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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1013 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly - Disassemble (9.25 Inch Axle) >> Disassembly Procedure

Disassembly Procedure

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  1. Remove the upper differential carrier assembly bushing by performing the following steps:
    1. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown.
    2. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
      Fig 1: Removing The Upper Differential Carrier Assembly Bushing Using J 36616-2, J 33791-1, Thrust Bearing, J 21474-18 (9.25 Inch Axle)
      GM893247Courtesy of GENERAL MOTORS CORP.
  2. Remove the lower differential carrier assembly bushing by performing the following steps:
    1. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown.
    2. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
    3. Fig 2: Removing The Lower Differential Carrier Assembly Bushing Using J 21474-18, Thrust Bearing, J 33791-1, J 36616-2 (9.25 Inch Axle)
    GM892847Courtesy of GENERAL MOTORS CORP.
  3. Remove the front axle actuator.
  4. Remove the inner axle shaft housing to differential carrier assembly bolts.
    5. Fig 3: Removing Inner Axle Shaft Housing (9.25 Inch Axle)
    GM893264Courtesy of GENERAL MOTORS CORP.
  5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly.
    6. Fig 4: Removing Inner Axle Shaft Housing With Inner Axle Shaft (9.25 Inch Axle)
    GM893259Courtesy of GENERAL MOTORS CORP.
  6. Remove the following components from the inner axle shaft housing (4):
    1. The clutch fork inner spring (10)
    2. The clutch fork assembly (11)
    3. The clutch shaft shim (9)
    4. The clutch shaft sleeve (8)
    5. The retainer ring (7)
    6. The thrust washers (5, 6)
    7. Fig 5: Inner Axle Shaft Housing Components (9.25 Inch Axle)
    GM892812Courtesy of GENERAL MOTORS CORP.
  7. Remove the inner axle shaft (2).
    8. Fig 6: Removing Inner Axle Shaft (9.25 Inch Axle)
    GM615683Courtesy of GENERAL MOTORS CORP.
  8. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Install the inner axle shaft housing into a vise.

      Clamp only on the mounting flange of the inner axle shaft housing.

    2. Install the J 29369-2  (1) behind the inner axle shaft bearing.
  9. Install the J 2619-01  (2) to the J 29369-2  (1).
    10. Fig 7: Removing The Inner Axle Shaft Bearing And The Inner Axle Shaft Seal Using J 2619-01 & J 29369-2 (9.25 Inch Axle)
    GM834245Courtesy of GENERAL MOTORS CORP.
  10. Remove the inner axle shaft bearing and the inner axle shaft bearing and the seal using the J 2619-01  .
  11. Remove the inner axle shaft housing from the vise.
  12. Remove the front drive axle clutch shaft.
  13. Use the J 34011  in order to remove the clutch shaft bearing.
    14. Fig 8: Removing Clutch Shaft Bearing (9.25 Inch Axle)
    GM680254Courtesy of GENERAL MOTORS CORP.
  14. Place the differential carrier assembly into a vise.

    Clamp only on the mounting flange of the differential carrier assembly case.

  15. Remove the inner axle shaft using a hammer and a brass drift.
  16. Install the J 29369-2  (1) behind the inner axle shaft bearing.
  17. Install the J 2619-01  (2) to the J 29369-2  (1).
  18. Remove the inner axle shaft bearing and the inner axle seal bearing and the seal using the J 2619-01  .
    Fig 9: Removing The Inner Axle Shaft Bearing And The Inner Axle Seal Bearing (9.25 Inch Axle)
    GM1332786Courtesy of GENERAL MOTORS CORP.
  19. Remove the differential carrier assembly from the vise.
  20. Remove the vent connector.
    21. Fig 10: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  21. Remove the differential carrier assembly bolts.
    22. Fig 11: Removing Differential Carrier Assembly Bolts (9.25 Inch Axle)
    GM205917Courtesy of GENERAL MOTORS CORP.
  22. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case with a hammer and a brass drift.
  23. Remove the differential case assembly.

    Disconnect the right side differential bearing adjuster nut lock from the differential bearing adjuster nut by prying up on the lock.

  24. Remove the left side differential bearing adjuster nut lock and the bolt.
    25. Fig 12: Left Side Differential Bearing Adjuster Nut Lock & Bolt (9.25 Inch Axle)
    GM685960Courtesy of GENERAL MOTORS CORP.
  25. Remove the left side differential bearing adjuster by doing the following:
    1. Install the J 36615  onto the differential bearing adjuster nut as shown.
    2. Turn the J 36615  counterclockwise in order to remove the differential bearing adjuster nut and the O-ring.
    26. Fig 13: Removing Left Side Differential Bearing Adjuster (9.25 Inch Axle)
    GM680888Courtesy of GENERAL MOTORS CORP.
  26. Remove the right side differential bearing adjuster by doing the following:
    1. Install the J 36599-A  onto the differential bearing adjuster nut.
    2. Turn the J 36599-A  clockwise in order to push the bearing cup out of the bore.
  27. Remove the right side differential bearing adjuster nut sleeve using a hammer and brass drift.
    Fig 14: Removing Right Side Differential Bearing Adjuster (9.25 Inch Axle)
    GM680101Courtesy of GENERAL MOTORS CORP.
  28. Install the J 8614-01  as shown.

    Remove the pinion nut while holding the J 8614-01  .

    29. Fig 15: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS CORP.
  29. Remove the washer.
  30. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
    31. Fig 16: Removing Pinion Yoke
    GM664070Courtesy of GENERAL MOTORS CORP.
  31. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
  32. Install the J 45765  to the left side differential carrier case half over the drive pinion as shown.
    33. Fig 17: Installing J 45765 To The Left Side Differential Carrier Case (9.25 Inch Axle)
    GM847067Courtesy of GENERAL MOTORS CORP.
  33. Turn the forcing screw of the J 45765  clockwise to remove the following components from the left side differential carrier case half:
    • The drive pinion gear
    • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer
  34. Remove the drive pinion seal using a suitable seal remover.
  35. Remove the outer pinion bearing from the differential carrier case half.
  36. Install the J 45754-3 over the inner pinion bearing cup.
    37. Fig 18: Installing J 45754-3 Over The Inner Pinion Bearing Cup (9.25 Inch Axle)
    GM866062Courtesy of GENERAL MOTORS CORP.
  37. Install the forcing screw (1) of the J 45754 into the J 45754-3 (2).
    38. Fig 19: Installing J 45754 Forcing Screw Into J 45754-3 (9.25 Inch Axle)
    GM866059Courtesy of GENERAL MOTORS CORP.
  38. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
  39. Install the J 45754-2 (2) and the forcing screw (1) over the outer pinion bearing cup bore.
    40. Fig 20: Installing J 45754-2 & Forcing Screw (9.25 Inch Axle)
    GM866064Courtesy of GENERAL MOTORS CORP.
  40. Install the J 45754-4 (3) into the pinion bearing bore behind the outer pinion bearing cup.

    Slowly turn the forcing screw (1) until the J 45754-4 is evenly seated behind the outer pinion bearing cup bore and the J 45754-2 (2) is evenly seated over the outer pinion bearing cup bore.

    41. Fig 21: Forcing Screw, J 45754-2 & J 45754-4 (9.25 Inch Axle)
    GM866067Courtesy of GENERAL MOTORS CORP.
  41. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
  42. Install the J 22912-01  between the pinion bearing and the drive pinion.
  43. Remove the inner pinion bearing using the J 22912-01  and a hydraulic press.
    44. Fig 22: Removing Inner Pinion Bearing Using Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  44. Remove the pinion gear selectable shim.
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