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Front Axle Assembly: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. To install pinion bearing races, install left carrier case to holding fixture from Pinion Service Set (J-36598 ). See Fig 1. On K2, use Adapter Plate (J-36598-6 ). Lightly lubricate outer and inner pinion bearing races. Using Race Installer (J-36598-3 for K2; J-36598-4 for K3), press in outer pinion race and pull in inner pinion race until both are seated in housing. See Fig 1. Lubricate inner and outer bearings. Set pinion depth. See DRIVE PINION DEPTH  under ADJUSTMENTS.
    Fig 1: Installing Pinion Races
    G92I22283Courtesy of GENERAL MOTORS CORP.
  2. Install appropriate shim onto pinion. Shim size is determined during pinion depth adjustment. Using Pinion Bearing Installer (J-35512 for K2; J-36614 for K3), install inner pinion bearing onto pinion. Install NEW collapsible spacer onto pinion shaft. Lubricate outer pinion bearing, and install bearing and pinion seal into carrier case using Seal Installer (J-36366 ). Insert pinion, with attached inner bearing and collapsible spacer, into carrier case.
  3. Install deflector and pinion flange. Apply GM PST sealant to area where pinion threads meet pinion flange. Install pinion washer and nut. Install flange holder. Hold flange while slowly tightening nut and checking pinion flange until no end play is present. DO NOT  tighten nut any further.
  4. Rotate pinion several times to ensure bearings have been seated. Recheck end play. Set final pinion rotational preload to 15-25 INCH lbs. (1.7-2.8 N.m) by tightening pinion nut in small increments, testing pinion preload between increments. Each increment increases preload by several INCH lbs.
  5. If preload specification is exceeded, remove pinion and install NEW collapsible spacer. Once preload has been obtained, rotate pinion several times to ensure bearings have seated and recheck preload.
  6. Install side gears and thrust washers into differential case (on K3, install side gear spacer to left side). If old side gears are being reinstalled, place them in their original locations as marked during disassembly.
  7. Position one pinion gear between side gears and rotate gears until pinion gear is directly opposite opening in case. Place remaining pinion gear between side gears. Ensure holes in both pinion gears line up. Rotate pinion gears toward opening just enough to allow installation of thrust washers.
  8. Install differential pinion gear shaft. Install roll pin (or shaft bolt) through case and into pinion gear shaft. Install ring gear onto differential assembly. Tighten NEW bolts alternately in progressive steps to specification (left-hand thread). Refer to TORQUE SPECIFICATIONS .
  9. Press side bearings onto differential assembly using Adapter (J-8092 ) and Side Bearing Installer (J-22761 for K2; J-29710 for K3). Press bearings onto sleeves (and onto adjuster plug on left side of K3) using Adapter (J-8092 ) and Bearing Installer (J-36612 for K2; J-36613 for K3).
  10. On K3, install NEW "O" ring to adjuster plug. On all models, use sleeve adjusting wrench to install sleeves into carrier case (on left side on K3, install adjuster plug using adjuster plug wrench).
  11. Install side bearing races into carrier using Adapter (J-8092 ) and Race Installer (J-36603 ). Place differential assembly into left carrier case half. On K2, turn left sleeve inward until backlash is felt between ring and pinion. On K3, turn left adjuster plug inward until backlash is felt between ring and pinion.
  12. On all models, remove carrier case from holding fixture, and attach carrier halves together using 4 bolts. If halves DO NOT  make complete contact, back out right sleeve. Install carrier case bolts, and tighten to specification. Set ring gear backlash adjustment to specification. See RING GEAR BACKLASH  under ADJUSTMENTS.
  13. On K2, bend lock tabs over left and right sleeves. On K3, install left adjuster plug lock and bolt, and bend lock tab over right sleeve. On all models, remove 4 bolts holding axle carrier halves together and separate housing halves. Apply Sealant (GM 1052942 or Loctite 518) to one carrier housing surface.
  14. Reconnect axle carrier housing halves. Install 10 attaching bolts and tighten to specification. Refer to TORQUE SPECIFICATIONS . Using appropriate Seal Installer (J-36600 for K2; J-22833 for K3), install/drive seal into left side of carrier case. Install deflector onto left output shaft and insert shaft into left side of carrier. Drive shaft into place with a soft-faced mallet.
  15. Install NEW pilot bearing into right output shaft using Pilot Bearing Installer (J-33842 ). Insert right output shaft into right side of carrier. Apply Sealant (GM 1052942 or Loctite 518) to threads of vent plug. Install vent plug into left side of carrier.
  16. Install right axle tube and inner shaft assembly. See RIGHT AXLE TUBE & INNER AXLE SHAFT  under REMOVAL & INSTALLATION. To complete reassembly, reverse disassembly procedure.
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