GM 9422481
Inner Bearing

Start by unscrewing and removing the j 42168-9 (2) and corresponding thumbscrew from the j 42168-1 (1) rod of the Differential side bearing, then remove the actual bearing (J 42168-1 (1)) from the housing with precision. Set the dt-48009-2 on a vice, align the bearing cup (2) to it and insert the Differential case (1) into the bearing cup (2). After this, rotate the Differential in both directions to evenly fit the bearing into its groove. Insert the dt-48009-3 (2) into the hole of dt-48009-1 (1) and run the eccentric to lay against the bottom of the bearing race bore. Place the dt-48009-3 (2) under the ring gear of the Differential (1), holding it in place with a ring gear bolt and turn the Differential until the dt-48009-3 shaft (2) is above the dt-48009-2 gage block (3). Use a feeler gage to measure the distance between the dt-48009-3 (2) rod and the dt-48009-2 (3) gage block. Write down the value as dimension c1 and then subtract it from 3 mm (0.118 in) to obtain c2. Measure the distance from the ring gear side to the a2 point and record it as c3. Next, subtract the nominal value of 65.8 mm for d from the value for c3 to get c2 and then add the two together for the correct shim thickness on the left Differential bearing. Choose shims that are the closest match to your calculated thickness. Unscrew the Differential pinion housing/cage bolts and remove it and the housing from the Differential. Gently pull out the j 42168-11 (1), bearings (2 and 5), spacer (4) and dt-48009-1 (6) from the pinion housing/cage (3) with the assistance of the dt-48008. Place a dt-48008 mount, j 42170 pad and use a hydraulic press to mount the Differential shim and bearing race into the Differential housing. Afterward, affix the ring gear to the Differential while appropriately aligning with various bolts and employing a hammer and brass punch as needed. Use a torque wrench set to 195 n.m (144 lb ft) for the first design bolts or 145 n.m (107 lb ft) for the second design bolts to tighten the new ring gear bolts. Place the Differential assembly inside the j 42173, fit the Differential case into the Differential housing by means of the j 42155 and attach the bearing cup and j 42168-15 to the Differential. Take out the right cover oil seal and check that the pinion housing/cage has not yet been installed for the shim assessment. Bolt the right cover (2), the j 42168-16 bolts (1) and spacers (3) using 30 n.m (22 lb ft) of torque. Check the play between the bearings using a feeler gage inserted into the j 42168-15 part and loosen the bolts and cover to determine the appropriate shim for the right side bearing setup. Next, insert the right side bearing shim (2) and the bearing cup (1) into the right cover using the j 42170 tool and a hydraulic press.

To service and repair the carrier bearings remove the j 42168-9 and the thumbscrew from the j 42168-1 then remove the j 42168-1 from the bore of the Differential housing on the left bearing cup making sure the tool is level to take accurate measurements. Attach the dt-48009-2 to a vice, then fit the bearing cup to it and set the Differential case in place over the bearing cup, turning the Differential to locate the bearing with the race. Place dt-48009-3 in the j 42168-2 hole, back out the thumbscrew enough to get the rod touching the bottom of the bearing race hole, reinstall the dt-48009-3 and tighten the thumbscrew and remove the dt-48009-3 from j 42168-2. Cinch the dt-48009-3 to the ring gear side of the Differential using a ring gear bolt and rotate Differential until the rod is above the dt-48009-2 gage block, use upper gage block location for 2.56 Differential ratio or lower for 3.42 ratio differentials. Measure the distance between the rod of the dt-48009-3 and gage block and record as dimension c1, then subtract c1 from a nominal value of 5 mm and get c2. Find the a2 value on the side of the ring gear, keep in mind that it is not the same for a2 value 65.5 mm for 3.42 ratio differentials or 74.5 mm for 2.56 ratio differentials. Subtract the d nominal value from a2 to determine c3 and add c2 and c3 for the left side Differential Bearing shim thickness to pick shims equal to this computed value. Loosen pinion housing-cage bolts and remove pinion housing-cage from Differential and then remove j 42168-11, bearings, sparer and j 42168-2 from pinion housing-cage with the help of dt-48008 to support Differential housing in press. Apply the shim and bearing race selected to the Differential housing with the aid of the dt-48008, j 42170 and a hydraulic press and then fit the ring gear to the Differential with proper alignment against several bolts, or with the help of hammering and a brass punch if needed. Insert new ring gear bolts and tighten to 195 n.m for first design or 145 n.m for second design bolts, and install Differential assembly onto j 42173 and the j 42155 to place Differential case into housing. Fit the right side bearing cup and j 42168 15 to the Differential with oil seal taken out of right cover and the pinion housing-cage not fitted. Install correct cover and j 42168-16 bolts and spacers and tighten to 30 n.m, then measure the gap with a feeler gage to find the right side Differential Bearing shim size. Loose the bolts, cover and tool and install the chosen shim and bearing cup in the right cover with the j 42170 and hydraulic press.

Attach the ring gear to the differential, aligning it with several bolts, and use a hammer and brass punch if necessary to seat it properly. Install new ring gear bolts and position the differential assembly onto the J 42173, tightening the ring gear bolts to 145 N.m.