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Installation Procedure

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 GMC Sierra, 2002 Chevrolet Tahoe, and 2002 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the differential carrier assembly.
  2. Install the differential carrier assembly lower mounting bolt and the nut.

    Do not tighten the bolt at this time.

    Fig 1: Installing Differential Carrier Assembly Lower Mounting Bolt And Nut
    G01455881Courtesy of GENERAL MOTORS CORP.
  3. Pivot the differential carrier assembly up and back on the lower mount bolt while it is being supported by the transmission jack.
  4. Install the differential carrier assembly upper mounting bolt and the nut.
    Fig 2: Installing Differential Carrier Assembly Upper Mounting Bolt And Nut
    G01455882Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  5. Install the inner axle housing washers and nuts to the bracket.

    Tighten 

    • Tighten the inner axle housing nuts to 100 N.m (75 lb ft).
    • Tighten the upper and the lower differential carrier assembly bolts to 100 N.m (75 lb ft).
    Fig 3: Installing Inner Axle Housing Washers And Nuts To Bracket
    G01455883Courtesy of GENERAL MOTORS CORP.
  6. Connect the vent hose to the differential carrier assembly.
    Fig 4: Connecting Vent Hose To Differential Carrier Assembly
    G01455884Courtesy of GENERAL MOTORS CORP.
  7. Remove the transmission jack.
  8. Connect the wire harness to the differential carrier assembly, S4WD axle only.
    Fig 5: Connecting Wire Harness To Differential Carrier Assembly
    G01455885Courtesy of GENERAL MOTORS CORP.
  9. Connect the wire harness to the inner axle shaft housing, S4WD axle only.
    Fig 6: Connecting Wire Harness To Inner Axle Shaft Housing, S4WD Axle Only
    G01455886Courtesy of GENERAL MOTORS CORP.
  10. Connect the electrical connector to the front axle actuator, S4WD axle only.
    Fig 7: Connecting Electrical Connector To Front Axle Actuator, S4WD Axle Only
    G01455887Courtesy of GENERAL MOTORS CORP.
  11. Install the wheel drive shaft inboard flange to inner axle shaft bolts, both sides.

    Tighten 

    Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).

    Fig 8: Installing Wheel Drive Shaft Inboard Flange To Inner Axle Shaft Bolts
    G01455888Courtesy of GENERAL MOTORS CORP.
  12. Install the relay rod. Refer to RELAY ROD REPLACEMENT .
  13. Install the front propeller shaft to the differential carrier assembly.
  14. Check the differential carrier assembly fluid level. Refer to LUBRICANT LEVEL INSPECTION - FRONT DRIVE AXLE .
  15. Install the front differential carrier assembly shield, if equipped. Refer to SHIELD REPLACEMENT .
  16. Install the engine protection shield. Refer to ENGINE PROTECTION SHIELD REPLACEMENT .
  17. Remove the utility stands.
  18. Lower the vehicle.
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