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HOMESERVICE MANUALSCHEVROLET2006SUBURBAN C2500, 6.0 UREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1521 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY FINAL ASSEMBLY (8.25 F4WD AXLE)ASSEMBLY PROCEDURE
2006 Chevrolet Suburban C2500, 6.0 U

Assembly Procedure

2006 Chevrolet Suburban C2500, 6.0 USECTION Assembly Procedure
WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
  2. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
  3. Install the differential carrier assembly into a vise.
    4. Fig 1: View Of J 45225 & J 8092 Axle Shaft Seal Installation Tools - Front Drive Axle
    GM1486568Courtesy of GENERAL MOTORS CORP.
  4. Using the J 45225:  installer (1) and the J 8092:  handle (2), install the new left side axle shaft seal.
  5. Install the new left side inner axle shaft retainer ring.
  6. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
    7. Fig 2: View Of Left Side Inner Axle Shaft
    GM1332794Courtesy of GENERAL MOTORS CORP.
  7. 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.
  8. Using a soft-faced mallet, drive the inner shaft into the differential case side gear until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
  9. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
    10. Fig 3: Installing Side Bearing Using J 36609 & J 8092 -- Front Drive Axle
    GM834254Courtesy of GENERAL MOTORS CORP.
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.