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HOMESERVICE MANUALSCHEVROLET1999SUBURBAN C2500, 6.5 FREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDRIVE AXLE - FRONTREPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY - FINAL ASSEMBLY (8.25 F4WD AXLE)ASSEMBLY PROCEDURE

1999 Chevrolet Suburban C2500, 6.5 F

Assembly Procedure

1999 Chevrolet Suburban C2500, 6.5 FSECTION Assembly Procedure

Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
Remove the differential carrier assembly bolts.

Fig 1: Differential Carrier Assembly Bolts
Remove the right differential carrier case half.

Fig 2: Removing Differential Case Assembly
Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly.
The surfaces must be clean of all the grease and the oil.
Apply a bead of sealer to one differential carrier case half sealing surface. Use the correct sealer. Refer to Figure.
Install the right differential carrier case half.
Install the differential carrier case bolts.
Tighten

Tighten the differential carrier case bolts to 47 N.m (35 lb ft).
Install the vent hose connector.
Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent, onto the threads.

Tighten

Tighten the vent hose connector to 28 N.m (21 lb ft).

Fig 3: Installing Vent Hose Connector
Courtesy of GENERAL MOTORS CORP.
Install the new left side axle shaft seal using the J 36600 .
Install the new left side inner axle shaft retainer ring.
Install the left side inner axle shaft by doing the following:
1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear.
3. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
Fig 4: Installing Left Side Inner Axle Shaft
Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
1. Install the inner axle shaft housing into a vise.
  Clamp only on the mounting flange of the inner axle shaft housing.
2. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
Fig 5: Installing Bearing With Square Shoulder
Courtesy of GENERAL MOTORS CORP.
Install the new inner shaft seal using the J 36600 .
Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Figure.
Install the inner shaft housing to the differential carrier assembly case.
Install the inner shaft housing bolts.
Tighten

Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
Install the inner shaft (2) into the inner shaft housing (1) by doing the following:
1. Install the inner shaft into the inner axle shaft housing until the inner shaft is seated against the differential side gear.
2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear.
3. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
Fig 6: Axle Shaft & Inner Axle Shaft Housing
Install the drain plug and the washer.
Install the fill plug and the washer.
Tighten

Tighten the drain plug and the fill plug to 33 N.m (24 lb ft).
Install the lower differential carrier assembly bushing by performing the following steps:
1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
Fig 7: Install the lower differential carrier assembly bushing
Courtesy of GENERAL MOTORS CORP.
Install the upper differential carrier assembly bushing by performing the following steps:
1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
Fig 8: Installing Upper Differential Carrier Assembly Bushing
Courtesy of GENERAL MOTORS CORP.