Operation CHARM: Car repair manuals for everyone.
Home >> Chevy Truck >> 2011 >> Avalanche 4WD V8-5.3L >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Removal and Replacement >> Front Drive Axle >> Differential Carrier Assembly Final Assembly

Differential Carrier Assembly Final Assembly




Differential Carrier Assembly Final Assembly

Special Tools
* J 8092 - Universal Driver Handle - 3/4 in - 10
* J 21474-18 - Long Nut
* J 33791 - Carrier Bushing Remover/Installer
* J 33842 - Pilot Bearing Installer
* J 36609 - Axle Tube Bearing Installer
* J 36616 - Axle Mount Bushing Remover/Installer
* J 45225 - Axle Seal Installer

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. Install the differential carrier assembly into a vise.




3. Using a suitable size socket, install the NEW differential adjuster nut lock ring (1).
4. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.




5. Using the J 33842 - installer , install the clutch shaft pilot bearing.




6. Install the clutch shaft to the differential carrier case half.





Caution: Refer to Fastener Caution Fastener Caution.

7. Install the vent connector (1) and tighten to 20 Nm (15 lb ft).




8. Using the J 45225 - installer (1) and the J 8092 - handle (2), install the new left side axle shaft seal.
9. Install the new left side inner axle shaft retainer ring.
10. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.




11. 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.
12. 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.
13. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.





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

14. Install the inner axle shaft housing into a vise.
15. Using the J 36609 - installer (1) and the J 8092 - handle (2), install the bearing with the square shoulder.




16. Using the J 45225 - installer (1) and the J 8092 - handle (2), install the new inner shaft seal.
17. Install the differential axle housing gasket.




18. Using a soft face mallet, install the inner axle shaft (1) in the axle shaft housing (4).

Note: Apply a small amount of clean grease to hold the thrust washer in place.

19. Align the tabs on the thrust washer (with tabs) (5) with the slots in the inner shaft housing.
20. Install the NEW retainer ring (7) on the inner axle shaft (1).
21. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment Adjustments.
22. Install the clutch sleeve (9).
23. Install the clutch fork (11).
24. Install the clutch fork inner spring (10).
25. Apply sealant to the surface between the inner shaft housing and the differential carrier. For the correct sealant, refer to Adhesives, Fluids, Lubricants, and Sealers.




26. Install the inner shaft housing to the differential carrier assembly case.
27. Install the inner shaft housing bolts and tighten to 40 Nm (30 lb ft).
28. Install the washer and the drain plug. Tighten the drain plug to 33 Nm (24 lb ft).
29. Install the washer and fill plug. Tighten the fill plug to 33 Nm (24 lb ft).




30. Apply the correct thread sealant to the threads of the front drive actuator. Refer to Adhesives, Fluids, Lubricants, and Sealers.
31. Install the front drive actuator and tighten to 20 Nm (15 lb ft).

Note: Ensure that the lower bushing is centered in the bore before installation.

32. Using the J 36616 - remover/installer (2, 3, 4, 5) and the J 21474-18 - nut (1), install the lower differential carrier bushing.





Note: Ensure that the lower bushing is centered in the bore before installation.

33. Using the J 36616 - remover/installer (2, 3, 4, 5) and the J 21474-18 - nut (1), install the upper differential carrier bushing.
34. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .

pro multis · About Operation CHARM