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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Front Drive Axle - 4WD >> Overhaul >> Differential Carrier >> Disassembly

Differential Carrier: Disassembly

  1. Remove differential carrier. See DIFFERENTIAL CARRIER  under REMOVAL & INSTALLATION. Remove bolts, shift cable housing and spring. Remove right axle housing, right axle shaft assembly and thrust washers. See RIGHT AXLE SHAFT & HOUSING  under REMOVAL & INSTALLATION.
  2. Remove shift fork assembly consisting of sleeve, springs and seals. See Figure.
  3. Remove right output shaft bearing using Bearing Remover (J-34011). Remove washer from right side of carrier assembly. Remove left side carrier cover bolts. Remove left side cover and seal assembly. Remove carrier halves assembly bolts. Insert screwdriver into slots provided. Pry to separate carrier.
  4. Remove differential assembly from carrier. See Figure. Remove bolts and lock tabs from side bearing adjuster sleeves. Remove bearing cups and sleeves from carrier. Using Side Bearing Adjusting Socket (J-42213), rotate left adjusting sleeve until cup is pushed out of carrier. Using Side Bearing Adjusting Socket (J-33792), rotate right adjusting sleeve until cup is pushed out of carrier.
  5. Remove side bearings from right adjusting sleeve using Bearing Remover (J-21551). Remove side bearing from left adjusting sleeve using Bearing Remover (J-36611). Mark pinion flange, pinion shaft and pinion nut to ensure alignment and bearing preload are maintained on installation. Record number of exposed threads on pinion shaft for reassembly. Using Pinion Yoke Holder (J-8614-01), remove pinion yoke nut and washer. Using Pinion Bearing Cup Remover (J-33837), remove pinion out of carrier from left carrier case half. See Fig 1. Remove pinion yoke and deflector. Remove pinion, spacer, pinion bearing and shim. Remove pinion spacer.
  6. Press bearing from pinion. Remove shim. Using Pinion Bearing Cup Remover (J-33837), remove outer pinion bearing, seal and cup. See Fig 2. Remove differential pinion bolt and shaft from differential case. Remove differential pinion gears and thrust washers. Mark side gears and case for reinstallation. Remove side gear and thrust washers. Remove ring gear bolts. Using brass drift, remove ring gear. DO NOT pry between ring gear and differential case. Using Differential Slide Bearing Puller (J-22888-20), remove side bearings. Using Bushing Remover (J-33791), remove case bushing.
Fig 1: Installing Pinion Holding Fixture Tool
G95H27083Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing Right Pinion Bearing Race
G95I27084Courtesy of GENERAL MOTORS CORP.
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