to 73 N.m (54 lb ft).

  22. If servicing the 9.25 inch axle, install the inner shaft housing bolts.

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

  23. Install the drain plug and the washer.
  24. Install the fill plug and the washer.

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

    25. Fig 11: Inner Axle Shaft (8.25 Inch Axles)
    GM893264Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Apply the correct sealant to the threads of the front axle actuator. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    NOTE: Refer to Component Fastener Tightening Notice .
  25. Install the front drive axle actuator.

    Tighten:  Tighten the front drive axle actuator to 20 N.m (15 lb ft).

    26. Fig 12: Installing Differential Carrier Bushing (9.25 Inch)
    GM2047519Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The following service procedures are for the 9.25 inch axle ONLY.
  26. Using the J 21474-18 (2), J 36616-2 (1), and the J 36616-1 (1), install the differential carrier bushing (3).
    27. Fig 13: Installing Differential Carrier Assembly Bushing (9.25 Inch)
    GM2047520Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The following service procedures are for the 9.25 inch axle ONLY.
  27. Using the J 21474-18 (2), J 36616-2 (1), and the J 36616-1 (1), install and the differential carrier assembly bushing.
  28. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (8.25 inch)  or Differential Carrier Assembly Replacement (9.25 inch) .
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