Differential Carrier Assembly - Final Assembly

Tools Required

• J 36609  Axle Tube Bearing Installer. See Special Tools and Equipment .
• J 45225  Axle Seal Installer. See Special Tools and Equipment .
• J 45755  Front Axle Bushing Remover/Installer - 9. See Special Tools and Equipment .25 inch Axle
• J 8092  Universal Driver Handle - 3/4 in - 10. See Special Tools and Equipment .

Fig 1: Bending Right Side Differential Adjuster Nut Lock Tab Over Differential Adjuster Nut Sleeve
Courtesy of GENERAL MOTORS CORP.
1. Bend the right side differential adjuster nut lock tab over the differential adjuster nut sleeve.
Fig 2: Differential Adjuster Nut Lock
Courtesy of GENERAL MOTORS CORP.
2. Install the differential adjuster nut lock.
Fig 3: Differential Adjuster Nut Lock Bolt
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the differential adjuster nut lock bolt.

   Tighten:  Tighten the differential adjuster lock nut bolt to 20 N.m (15 lb ft).

4. Remove the differential carrier assembly bolts.
5. Remove the right differential carrier case half.
6. 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.

7. Apply a bead of sealer to one differential carrier case half sealing surface. Use the correct sealer. Refer to Sealers, Adhesives, and Lubricants .
8. Install the right differential carrier case half.
9. Install the differential carrier case bolts.

   Tighten:  Tighten the differential carrier case bolts to 47 N.m (35 lb ft).

10. Install the upper differential carrier assembly bushing into the upper differential carrier assembly bushing bore.
Fig 4: Installing J 45755-2, J 45755-1, Forcing Screw, Bearing & Washers Over Differential Carrier Assembly Bushing
Courtesy of GENERAL MOTORS CORP.
11. Install the J 45755-2 (2), J 45755-1 (3), and the forcing screw, bearing and washers (1) over the differential carrier assembly bushing as shown.
12. Press the bushing into the differential carrier assembly bushing bore using the J 45755  . See Special Tools and Equipment .
Fig 5: Differential Carrier Assembly & Hole Plug
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
13. Install the differential carrier hole plug.

    Tighten:  Tighten the differential carrier hole plug to 28 N.m (21 lb ft).

14. Install the new axle shaft seal using the J 45225  and the J 8092  . See Special Tools and Equipment .
15. Install the left side inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
16. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
Fig 6: Installing Bearing With Square Shoulder Using J 36609 & J 8092
Courtesy of GENERAL MOTORS CORP.
17. Install the right side inner axle shaft bearing by performing the following steps:
    1. Install the inner axle shaft housing into a vise.
    2. Install the bearing with the square shoulder in using the J 36609  (1) and theJ 8092  (2). See Special Tools and Equipment 
Fig 7: Installing New Axle Shaft Seal Using J 45225 & J8092
Courtesy of GENERAL MOTORS CORP.
18. Install the right side inner axle shaft seal by performing the following steps:
    • Install the inner axle shaft housing into a vise.
    • Install the new axle shaft seal using the J 45225  and theJ 8092  . See Special Tools and Equipment .
Fig 8: Install Inner Axle Shaft Into Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
19. Install the inner axle shaft into the inner axle shaft housing.

    Carefully tap the inner axle shaft into place with a soft-faced mallet.

20. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealer. Refer to Sealers, Adhesives, and Lubricants .
Fig 9: Inner Axle Housing & Inner Axle Shaft
Courtesy of GENERAL MOTORS CORP.
21. Install the inner axle shaft housing to the differential carrier case.
Fig 10: Inner Axle Shaft Housing & Differential Carrier Assembly Bolts
Courtesy of GENERAL MOTORS CORP.
22. Install the inner axle shaft housing bolts.

    Tighten:  Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).

NOTE: Refer to Fastener Notice in Cautions and Notices.
23. Install the drain plug and the washer.

    Tighten:  Tighten the drain plug to 33 N.m (24 lb ft).

24. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle .
25. Install the fill plug and the washer.

    Tighten:  Tighten the fill plug to 33 N.m (24 lb ft).