Rear Axle Assemble 9.5 Inch Axle

Tools Required

1. Install the outer pinion bearing cup using the J 7818  (2) and the J 8092  (1).



2. Install the inner pinion bearing cup using the J 22306  (1) and the J 8092  (2).
3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment .



4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J 36614 .

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. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
8. Install the pinion into the axle housing.
9. Install the outer pinion bearing onto the pinion.



10. Install a new seal using the J 22388 .
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 J 8614-01 onto the pinion yoke as shown.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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
Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

17. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.



18. Place the differential case, with the bearing cups installed, into the axle housing.

Support the case in order to keep the case from falling out of the axle housing.




19. Install the bearing caps and the bolts.

Do not torque the bearing cap bolts at this time.

20. Turn the adjuster using the J 24429 until snug against the differential.
21. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment .



22. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal.

Tighten
Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N·m (3-5 lb in) greater than the rotating torque recorded during removal.

23. 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.
24. Adjust the backlash. Refer to Backlash Adjustment .
25. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
26. Tighten the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 85 N·m (63 lb ft).

27. Install the differential adjuster nut lock.
28. Install the differential adjuster nut lock bolt.

Tighten
Tighten the differential adjuster nut lock bolt to 26 N·m (19 lb ft).




29. Install the axle shaft bearing using the J 29709  (1) and the J 8092  (2).
30. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.



31. Install the axle shaft seal using the J 29713 .
32. 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.

33. Install the axle shaft (1) into the housing (5).
34. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
35. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
36. On axles with a locking differential, keep the pinion shaft partially withdrawn.



37. 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).
38. Pull the shaft flange outward in order to seat the lock in the differential gear.



39. Align the hole in the pinion shaft with the bolt hole in the differential case.
40. Install the new pinion shaft locking bolt.

Tighten
Tighten the pinion shaft locking bolt to 50 N·m (37 lb ft).




41. Install the rear axle housing cover (2) and a new gasket.

Important: Do not reuse the rear axle housing cover bolts.

42. Install the new rear axle housing cover bolts (1).

Tighten
Tighten the rear housing cover bolts in a crosswise pattern to 40 N·m (30 lb ft).




43. Install the drain plug.

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

44. Fill the axle using the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.



45. Install the fill plug.

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

Rear Axle Assemble 8.6 Inch Axle

Tools Required

1. Install the outer pinion bearing cup using the J 8611-01  (2) and the J 8092  (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. Refer to Pinion Depth Adjustment .



4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J 24433 .

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. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
8. Install the pinion into the axle housing.
9. Install the outer pinion bearing onto the pinion.



10. Install a new seal using the J 22388 .
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 J 8614-01 onto the pinion yoke as shown.

Notice: Refer to Fastener Notice in the Preface section.

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
Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

17. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.



18. Place the differential case, with the bearing cups installed, into the axle housing.



19. Install the bearing caps and the bolts.

Do not torque the bearing cap bolts at this time.

20. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment .



21. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal.

Tighten
Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N·m (3-5 lb in) greater than the rotating torque recorded during removal.

22. 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.
23. Adjust the backlash. Refer to Backlash Adjustment .
24. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
25. Tighten the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 75 N·m (55 lb ft).




26. Install the axle shaft bearing using the J 23690  (1) and the J 8092  (2).
27. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.



28. Install the axle shaft seal using the J 21128 .
29. 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.




30. Install the axle shaft (1) into the housing (5).
31. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
32. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
33. On axles with a locking differential, keep the pinion shaft partially withdrawn.



34. 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).
35. Pull the shaft flange outward in order to seat the lock in the differential gear.



36. Align the hole in the pinion shaft with the bolt hole in the differential case.
37. Install the new pinion shaft locking bolt.

Tighten
Tighten the pinion shaft locking bolt to 36 N·m (27 lb ft).




38. Install the rear axle housing cover (2) and a new gasket.

Important: Do not reuse the rear axle housing cover bolts.

39. Install the new rear axle housing cover bolts (1).

Tighten
Tighten the rear housing cover bolts in a crosswise pattern to 40 N·m (30 lb ft).




40. Install the drain plug, if equipped.

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

41. Fill the axle using the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.



42. Install the fill plug.

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