Differential Carrier Final Assembly A4WD

1. Remove the four case bolts.
2. Remove the right carrier case half.
3. Clean the sealing surfaces on the carrier case halves. Remove all the oil and grease. Use a chlorinated solvent, such as carburetor cleaner.

Tools Required

1. Apply a bead of sealer (GM P/N 1052357 or equivalent) to one carrier half mounting surface. Follow the sealer manufacturer's instructions to apply the sealer.
2. Assemble the carrier halves.

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.

3. Install the carrier halves assembly bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

4. Ensure that the sleeves are positioned properly, as previously marked .



5. Install the bolts and the lock tabs.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

6. Clean all the oil and grease from the left cover and seal assembly, the bolts and the carrier sealing surfaces. Use carburetor cleaner or equivalent.
7. Apply sealer (GM P/N 1052357 or equivalent) to the cover.
8. Install the left cover and seal assembly.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

9. Install the left output shaft. Tap into place.



10. Install the bearing. Use the J 42211 and the J 8092 .



11. Install the seal. Use the J 23911 .
12. Install the inner axle shaft housing to the carrier.
13. Install the inner axle shaft housing to carrier bolts.

Tighten
Tighten the bolts to 48 N·m (36 lb ft).

14. Install the axle shaft. Tap into place using a soft-faced hammer.



15. Install the case bushings. Use the J 33791 -1, J 33791-2, and J 33791-3.