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Installation Procedure

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  1. GM5873283Courtesy of GENERAL MOTORS COMPANY

    Using J-29710  Differential Side Bearing Installer (4) and a shop press, Install the 2 differential bearing cones (1) onto the front differential bearing adjuster (2).

  2. GM5873281Courtesy of GENERAL MOTORS COMPANY

    Using GE-8092  Driver Handle (2) and J-36603  Side Bearing Cup Installer (3), Install the 2 differential bearing cups (1) into the differential case.

  3. GM5864478Courtesy of GENERAL MOTORS COMPANY

    Front Differential (1) - Install

  4. GM5864477Courtesy of GENERAL MOTORS COMPANY

    Front Differential Bearing Adjuster (1) - Install [2x]

  5. Measure and adjust the carrier preload, refer to Differential Carrier Bearing Preload Adjustment .
  6. Measure and adjust the backlash, refer to Backlash Inspection and Adjustment .
  7. GM5864476Courtesy of GENERAL MOTORS COMPANY

    Front Differential Bearing Adjuster Nut Lock (1) - Install [2x]

  8. GM5864364Courtesy of GENERAL MOTORS COMPANY

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers 
  9. Front Differential Carrier Cover Gasket (3) - Install
  10. Front Differential Carrier Cover (2) - Install
    11. CAUTION:

    Refer to Fastener Caution .

  11. Front Axle Housing Cover Bolt (1) - Install and tighten [12x] - Fastener Specifications 
  12. GM5864362Courtesy of GENERAL MOTORS COMPANY

    Using the large end of DT-52761  Pinion and Output Seal Installer (2) and GE-8092  Driver Handle (3), Install New front wheel drive shaft seal (1).

  13. GM5864360Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Shaft Retaining Ring (1) - Install NEW

  14. Front Wheel Drive Shaft (2) - Install
  15. GM5864359Courtesy of GENERAL MOTORS COMPANY

    Front Drive Axle Clutch Shaft (1) - Install

  16. GM5840631Courtesy of GENERAL MOTORS COMPANY

    Install the front wheel drive shaft (1) into the front drive axle inner shaft housing (3).

  17. GM5840655Courtesy of GENERAL MOTORS COMPANY

    Measure the distance from the end of the front wheel drive shaft (1) to the machined surface of the front drive axle inner shaft housing (2). Record the measurement.

  18. GM5864496Courtesy of GENERAL MOTORS COMPANY

    Measure the distance from the end of the front drive axle clutch shaft (1) to the machined surface of the front differential carrier (2). Record the measurement.

  19. Subtract the measurement obtained in step 18 from the measurement obtained in step 17. Record calculation figure.
  20. Add 0.69 mm (0.027 in) to the calculation figure from step 19, this is the correction factor for the compressed gasket. Record calculation figure.

    This is the shim thickness needed for zero front wheel drive shaft end play.

  21. The correct shim size will be one size smaller than the calculation figure obtained in the previous step.

    Front Drive Axle Clutch Gear Shim Sizes

    • 1.30 mm (0.05 in)
    • 1.52 mm (0.06 in)
    • 1.80 mm (0.07 in)
    • 2.03 mm (0.08 in)
    • 2.30 mm (0.09 in)
    • 2.54 mm (0.10 in)
    • 2.80 mm (0.11 in)
    • 3.05 mm (0.12 in)
    • 3.30 mm (0.13 in)
    • 3.55 mm (0.14 in)
    • 3.80 mm (0.15 in)
    • 4.05 mm (0.16 in)
    • 4.30 mm (0.17 in)
    • 4.55 mm (0.18 in)
    • 4.80 mm (0.19 in)
  22. GM5840631Courtesy of GENERAL MOTORS COMPANY

    Install the original front drive axle clutch gear thrust washer (4) onto the front wheel drive shaft (1).

  23. Install NEW front drive axle inner shaft retaining ring (2).
  24. Install the front drive axle clutch sleeve (5), the correct size front drive axle clutch gear shim (6) determined in step 20, front drive axle clutch fork (8), and the front drive axle clutch fork inner spring (7), into the front drive axle inner shaft housing (3).
  25. GM5864358Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Cover Gasket (2) - Install NEW

  26. Front Drive Axle Inner Shaft Housing (1) - Install
  27. GM5864357Courtesy of GENERAL MOTORS COMPANY

    Front Drive Axle Inner Shaft Housing Bolt (1) - Install and tighten [6x] - Fastener Specifications 

  28. GM5864348Courtesy of GENERAL MOTORS COMPANY

    Apply sealant to the threads of the front drive axle actuator (1). Adhesives, Fluids, Lubricants, and Sealers 

    29. CAUTION:

    Refer to Component Fastener Tightening Caution .

  29. Front Drive Axle Actuator (1) - Install and tighten - Fastener Specifications 
  30. GM5337585Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The front axle may have to be maneuvered to install it into the vehicle.

    Front Axle (1) - Install

  31. GM5335440Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications 

  32. GM5337579Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bracket- Left Side (2) - Install

  33. GM5337582Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bolt (1) - Install and tighten - Fastener Specifications 

  34. Raise the front axle assembly into position with a jack.
  35. GM5337579Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bracket Bolt (3) - Install [2x]

  36. Front Differential Carrier Bracket Nut (1) - Install [2x]
  37. Front Differential Carrier Bracket Bolt (3) - Tighten [2x] - Fastener Specifications 
  38. GM5337584Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bolt (1) - Install and tighten [2x] - Fastener Specifications 

  39. Remove the hydraulic jack from under the front axle assembly.
  40. Have an assistant apply the brakes.
  41. GM5283640Courtesy of GENERAL MOTORS COMPANY

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
  42. Front Wheel Drive Half Shaft- Right Side - Reposition
  43. Install and Tighten the 8 front wheel drive shaft bolts (1) in a crisscross pattern. Fastener Specifications .
  44. GM5282811Courtesy of GENERAL MOTORS COMPANY

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
  45. Front Wheel Drive Half Shaft- Left Side - Reposition
  46. Install and tighten the 8 front wheel drive shaft bolts (1) in a crisscross pattern. Fastener Specifications .
  47. Have the assistant release the brakes.
  48. GM5336927Courtesy of GENERAL MOTORS COMPANY

    Install the front axle vent hose (1) to the front axle vent hose connector.

  49. GM5792811Courtesy of GENERAL MOTORS COMPANY

    Reposition the wiring harness and connect the 3 retainers (1).

  50. Connect the electrical connector to the actuator.
  51. GM5226586Courtesy of GENERAL MOTORS COMPANY

    Drivetrain and Front Suspension Frame Front Crossmember (1) - Install

  52. GM5226576Courtesy of GENERAL MOTORS COMPANY

    Drivetrain and Front Suspension Frame Reinforcement Bolt (1) - Install [4x]

  53. Drivetrain and Front Suspension Frame Reinforcement Nut (2) - Install and tighten [4x] - Fastener Specifications
  54. GM5659419Courtesy of GENERAL MOTORS COMPANY

    Front Axle Propeller Shaft (3) - Install

  55. GM5659414Courtesy of GENERAL MOTORS COMPANY

    Align the reference marks made between the front axle propeller shaft and the front axle drive pinion flange.

  56. Front Axle Propeller Shaft Retainer (2) - Install NEW [2x]
  57. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
  58. Front Axle Propeller Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
  59. GM5336033Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Oil Filler Plug (1) - Remove

  60. Inspect the axle lubricant level, it should be 0 - 6 mm (0 - 0.24 in) below the plug opening.
  61. If the level is low, add axle lubricant until the level is 0 - 6 mm (0 - 0.24 in) below the plug opening. Use the appropriate axle lubricant: Adhesives, Fluids, Lubricants, and Sealers 
  62. Front Differential Carrier Oil Filler Plug (1) - Install and tighten - Fastener Specifications 
  63. GM5225390Courtesy of GENERAL MOTORS COMPANY

    {If equipped} Underbody Skid Shield (1) - Install

  64. GM5225386Courtesy of GENERAL MOTORS COMPANY

    {If equipped} Underbody Skid Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications

  65. {If equipped} Underbody Splash Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
  66. Remove the support and lower the vehicle.
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