Rear Axle - Assemble
Rear Axle - Assemble^ Tools Required
- J 21128 Axle Pinion Oil Seal Installer
- J 23690 Bearing Installer
- J 24433 Pinion Cone and Side Bearing Installer
- J 33782 Pinion Oil Seal Installer
- J 34178 Spreader Gage Adapter
- J 38694 Extension Housing Oil Pump/Seal Installer
- J 44685 Rear Axle Seal and Bearing Remover
- J 45222 Axle Housing Spreader
- J 7817 Outer Bearing Race Installer
- J 8001 Dial Indicator Set
- J 8092 Universal Driver Handle- 3/4 in - 10
- J 8608 Rear Pinion Bearing Race Installer
- J 8611-01 Rear Pinion Bearing Race Installer
- J 8614-01 Flange and Pulley Holding Tool
1. Install the outer pinion bearing cup using the J 7817, 8.0 inch axle, or the J 8611-01, 8.6 inch axle (2) and the J8092 (1).
2. Install the inner pinion bearing cup using the J 8608 (1) and the J 8092 (2).
3. Determine the selective shim thickness for the pinion.
4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J24433.
Press the bearing on until the cone seats on the pinion shim.
6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid.
8. Install the pinion into the axle housing.
9. Install the outer pinion bearing onto the pinion.
10. Install a new seal using the J33782, 8.0 inch axle, or the J 38694, 8.6 inch axle.
11. Apply sealant (GM P/N 12346004 or equivalent) to the splines of the pinion yoke.
12. Install the pinion yoke.
Align the marks make during removal.
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.
13. 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.
14. Install the washer and a new pinion nut.
15. Install the J8614-01 onto the pinion yoke as shown.
Notice: Refer to Fastener Notice in Service Precautions.
Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
16. Tighten the pinion nut while holding the J 8614-01.
^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
17. Measure the rotating torque of the pinion using an inch-pound torque wrench.
^ The rotating torque of the pinion should be 1.0 - 2.8 Nm (10 - 25 inch lbs.) (used bearings) or 1.7 - 3.4 Nm (15 - 30 inch lbs.) (new bearings).
18. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) (used bearings) or 1.7 Nm (15 inch lbs.) (new bearings), continue to tighten the pinion nut.
^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0 - 2.8 Nm (10 - 25 inch lbs.) (used bearings) or 1.7 - 3.4 Nm (15 - 30 inch lbs.) (new bearings).
19. 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.
20. Install the ring gear, if necessary.
21. Install the differential side bearings, if necessary.
22. Lubricate the differential side bearings with axle lubricant. Use the proper fluid.
23. Install the J 45222 to the axle housing as shown.
24. Install the J 8001-1 (2), the J 8001-2 (3), the J34178 (4, 6), and the J 8001-3 (5) as shown
25. Preload the J 8001-3 (5) approximately 3/4 of Et turn clockwise.
26. Rotate the indicator housing to align the indicator needle of the J 8001-3 (5) and the dial indicator face to ZERO.
27. Spread the axle housing by turning the clevis screw of the J34178 while observing the J 8001-3.
Spread the housing just enough to install the differential assembly. Do not spread the housing more than 1.02 mm (0.040 inch).
28. Place the differential case, with the bearing cups installed, into the axle housing.
29. Install the bearing caps and the bolts.
Do not torque the bearing cap bolts at this time.
30. Remove the J 8001-1, the J 8001-2, the J34178, and the J 8001-3.
31. Adjust the differential side bearing preload.
32. Adjust the backlash.
33. Perform a gear tooth contact pattern check.
34. Tighten the bearing cap bolts.
^ Tighten the bearing cap bolts to 75 Nm (55 ft. lbs.).
35. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2).
36. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.
37. Install the axle shaft seal using the J 21128.
38. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube.
Important: Carefully insert the axle shaft in order to not damage the seal.
39. Install the axle shaft (1) into the housing (5).
40. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
41. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
42. On axles with a locking differential, keep the pinion shaft partially withdrawn.
43. On axles with a locking differential, place the lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
44. Pull the shaft flange outward in order to seat the lock in the differential gear.
45. Align the hole in the pinion shaft with the bolt hole in the differential case.
46. Install the new pinion shaft locking bolt.
^ Tighten the pinion shaft locking bolt to 36 Nm (27 ft. lbs.).
47. Install the rear axle housing cover (2) and a new gasket.
48. Install the rear axle housing cover bolts (1).
^ For the 8.0 inch axle, tighten the rear axle housing cover bolts in a crosswise pattern to 30 Nm (20 ft. lbs.).
^ For the 8.6 inch axle, tighten the rear axle housing cover bolts in a crosswise pattern to 25 Nm (18 ft. lbs.).
49. Install the drain plug.
^ Tighten the drain plug to 48 Nm (35 ft. lbs.).
50. Fill the axle with axle lubricant. Use the proper fluid.
51. Install the fill plug.
^ Tighten the fill plug to 33 Nm (24 ft. lbs.).