How to Rebuild a GM 9.25 Front Differential: 3/4 and 1 ton Chevy, GMC Trucks

This video describes in detail how to rebuild the front differential in any GM truck with an independent front suspension. Although this video specifically shows how to rebuild an AAM 9.25 front diff, you can use this video to rebuild your 8.25 front differential as well.
Consider buying your Rebuild kit through one of the following links to help support this channel! Note: I am an Amazon Associate and earn a small percentage from purchases made at any of the following Amazon links. The price is the same whether you use these links or not.
GM 9.25: amzn.to/2LW9EnE
GM 8.25: Yukon amzn.to/2LV445b
USA Standard amzn.to/3124uKu
I also used the following lubricants and adhesives:
3 Quarts Mobile 1 75w90 Full synthetic. amzn.to/2LV4cSd
Ultra Black Permatex Gasket Maker amzn.to/2YzUhHD
Thread Sealant amzn.to/2Yw4rcl
Gear Marking Compound amzn.to/2Kc9Ihe
Vaseline amzn.to/336WZ6U
Brakleen amzn.to/31a3Jz6
Here is a list of tools you likely won't have and should purchase:
Brass Punch amzn.to/31j2EVR
Dial Indicator with Stand amzn.to/2LVd2iy
Inch/lb torque wrench amzn.to/2Mx3slK
Kent Moore J36615A Spanner Wrench
2-Jaw Puller (mine is a Snap-On) amzn.to/2Ozgguu
Shop Press amzn.to/313PBaq
1 1/4 inch socket amzn.to/2YFMQ1q
Here are a lists of tools you may be able to find as a loaner tool at your local auto parts store. If not, I'm posting links to where you can buy them.
Axle Flange Puller amzn.to/2YCiugj
Slide Hammer amzn.to/317uUud
Bearing Separator amzn.to/2yxsFEc
Race Installer Set (Wish I had this bigger set) amzn.to/31dxXBl
(i had a smaller set like this: amzn.to/2LUr6cl)
Pilot Bearing Puller amzn.to/336ZR3G
Other Tools I used:
Air Ratchet amzn.to/2yxu0Le
Impact amzn.to/2YzgelR
Punch Set amzn.to/2GJGkNc
Sledge Hammer amzn.to/2SZFdh7
Deadblow Hammer amzn.to/2LVqPpI
Claw Hammer amzn.to/2GGKc1o
Torque Wrench amzn.to/2LU2Tmz
Dremel with Cut Off tool amzn.to/2YAlpq0
Socket set amzn.to/2SYMzl6
24mm socket amzn.to/2SZrHKE
Brass Hammer amzn.to/2ywHCq6
Parts Washer amzn.to/2GBGdTN
MAP Torch
Link to How To Remove Your Differential Video: • Video

[@mechanicdanimal]

This is a loaner tool. Then puts it in the press. I'm dying. That's awesome. I love it.

[@FarmDad]

🤟😁🤣🤣🤣

[@scottresch9912]

You are the most true to form realistic day garage mechanic I have seen. I will differ to you from now on on my gmc 3500 repairs if you have a video on it. Thank you for being a straight shooter.

[@FarmDad]

Really appreciate that. Means a lot to me.

[@mr.thomas7590]

I respect your hard work and dedication to this job. I watched it and learned a lot. Gonna rebuilt my 8.25 this spring! Peace and Blessings. I am subscribing.

[@FarmDad]

Thanks! It's definitely a job but will save you a bunch of money.

[@oldpartsnrust]

Great Job!!! Hope she holds up for you. I am in the middle of doing mine using your video. I had the transfer case replaced about 5 yrs ago and they left off the front driveshaft boot. This caused the front driveshaft to seize in the transfer case output shaft and it then hammered the output shaft bearings in the transfer case as well as the pinion bearings in the front diff. Unexpected, expensive repairs. I decided to attempt all myself and videos like yours are a fantastic help!

[@FarmDad]

Only way to know a job is done right is to do it yourself. This one was done 11 months ago and is working flawlessly. I use my 4-wheel drive daily too as we have a 90 acre farm that's only accessed by miles of dirt roads.

[@oldpartsnrust]

@@FarmDad I hear you! I was a professional mechanic for 20 or so years until I hurt my spine. I can't even count the number of times where I had to rework what someone else had done. Glad to hear it's going strong. I had to do this as part of a frame swap and still think it's worth it considering the "quality" of what they are making nowadays. Seems everything is now half as strong and fails right after the warranty!

[@mrmotofy]

@@oldpartsnrust Yep they can pretty much everything so exact these days I swear it engineered obsolescence and failures. But a lot can be avoided by changing fluids.

[@fatt-ass-pro]

DADs FIX THINGs...!!! GREAT INFO... NAILED IT...!!!

[@FarmDad]

Yes we do. Thanks!

[@pacora07]

I am doing the same job on a 2004 chevy astro. and you made a good point, since you are using the same gears and all that, I just do not see the reason to put paint marking on the gear.and trying to do if would were rebuilding the rear differential where is more to it, but your video gave a couple ideas for my project.

[@FarmDad]

Glad you found some helpful things here 👍👍

[@IBWatchinUrVids]

Great video, thanks for taking the time to show all the details.

[@FarmDad]

Glad it helped!

[@7362Carlos]

Thanks for showing these I learn very much.

[@FarmDad]

Glad to do it! Appreciate you.

[@davewolf8869]

Nice video!

[@FarmDad]

Thanks! 😁

[@paulwhite8265]

Old school! Love it. Thanks for the great video.

[@FarmDad]

Most welcome!

[@Dark_Knight_USA]

"Old school"?

[@rodleypumpkins4174]

I’m about to attempt this and man you make it look about as hard as I figured it would be. Torches and home made tools lol.

[@spelunkerd]

This was really helpful, nice job!

[@FarmDad]

Thanks! Glad to hear it!

[@mrmotofy]

For that shop press get the Harbor Freight Pneumatic bottle jack, it makes life so much more convenient

[@FarmDad]

That's definitely a nice upgrade.

[@jacojanks5985]

Great video. I just did a 8.25 and had a hell of a time removing and installing the pinion races. Seating was stripping out 1/2” all thread. Ended up hammering and pressing. It was a pain.

[@FarmDad]

That's my least favorite part of the whole job.

[@derrickmendoza4173]

This vid helped a ton. You got yourself all other subscriber

[@FarmDad]

Glad to hear it! Appreciate you!

[@SWTWHITEGSR]

Good video didn’t see you add oil on bearings for pinion. But very detailed video .

[@FarmDad]

Thank you.

[@brentfrederick6576]

You need to put the silicone inside the bolt holes. When you put the silicone on first you get your hands and parts in it.

[@davidhatzenbuhler6888]

Always wear a glove or wrap the pinion with a rag. It'll make it easier to avoid dropping it on the floor and slicing up your paw.

[@FarmDad]

Agreed! Haha

[@xXxjoemanxXx]

How bad would it be to replace the driver axle without the retaining ring, my ring broke and don’t really want to wait for the dealership to get it plus without it I assume replacing the seal would be easier in the future

[@ShaunStuto]

I was warned when opening the case that I could screw up the timing. How do I prevent this? Thank you!

[@matthewberry2953]

Very informative video. I have an 05 Chevy 2500 HD. I was wanting to know, and Ive been searching, if there was anything that can help with the front end? I was having my front diff worked on and I was asking if there can be a locker or a limited slip installed. Everyone was saying that because it is an IFS, whatever is in there is in there and cannot be swapped. Any thoughts?

[@FarmDad]

You can get a locker. It's been awhile, but last I checked, they don't make e-lockers anymore so you have to get an air one.

[@Nadimarco90]

Hey great job man will this work for 02 Escalade front diff

[@kevinday4490]

Dude that looks like it took you 5 weeks to do, but thank you for putting this video on here. I am considering tackling this project on my LBZ but I'm still nervous about it since I've never done anything with an axle. Most worrying part is setting backlash and checking the pattern. I'd like to find a book on doing this so I can really keep track of each step so if you know of any it would be really helpful.

[@kevinday4490]

P.S. I hit that subscribe button just for the fact you have this video.

[@FarmDad]

Thank you! I don't know of any good books, unfortunately. It definitely took me longer than I wanted, but that was mostly because of constant interruptions from my 4 kids.

[@shanerproductions]

How did you hold the yoke/pinion when trying to crush the pinon sleeve, I cannot get mine crushed to save my life!

[@500hardcore]

Thanks for the video. @ 1:11:00 is that bearing the same size as the shaft/tube bearings?

[@neighborhoodlawncare9872]

My question is, what made you decide too work on such a hard project. I’m having troubles with my four wheel drive and happen to come across your video. But I don’t remember why you took this project on. Did you just want to upgrade some parts or was this a project you been meaning to tackle awhile ago. I will be a subscriber cause your video is well put. Thanks for the pointers. I have a feeling this is my next project.

[@FarmDad]

I was getting a grinding noise coming from the differential because a bearing had gone bad. I regret not putting a locker in it while I was in there because I now live on a super muddy red clay road.

[@neighborhoodlawncare9872]

@@FarmDad mine started last week out of no where. Thought I had to reprogram the code. What a nightmare that was. The re-code helped a little but that sound is still there. After watching your videos everything makes sense. Great job on improvising tools , its like you read my mind. Lets just hope my bearing are the only thing that is wrong with mine. Glad to of subscribed to your channel, I am in the same boat as you when it comes to fixing my truck. Who knew kids would be such a distraction...... but we always get it done.

[@FarmDad]

@@neighborhoodlawncare9872 exactly. Good luck with the job.

[@David-yy7lb]

Those differentials have a weak link and it's the powdered metal disconnect sleeve how I know I busted mine snow plowing so I surfed the internet and found a billet metal disconnect sleeve and it's much stronger than the powdered metal sleeve

[@blairjosephbernard2011]

Can you also put a locker kit in them as well just wondering

[@FarmDad]

Yes sir. I regret not putting one in mine. I didn't have the money at the time, but now I live off a red clay road and it would be useful on muddy days when I'm pulling my dump trailer.

[@insane97ram]

I just took mine apart. A large washer fell out when I was moving that inner sleeve to punch the shaft out. Any idea where that goes

[@FarmDad]

Man, I hate when that happens. I don't know off hand, but I bet you'll get it figured out. There's probably parts diagrams online somewhere too

[@tommypelletier4781]

@@FarmDad I ended up figuring it out. When I slid the pin down to punch the drivers side shaft out the washer/spacer fell out of one of the 4 gears in the center. Figured it out once I got it all apart. This video was perfect. Just got my truck back together yesterday and all is working well.

[@quackster970]

Do you know where i can buy the inner axel a connector gear

[@VanquisherUSMC]

Jokes on me, you time traveler! I saw the watch and sweatshirt!!!

[@FarmDad]

Yeah, I am a stay-at-home of 4 kids so projects like this get tackled a little at a time, whenever I can sneak out to the garage.

[@jdonez8347]

😂😂😂 stuck on tryin to pull the gear off that exposes the clip holding the axle on the passenger side...anyone have a puller part number I can buy? 😅😅

[@caseynagy9098]

Where can I get a complete rebuild kit

[@FarmDad]

I should have links in the video description.

[@shimaze5479]

Sure am glad the crocks didn't last too long! That was really bothering me a lot. Men should never wear crocks! ...It's just wrong

[@FarmDad]

Haha, they're perfect for slipping on and off when you are constantly running in and out of the house to check on the kids. Real men don't give a crap about what they look like, lol.

[@shimaze5479]

@@FarmDad Its all good. You can wear whatever you want. I just couldn't let it go unnoticed :-)

[@Realmccoymowers]

I see both sides of this

[@lionelyarde7465]

P

[@lionelyarde7465]

Ll

[@jimbob6048]

Good informative video…………. do you don’t own a table? Neanderthal way of working

[@Dark_Knight_USA]

Greetings: Real 4x4s do not have IFS.