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Differential Carrier Assembly Assemble (9.25 Inch Axle)

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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: View Of Inner Pinion Bearing & Pinion Gear
    GM651742Courtesy of GENERAL MOTORS COMPANY
  2. Using the J-36614  inner pinion bearing installer (1), install the inner pinion bearing (2) onto the pinion gear.
  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 .
  5. Install the outer pinion bearing into the differential carrier case half.
    6. NOTE:

    Place shop towels in the vise in order to protect the differential carrier case.

  6. Install the differential carrier case half into a vise.
    7. Fig 2: View Of Oil Seal & J 36366 - Front Axle
    GM664080Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Ensure the seal flange is seated on the axle housing surface.

  7. Using the J-36366  pinion oil seal installer, install the seal.
  8. Apply sealant to the splines of the pinion yoke. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  9. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
  10. Install the pinion yoke.
    11. CAUTION:

    Refer to Pinion Flange/Yoke Installation Caution .

  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. Install the washer and a new pinion nut.

    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 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 new pinion nut can be installed.
    4. Remove the old pinon nut.
    5. Install the pinion nut washer.
    6. Install the new pinion nut.
    13. Fig 3: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS COMPANY
  13. Install the J-8614-01  flange and pulley holding tool onto the pinion yoke as shown.
    14. CAUTION:

    Refer to Fastener Caution .

    NOTE:

    If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

  14. Tighten the pinion nut while holding the J-8614-01  flange and pulley holding tool.

    Tighten 

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

  15. Remove the J-8614-01  flange and pulley holding tool.
  16. Measure the rotating torque of the pinion using an inch-pound torque wrench.

    Specification 

    The rotating torque of the pinion should be1.0-2.3 (10-20 lb in) for used bearings, or 1.7-3.4 (15-30 lb in) for new bearings.

  17. If the rotating torque measurement is below 1.0 (10 lb in) for used bearings, or 1.7 (15 lb in) for new bearings, reinstall the J-8614-01  flange and pulley holding tool and continue to tighten the pinion nut.

    Specification 

    The rotating torque of the pinion should be 1.0-2.3 (10-20 lb in) for used bearings, or 1.7-3.4 (15-30 lb in) for new bearings.

  18. 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.

  19. Remove the J-8614-01  flange and pulley holding tool.
  20. Assemble the right side differential adjuster nut into the differential nut sleeve until fully seated.
    21. Fig 4: View Of Axle Shaft Bearings, Differential Adjuster Nut Sleeve, J 8092 & J 36612
    GM696522Courtesy of GENERAL MOTORS COMPANY
  21. Apply a small amount of lubricant on the right adjuster threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  22. Install the right side axle shaft bearings into the differential adjuster nut sleeve using the J-36612  output shaft bearing installer (2) and the GE-8092  universal driver handle (1).
  23. Apply a small amount of lubricant on the left adjuster threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  24. Install the left side axle shaft bearing into the differential adjuster nut sleeve using the J-36609  axle tube bearing installer and the GE-8092  universal driver handle.
  25. Install the right side differential adjuster nut assembly and new adjuster lock nut tab into the differential carrier case using the J-36609  axle tube bearing installer and the GE-8092  universal driver handle.
  26. Install the left side differential adjuster nut assembly into the differential carrier case.
    27. Fig 5: View Of Differential Case Side Bearing Cups, Differential Carrier Case, J 8092 & J 36603
    GM696524Courtesy of GENERAL MOTORS COMPANY
  27. Install the right side differential case side bearing cups to the differential carrier case using the J-36603  side bearing cup installer (2) and the GE-8092  universal driver handle (1).
    28. Fig 6: Identifying Differential Case Assembly
    GM1332716Courtesy of GENERAL MOTORS COMPANY
  28. Install the differential case assembly into the left differential carrier case half.
  29. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly.

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

  30. Apply a bead of sealer to one differential carrier case half sealing surface. Use the correct sealer. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    31. Fig 7: Differential Case Assembly
    GM1332738Courtesy of GENERAL MOTORS COMPANY
  31. Install the right differential carrier case half to the left differential carrier case half.

    If the carrier case halves do not make complete contact, use the J-36599-A  side bearing nut wrench in order to back out the right differential adjuster nut sleeve until the differential carrier case halves make contact.

    32. Fig 8: Differential Carrier Assembly Bolts (8.25 Inch Axles)
    GM1332740Courtesy of GENERAL MOTORS COMPANY
  32. Install the differential carrier case bolts.

    Tighten 

    Tighten the differential carrier case bolts to 47 (35 lb ft).

  33. Install the differential carrier assembly into a vise.
    34. Fig 9: Identifying Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
    GM680101Courtesy of GENERAL MOTORS COMPANY
  34. While rotating the pinion yoke back and forth, turn the right side differential adjuster nut sleeve clockwise using the J-36599-A  side bearing nut wrench until 0.0254-0.0762 mm (0.001-0.003 in) 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 counterclockwise using the J-36599-A  side bearing nut wrench one notch at a time until the backlash specification can be obtained.

    35. Fig 10: View Of J 36615 On Left Side Differential Bearing Adjuster Nut
    GM680888Courtesy of GENERAL MOTORS COMPANY
  35. Turn the left side differential adjuster nut clockwise using the J-36615  side bearing nut wrench in order to preload the differential side bearings against the differential side bearing cups.

    Tighten 

    Tighten the differential adjuster nut to 75 (55 lb ft).

  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.

    Specification 

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

    38. Fig 11: Alignment Mark Between Differential Adjuster Nut Sleeve & Differential Carrier Case
    GM1332728Courtesy of GENERAL MOTORS COMPANY
  38. If the rotating torque measurement is below 2.8 (25 lb in) for used bearings, or 3.4 (30 lb in) for new bearings, 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  side bearing nut wrench or the J-36615  side bearing nut wrench, turn the left and the right side differential adjuster nut sleeves in or clockwise one notch.
    3. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
    4. Compare the new measurement to the specification listed in step 34. 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 one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
  39. If the rotating torque measurement is above 5.1 (45 lb in) for used bearings, or 6.2 (55 lb in) for new bearings, 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  side bearing nut wrench or the J-36615  side bearing nut wrench, turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch.
    3. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
    4. Compare the new measurement to the specification listed in step 34. 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 sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
  40. Once the specified rotating torque 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 ring gear backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment .
  42. Once the bearing preload and drive pinion to ring gear backlash is within specifications, perform a gear tooth contact pattern check to ensure proper contact between the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
  43. Complete the assembly of the differential carrier. Refer to Differential Carrier Assembly Final Assembly (8.25 Inch axle Lock Ring Type) , Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Lock Tab) .
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