Final Assembly

Differential Carrier Assembly - Final Assembly

^ Tools Required
- J 42738 Front Output Shaft Seal Installer
- J 33842 Pilot Bearing Installer
- J 33791 Carrier Case Bushing Installer
- J 42211 Inner Axle Shaft Housing Bearing Installer
- J 33799 Shaft Cable Housing Seal Installer





1. Install the differential adjuster nut lock tabs over the differential adjuster nut sleeves.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the differential adjuster nut lock tab bolts.
Tighten the differential adjuster nut lock tab bolt to 8 Nm (71 inch lbs.).
3. Remove the differential carrier assembly bolts.
4. Remove the right differential carrier case half.
5. 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.
6. Apply a bead of sealer (GM P/N 1052942 or the equivalent) to one differential carrier case half sealing surface.
7. Install the right differential carrier case half.
8. Install the differential carrier case bolts.
Tighten the differential carrier case bolts to 50 Nm (37 ft. lbs.).
9. Lubricate the clutch shaft pilot bearing with axle lubricant. Use the proper fluid.





10. Install the clutch shaft pilot bearing using the J 33842.
11. Install the clutch shaft thrust washer into the differential carrier assembly.
12. Install the clutch shaft to the differential carrier assembly.
13. Install the inner shaft seal cover.
14. Install the inner shaft seal cover bolts.
Tighten the inner axle shaft seal cover bolts to 25 Nm (18 ft. lbs.).
15. Install the new left side axle shaft seal using the J 42738.
16. Install the inner axle shaft retaining ring (A4WD only).
17. Install the left inner axle shaft (A4WD only).
Carefully tap the inner axle shaft into place with a soft mallet.





18. Install the differential carrier bushings using the J 33791.





19. Install the right side inner axle shaft housing bearing and the seal using the following procedure:
19.1. Install the bearing with the square shoulder in using the J 42211.
19.2. Install the new axle shaft seal using the J 42738.





20. Install the clutch cable housing seal using the J 33799 (S4WD only).





21. Install the new inner axle shaft retaining ring (A4WD only).
22. Install the inner axle shaft into the inner axle shaft housing.
23. Install the thrust washer into the inner axle shaft housing. Use chassis grease in order to hold the thrust washer in place (S4WD only).
Ensure the tabs on the thrust washer align with the slot in the inner axle shaft housing.
24. Install the new retaining ring into the clutch gear (S4WD only).
25. Install the clutch gear onto the inner axle shaft (S4WD only).
Drive the clutch gear into place with a plastic hammer.





26. Install the following components into the inner axle shaft housing (S4WD only):
^ The thrust washer (9)
^ The clutch fork inner spring (16)
^ The clutch fork (17)
^ The clutch fork sleeve (11)
27. Apply sealant (GM P/N 1052492 or equivalent) to the inner axle housing to differential carrier sealing surface.
28. Install the inner axle shaft housing to the differential carrier assembly.
29. Install the 2 upper inner axle shaft housing bolts (S4WD only). Tighten the bolts finger tight.
30. Install the 5 inner axle shaft housing bolts (A4WD only).
Tighten the inner axle shaft housing bolts to 48 Nm (36 ft. lbs.) (A4WD only).
31. The clutch cable retainer spring to the clutch fork (S4WD only).
32. Install the clutch cable housing (S4WD only).
33. Install the clutch cable housing bolts (S4WD only).
Tighten the inner axle shaft housing and the clutch cable housing bolts to 48 Nm (36 ft. lbs.).
34. Install the drain plug and the washer.
35. Install the fill plug and the washer.
Tighten the drain plug and the fill plug to 33 Nm (24 ft. lbs.).
36. Install the four-wheel drive indicator switch (S4WD only).
Tighten the four-wheel drive indicator switch to 5 Nm (44 ft. lbs.).