Differential Case
^ Tools Required
- J8092 Driver Handle
- J8614-01 Flange/Pulley Holder Tool
- J23423-A Side Bearing Cup Installer
- J23911 Seal Installer
- J29763 Dial Indicator
- J33782 Pinion Oil Seal Installer
- J33785 Pinion Bearing Installer
- J33788 Output Shaft Bearing Installer
- J33790 Differential Side Bearing Installer
- J33791 Bushing Remover and Installer Set
- J33792 Side Bearing Adjuster Socket
- J33798 Hub Engagement Tool
- J33799 Shift Cable Housing Seal Installer
- J33837 Pinion Bearing Cup Remover and Installer
- J33838 Pinion Shim Setting Gauge
- J33842 Pilot Bearing Installer
- J42211 Bearing Installer
- J42213 Side Bearing Adjuster Socket
1. Install the outer bearing into the case using the J33837-1, the J33837-3, and the J33837-4.
2. Install the inner and outer bearing race into the carrier using the J33837-1, the J33837-3, and the J33837-4.
3. Adjust the pinion depth by selecting a shim of the proper thickness.
4. Lubricate the inner and outer pinion bearings liberally using axle lubricant.
5. Hold the pinion bearings in position and install the J33838.
6. Install the J29763.
6.1. Set the J29763 at ZERO.
6.2. Position the J29763 in the J33838.
6.3. Push the J29763 downward until the needle rotates approximately 3/4 turns to the right.
7. Tighten the dial indicator in this position.
8. Set the button of the J33838 on the differential bearing bore.
9. Rotate the tool slowly back and forth until the J29763 reads the lowest point of the bore. Set the J29763 to ZERO. Repeat the rocking action of the tool in order to verify the ZERO setting.
10. After you obtain and verify the ZERO setting, move the tool button out of the differential side bearing bore. Record the J29763 reading.
The J29763 reading equals the shim size. For example, if the J29763 reads 0.84 mm (0.003 inch) in step 8, a 0.84 mm (0.003 inch) shim is required.
11. Remove the tools and bearing cones.
12. Install the selective shim between the inner bearing and the gear shoulder.
13. Install the inner pinion bearing onto the pinion gear using the J33785.
14. Install a new collapsible spacer onto the pinion gear.
15. Lubricate the pinion bearings using axle lubricant.
16. Install the outer pinion bearing into the carrier.
17. Install the pinion seal using the J33782.
18. Install the pinion gear (with the inner bearing and the spacer) into the carrier.
19. Apply sealant (GM P/N 12346004) to the inside sealing surface of the pinion yoke.
20. Apply special seal lubricant (GM P/N 12377985) to the outside sealing surface of the pinion yoke.
Notice: 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.
Important: Install the pinion yoke in the same position as marked during removal in order to maintain driveline balance.
21. Install the drive pinion yoke by tapping the yoke using a soft-faced hammer until a few pinion shaft threads show through the yoke. The pinion will need to be held in place from inside the carrier half.
Notice: Refer to Fastener Notice in Service Precautions.
Important: Reference the number of exposed threads on the pinion stem recorded during removal.
22. Install the washer and a new nut using the J8614-01.
^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order to seat the bearings.
Important: If the pinion bearing preload is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
23. Measure the pinion bearing preload using an inch-pound torque wrench.
23.1. Rotate the pinion with the torque wrench and observe the reading.
23.2. The correct preload is 1.7 - 2.8 Nm (15 - 25 inch lbs.).
^ Tighten the nut in small increments, as needed, until the preload is correct.
24. Once the specified preload is obtained, rotate the pinion several times in order to ensure the bearings are seated. Recheck the preload and adjust if necessary.
25. Install the thrust washers and side gears into the differential case. If reusing the original gears and washers, install the gears on the same side from which the parts were removed.
26. Install the pinion gears.
26.1. Position one pinion gear between the side gears. Rotate the gears until the pinion gear is directly opposite the opening in the case.
26.2. Place the other gear between the side gears. Ensure that the holes in both pinion gears are aligned.
27. Install the thrust washers. Rotate the pinion gears toward the opening in order to permit the thrust washers to slide in.
28. Install the shaft and the bolt.
29. Install the ring gear onto the differential case.
Important: Always install new bolts. Do not reuse the old bolts.
30. Install the ring gear mounting bolts.
^ Tighten the bolts, in progressive steps, to 80 Nm (59 ft. lbs.).
31. Install the side bearings using the J8092 and the J33790.
32. Install the bearing into the right sleeve using the 33788.
33. Install the bearing into the left sleeve using the J42211.
34. Install the sleeves into the carrier. Thread the sleeves in completely.
35. Install the side bearing cups into the carrier using the J23423-A and the J8092.
36. Install the differential case assembly to the carrier.
36.1. Place the differential case assembly into the carrier half that contains the pinion gear.
36.2. Turn the left sleeve in toward the differential case using the J42213 until backlash is felt between the ring and pinion gear.
37. Assemble the carrier halves. Do not use sealer at this time.
38. If the carrier halves do not contact completely, back out the right hand adjusting sleeve. Use the J33792.
39. Install the four carrier halves assembly bolts.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
40. Inspect and adjust the backlash. Refer to Backlash Inspection and Adjustment.
41. Inspect the gear tooth contact pattern. Refer to Gear Tooth Contact Pattern Check.
42. Remove the 4 case bolts.
43. Remove the right carrier case half.
44. Clean the sealing surfaces on the carrier case halves. Remove all oil and grease using a chlorinated solvent, such as carburetor cleaner.
45. Apply a bead of sealer (GM P/N 1052357 or equivalent) to one carrier half mounting surface.
46. Assemble the carrier halves.
47. Install the carrier halves assembly bolts.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
48. Ensure that the sleeves are positioned properly, as previously marked.
49. Install the bolts and lock tabs.
^ Tighten the bolts to 8 Nm (71 inch lbs.).
50. Clean all oil and grease from the left cover and seal assembly, the bolts and the carrier sealing surfaces using carburetor cleaner or equivalent.
51. Install the left cover and seal assembly.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
52. Install the bearing using the J42211 and the J8092.
53. Install the shaft seal using the J23911.
54. Install the shift housing seal using the J33799.
55. Install the clutch shaft pilot bearing using the J33842.
56. Install the washer to the clutch shaft.
57. Install the clutch shaft to the carrier assembly.
58. Install the clutch sleeve.
59. Install the thrust washer using grease in order to secure.
60. Install the spring with the shift shaft and fork.
61. Install the thrust washer using grease in order to secure. Align the notch and tab.
62. Install the inner axle shaft to the housing.
63. Install the clutch gear with the retaining ring. Tap into place.
63.1. Remove all oil and grease from the housing flange to carrier gasket surfaces using carburetor cleaner or equivalent.
63.2. Apply sealer (GM P/N 1052357 or equivalent) to the carrier.
64. Install the shaft and housing assembly to the carrier.
65. Install the two upper bolts finger-tight.
66. Install the shift cable housing and the remaining bolts.
^ Tighten the five bolts to 48 Nm (36 ft. lbs.).
67. Install the bushings using the J33791-1, the J33791-2 and the J33791-3.
68. Inspect the operation of the shift mechanism. Insert the J33798 into the shift fork.
69. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
70. The mechanism should operate smoothly. If not, remove the tube. Inspect for damaged or improperly installed parts.