Unit Overhaul
Differential Carrier OverhaulDisassembly Procedure
Tools Required
- J 2619-01 Slide Hammer
- J 8763-02 Holding Fixture Cycles if Clamp
- J 8614-01 Pinion Flange Remover
- J 21551 Output Shaft Bearing Remover
- J 22888 Differential Side Bearing Remover
- J 29307 Slide Hammer
- J 33791 Bushing Remover
- J 33792 Slide Bearing Adjuster Wrench
- J 33837 Pinion Bearing Cup Remover and Installer
- J 34011 Pilot Bearing Installer
1. Remove the bolts, the shift cable housing, and the spring.
2. Remove the tube and the thrust washer.
3. Remove the spring and shift shaft with fork.
4. Remove the axle shaft.
5. Remove the carrier connector with retaining ring.
6. Remove the right seal and bearing using tools J 29369-01 and J 29307.
7. Remove the seal from the tube, prying with a screwdriver.
8. Remove the thrust washer.
9. Remove the sleeve and output shaft.
10. Remove the differential pilot bearing from the output shaft using J 34011.
11. Remove the washer.
12. Remove the shaft. Pull the output shaft out of the case using.
13. Remove the bolts and cover.
14. Remove the left seal.
15. Remove the bolts.
16. Separate the carrier case. Insert a screwdriver into the slots provided and pry to separate the case.
17. Remove the differential case.
18. Remove the bolts and lock tabs from the side bearing adjuster sleeves.
19. Remove the bearing cups and sleeves from the case.
20. Turn the sleeves until the cups are pushed out of the case using J 33792
21. Remove the bearing from the sleeve using J 21551.
22. Remove the pinion flange nut and washer using J 8614-01. Mount the left carrier case half in J 33837.
23. Remove the pinion flange and deflector using J 33837 and J 33837-3.
24. Remove the pinion with the spacer and the pinion bearing and shim.
25. Remove the spacer from the pinion.
26. Remove the bearing from the pinion with a press and J 22912-01.
27. Remove the shim.
28. Remove the bearing and seal using J 33837 , J 33837-3 and J 33837-6.
1. Insert J 33837-6 into the pinion bore.
2. Thread the forcing screw (J 33837-3) into J 33837-6.
3. In order to pull the parts from the case, turn the forcing screw.
29. Remove the inner bearing cup by pushing out using tools J 33837, J 33837-3 and J 33837-6.
30. Remove the bolt and shaft from the differential case.
31. Remove the differential pinion gears and the thrust washers.
32. Remove the side gears and the thrust washers. Mark the side gears and case for reinstallation in their original location.
33. Remove the bolts.
34. Remove the ring gear. Drive the gear off with a brass drift and hammer, do not pry between the ring gear and the case.
35. Remove the side bearings using J 22888.
36. Remove the case bushing using J 33791.
Differential Assembly Installation
Installation Procedure
Tools Required
- J 33788 Output Shaft Bearing Installer
- J 23423-A Bearing Cup Installer
- J 33792 Side Bearing Adjuster Wrench
1. Install the bearings into the sleeves using the J 33788.
2. Install the sleeves into the carrier case. Thread the sleeves in all the way.
3. Install the side bearing cups into the carrier case using the J 23423-A.
4. Install the differential assembly to the carrier case.
1. Place the differential case assembly into the carrier case half that contains the pinion gear.
2. Turn the left sleeve in toward the differential case using the J 33792 until backlash is felt between the ring and pinion gear.
5. Install the carrier case halves. Do not use sealer at this time.
6. If the carrier halves do not contact completely, back out the right hand adjusting sleeve. Use the J 33792.
7. Install the four bolts.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
Ring and Pinion Gear Inspection
1. The ring and pinion gears are matched sets and must be replaced any time a replacement of either is necessary.
2. Inspect the pinion and the ring gear teeth for the following conditions:
- Cracking
- Chipping
- Scoring
- Excessive wear
3. Inspect the pinion gear splines for wear.
4. Inspect the pinion flange splines for wear.
5. Inspect the fit of the pinion flange on the pinion gear.
6. Inspect the sealing surface of the pinion flange for nicks, burrs, or rough tool marks which will damage the inside diameter of the pinion seal and result in an oil leak.
7. Inspect all of the parts for wear and replace as necessary.
Differential Case Assembly Assemble
Installation Procedure
Tools Required
J 33790 Differential Side Bearing Installer
1. 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.
2. Install the pinion gears.
1. Position one pinion gear between the side gears. Rotate the gears until the pinion gear is directly opposite the opening in the case.
2. Place the other gear between the side gears. The hole in both pinion gears must be aligned.
3. Install the thrust washers. Rotate the pinion gears toward the opening in order to permit the thrust washers to slide in.
4. Install the shaft and the bolt.
5. Install the ring gear onto the differential case.
Important: Always install new bolts. Do not reuse the old bolts.
6. Install the differential case bolts.
Tighten
Tighten the bolts, in progressive steps, to 80 N.m (59 lb ft).
7. Install the side bearings using the J 33792.
Backlash Inspection and Adjustment
Tools Required
- J 33792 Side Bearing Adjuster Wrench J 8001 Dial Indicator Set
- J 25025-1 Dial Indicator Stand
1. Tighten the right sleeve using the J 33792.
Tighten
Tighten the right sleeve to 140 N.m (103 lb ft).
2. Tighten the left sleeve using the J 33792.
Tighten
Tighten the left sleeve to 140 N.m (103 lb ft).
3. Mark the location of the adjusting sleeves in relation to the carrier halves (1), in order to count the notches in the adjusting sleeves when turned.
4. Turn the right adjusting sleeve out two notches using the J 33792.
5. Turn the left adjusting sleeve in one notch using the J 33792.
6. Rotate the pinion several times in order to seat the bearings.
7. Install the J 34047, the J 25025-1, and the J 8001 (A4WD only).
8. Place the indicator stem at the heel end of a tooth (A4WD only).
9. Install a dial indicator so the button contacts the outer edge of the pinion flange. The plunger must be at a right angle to the pinion flange.
10. Move the pinion flange through the flange's free play while holding the differential carrier. Record the dial indicator reading.
11. Divide the dial indicator reading by two in order to obtain the actual backlash. For example, a dial indicator reading of 0.16 mm (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash.
12. Check and record the backlash at three or four points around the ring gear.
- Hold the pinion stationary when checking backlash.
- If the backlash varies more than 0.05 mm (0.002 in), check for the following conditions:
- Burrs
- A distorted case flange
- Uneven bolting conditions
- Foreign matter between the case and the ring gear
- Gear backlash should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred specification of 0.013- 0.018 mm (0.005-0.007 in).
- If the backlash is incorrect, adjust the sleeves as necessary. Maintain one notch preload on the side bearings. For example, if the right sleeve needs to be turned out one notch, turn out the left sleeve one notch.
- In order to increase backlash, turn the left sleeve in and turn the right sleeve out the same amount. In order to decrease backlash, turn the right sleeve in and turn the left sleeve out the same amount.
13. When the backlash is correct, mark the position of the sleeves in order to keep the sleeves in the same location.
Differential Carrier Final Assembly
Removal Procedure
1. Remove the 4 case bolts.
2. Remove the right carrier case half.
3. Clean the sealing surfaces on the carrier case halves. Remove all oil and grease using a chlorinated solvent, such as carburetor cleaner.
Installation Procedure
Tools Required
- J 33844 Axle Tube Bearing Installer
- J 33893 Axle Shaft Seal Installer
- J 22388 Pinion Oil Seal Installer
- J 33842 Pilot Bearing Installer
- J 33791 Bushing Remover and Installer
1. Apply a bead of sealer (GM P/N 1052357) or equivalent to one carrier case surface.
2. Install the right carrier case.
3. Install the bolts.
Tighten
Tighten the bolts to 47 N.m (35 lb ft).
4. Ensure that the sleeves are positioned properly, as previously marked.
5. Install the bolts and locks.
Tighten
Tighten the bolts to 8 N.m (71 lb in).
6. Fully support the seal bore area of the left seal to cover while installing.
7. Clean all oil and grease from the cover, bolts and carrier sealing surfaces using carburetor cleaner or equivalent.
8. Apply sealer (GM P/N 1052357) or equivalent to the cover.
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
9. Install and tap into place the shaft.
10. Install the bearing using tool J 33844.
11. Install the shaft seal using J 33893.
12. Install the shift housing seal using J 33796.
13. Install the differential pilot bearing using J 33842.
14. The washer to output shaft.
15. The output shaft to carrier assembly.
16. The sleeve.
17. The thrust washer using grease to secure.
18. The spring with shift shaft and fork.
19. Install the thrust washer using grease to secure, align the notch and tab.
20. The shaft to the tube.
21. The carrier connector with retaining ring, tap into place.
1. Remove all oil and grease from the tube and carrier gasket surfaces using carburetor cleaner or equivalent.
2. Apply sealer (GM P/N 1052357) or equivalent to the carrier.
22. Install the tube assembly to the carrier.
23. Install the two upper bolts, leave finger tight.
24. Install the shift cable housing and remaining bolts.
Tighten
Tighten the bolts to 47 N.m (35 lb ft).
25. Install the bushings using tool J 33791.
Inspection Procedure
Tools Required
J 33798 Hub Engagement Tool
1. Inspect the operation of the shift mechanism. Insert J 33798 into the shift fork.
2. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
3. The mechanism should operate smoothly. If not, remove the tube. Check for damaged or improperly installed parts.