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HOMESERVICE MANUALSCHEVROLET2002AVALANCHE 2500, RWDREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDRIVE AXLES - FRONTREPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY - ASSEMBLEASSEMBLY PROCEDURE
2002 Chevrolet Avalanche 2500, RWD

Assembly Procedure

2002 Chevrolet Avalanche 2500, RWDSECTION Assembly Procedure
  1. Install the pinion bearing cups into the differential carrier assembly. Refer to PINION BEARING CUP INSTALLATION .
  2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
  3. Install the inner pinion bearing onto the pinion gear using the J 35512  , 8.25 inch axle, or the J 36614  , 9.25 inch axle.
    Fig 1: Installing New Collapsible Spacer Onto Pinion Gear
    G01455953Courtesy of GENERAL MOTORS CORP.
  4. Install the new collapsible spacer onto the pinion gear.
  5. Install the outer pinion bearing into the differential carrier case half.
  6. Install the pinion oil seal using J 36366  .
  7. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
  8. Lubricate the pinion bearings with axle lubricant. Use the correct sealant. Refer to Figure.
  9. Install the pinion yoke.
    NOTE: Refer to PINION FLANGE/YOKE INSTALLATION NOTICE .
  10. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
  11. Install the washer and a new pinion nut.

    If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed:

    1. Remove the pinion nut washer.
    2. Install the old pinion nut.
    3. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed.
    4. Remove the old pinon nut.
    5. Install the pinion nut washer.
    6. Install the new pinion nut.
  12. Install the J 8614-01  onto the pinion yoke as shown.
    Fig 2: Installing The J 8614-01 Onto The Pinion -- Front Axle
    GM664065
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.