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Installation Procedure

WARNING: This page is about a different car, the 2023 GMC Sierra 3500 HD and 2023 GMC Sierra 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
  1. GM5869172Courtesy 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 
    2. CAUTION:

    Refer to Component Fastener Tightening Caution .

  2. Front Differential Carrier Vent Hose Connector (1) - Install and tighten - Fastener Specifications 
  3. GM5864495Courtesy of GENERAL MOTORS COMPANY

    Using J-45754-1  and J-45754-2  , Install the front differential drive pinion gear outer bearing race (1).

  4. Using J-45754-1  and J-45754-2  , Install the front differential drive pinion gear inner bearing race (2).
  5. GM5823685Courtesy of GENERAL MOTORS COMPANY

    Measure the pinion shim (1) thickness needed, refer to Pinion Depth Adjustment .

  6. Install the pinion shim (1) onto pinion gear (2).
  7. GM5619762Courtesy of GENERAL MOTORS COMPANY

    Using DT-36614  Inner Pinion Bearing Installer (1) and a shop press, Install the differential drive pinion gear inner bearing (2).

  8. GM5619760Courtesy of GENERAL MOTORS COMPANY

    Front Differential Drive Pinion Gear Bearing Spacer (1) - Install NEW

  9. GM5864492Courtesy of GENERAL MOTORS COMPANY

    Front Differential Drive Pinion Gear (1) - Install

  10. GM5864491Courtesy of GENERAL MOTORS COMPANY

    Front Differential Drive Pinion Gear Outer Bearing (1) - Install

  11. GM5864489Courtesy of GENERAL MOTORS COMPANY

    Using GE-8092  Driver Handle (3) and DT-52761  Pinion and Output Seal Installer (2), Install NEW front differential drive pinion gear seal (1).

  12. GM5864486Courtesy of GENERAL MOTORS COMPANY

    Front Differential Drive Pinion Gear Yoke (1) - Install

  13. GM5864484Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

    CAUTION:

    Refer to Fastener Caution .

    Front Differential Drive Pinion Gear Washer (2) - Install

  14. Using J-08614 - A  Flange Holder Remover (1), Install NEW front differential drive pinion gear nut (3) hand tight.
  15. Tighten the front differential drive pinion gear nut (3) until there is no end play.
  16. Measure the rotating torque of the pinion using an inch-pound torque wrench. Continue tightening the front differential drive pinion gear nut (3) until specified rotating torque is obtained, refer to Fastener Specifications .
  17. 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.
  18. J-08614 - A  Flange Holder Remover (1) - Remove
  19. GM5864478Courtesy of GENERAL MOTORS COMPANY

    Front Differential (1) - Install

  20. GM5864477Courtesy of GENERAL MOTORS COMPANY

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

  21. Measure and adjust the carrier preload, refer to Differential Carrier Bearing Preload Adjustment .
  22. Measure and adjust the backlash, refer to Backlash Inspection and Adjustment .
  23. GM5864476Courtesy of GENERAL MOTORS COMPANY

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

  24. 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 
  25. Front Differential Carrier Cover Gasket (3) - Install
  26. Front Differential Carrier Cover (2) - Install
  27. Front Axle Housing Cover Bolt (1) - Install and tighten [12x] - Fastener Specifications 
  28. 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).

  29. GM5864360Courtesy of GENERAL MOTORS COMPANY

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

  30. Front Wheel Drive Shaft (2) - Install
  31. GM5864359Courtesy of GENERAL MOTORS COMPANY

    Front Drive Axle Clutch Shaft (1) - Install

  32. GM5840631Courtesy of GENERAL MOTORS COMPANY

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

  33. 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.

  34. 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.

  35. Subtract the measurement obtained in step 34 from the measurement obtained in step 33. Record calculation figure.
  36. Add 0.69 mm (0.027 in) to the calculation figure from step 35, 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.

  37. 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)
  38. GM5840631Courtesy of GENERAL MOTORS COMPANY

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

  39. Install NEW front drive axle inner shaft retaining ring (2).
  40. Install the front drive axle clutch sleeve (5), the correct size front drive axle clutch gear shim (6) determined in step 36, 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).
  41. GM5864358Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Cover Gasket (2) - Install NEW

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

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

  44. GM5864348Courtesy of GENERAL MOTORS COMPANY

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

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

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

    Front Axle (1) - Install

  47. GM5335440Courtesy of GENERAL MOTORS COMPANY

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

  48. GM5337579Courtesy of GENERAL MOTORS COMPANY

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

  49. GM5337582Courtesy of GENERAL MOTORS COMPANY

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

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

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

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

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

  55. Remove the hydraulic jack from under the front axle assembly.
  56. Have an assistant apply the brakes.
  57. 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
  58. Front Wheel Drive Half Shaft- Right Side - Reposition
  59. Install and Tighten the 8 front wheel drive shaft bolts (1) in a crisscross pattern. Fastener Specifications .
  60. 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
  61. Front Wheel Drive Half Shaft- Left Side - Reposition
  62. Install and tighten the 8 front wheel drive shaft bolts (1) in a crisscross pattern. Fastener Specifications .
  63. Have the assistant release the brakes.
  64. GM5336927Courtesy of GENERAL MOTORS COMPANY

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

  65. GM5792811Courtesy of GENERAL MOTORS COMPANY

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

  66. Connect the electrical connector to the actuator.
  67. GM5226586Courtesy of GENERAL MOTORS COMPANY

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

  68. GM5226576Courtesy of GENERAL MOTORS COMPANY

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

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

    Front Axle Propeller Shaft (3) - Install

  71. GM5659414Courtesy of GENERAL MOTORS COMPANY

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

  72. Front Axle Propeller Shaft Retainer (2) - Install NEW [2x]
  73. 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
  74. Front Axle Propeller Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
  75. GM5336033Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Oil Filler Plug (1) - Remove

  76. Inspect the axle lubricant level, it should be 0 - 6 mm (0 - 0.24 in) below the plug opening.
  77. 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 
  78. Front Differential Carrier Oil Filler Plug (1) - Install and tighten - Fastener Specifications 
  79. GM5225390Courtesy of GENERAL MOTORS COMPANY

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

  80. GM5225386Courtesy of GENERAL MOTORS COMPANY

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

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