Axle Carrier: Disassembly

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Remove axle carrier. See FRONT AXLE CARRIER ASSEMBLY under REMOVAL & INSTALLATION. Remove solenoid and indicator switch from right axle tube. Remove tube and inner shaft assembly. See RIGHT AXLE TUBE & INNER SHAFT under REMOVAL & INSTALLATION.
Remove sleeve, shift shaft, damper spring, shift fork, clip and inner spring. See Figure or Figure . Remove shim. Remove output shaft from right side of carrier assembly. Remove left output flange from carrier assembly by prying on one side with a screwdriver while simultaneously tapping outward on other side with a soft faced hammer. See Fig 1. Remove deflector.
Pry out left output flange seal with a screwdriver. Remove left and right output shaft bearings using Bearing Remover (J-29369-1) for K10/20 Series or (J-29369-2) for K30 Series. Remove bolts holding carrier halves together. Tap on lugs provided to separate carrier halves. Pry up on left and right side bearing locks (right side only on K30 Series) and remove differential assembly from carrier. On K30 Series, remove adjuster plug bolt and lock at left half of carrier.

Fig 1: Removing Left Output Flange
Courtesy of GENERAL MOTORS CORP.
Using Sleeve Remover (J-36599), rotate sleeve and push side bearings (right side only on K30 Series) out of bores. See Fig 2. On K30 Series, remove adjuster plug, bearing and "O" ring from left side of carrier by rotating adjuster plug using Adjuster Plug Remover (J-36615). See Fig 3.

Fig 2: Removing Bearing Using Sleeve Adjuster
Courtesy of GENERAL MOTORS CORP.

Fig 3: Removing Bearing Using Adjuster Plug Remover
Courtesy of GENERAL MOTORS CORP.
Using Pinion Flange Remover Set (J-8614-01), hold pinion flange stationary and remove pinion nut, flat washer and pinion yoke. See Fig 4. Remove pinion deflector. Mount left carrier case half in Holding Fixture from Pinion Service Tool Set (J-36598). Remove pinion with shim, inner bearing and spacer as an assembly. See Fig 5. Remove bearing spacer.

Fig 4: Removing Pinion Nut & Flange
Courtesy of GENERAL MOTORS CORP.

Fig 5: Pressing Pinion From Carrier
Courtesy of GENERAL MOTORS CORP.
Using Pinion Bearing Remover (J-8612-B) for K10/20 Series or (J-36606) for K30 Series, press bearing from pinion. See Fig 6. Remove shim from pinion. Using Holding Fixture and Pinion Service Tool Set (J-36598), remove seal and outer bearing from left half of carrier. See Fig 7. Use Adapter Plate (J-36598-6) on K10/20 Series. Remove bearing races using same service tool set.

Fig 6: Pressing Bearing From Pinion
Courtesy of GENERAL MOTORS CORP.

Fig 7: Removing Bearing & Seal From Carrier
Courtesy of GENERAL MOTORS CORP.
Using Puller (J-22888-D) and Adapter (J-8107-2) for K10/20 Series or (J-36597) for K30 Series, remove side bearings from differential assembly. See Fig 8. Remove ring gear bolts. Ring gear bolts are left-hand thread. Using a brass drift, drive ring gear from differential case. DO NOT pry ring gear from case. This will damage ring gear and case.
Using a punch and hammer, drive out roll pin from differential pinion gear shaft. Remove pinion gear shaft. On K30 Series, a bolt may be used in place of a roll pin. Roll pinion gears and thrust washers out of differential case.
Remove side gears and thrust washers, marking side gears and differential case as left and right for reassembly reference. On K30 Series, remove spacer. Using a 6-point socket, remove vent plug. Upper and lower carrier mounting bushings may be replaced using Remover/Installer (J-36616).

Fig 8: Removing Side Bearing From Differential
Courtesy of GENERAL MOTORS CORP.