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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1040 (Rear Drive Axle) >> Repair Instructions >> Differential Replacement (8.6 Inch, 9.5 Inch Axles) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the carrier with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the carrier.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (8.6 Inch, 9.5 Inch Axles)  or Rear Axle Shaft Replacement (9.75 Inch Axle) .
  3. Remove the differential bearing adjuster nut lock (9.5 inch axle - right side).
    4. Fig 1: Differential Bearing Adjuster Nut Lock
    GM667492Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Differential Case Removal Caution in Cautions and Notices.
  4. Remove the bearing cap bolts.
    5. Fig 2: Removing/Installing Bearing Cap Bolt
    GM667502Courtesy of GENERAL MOTORS CORP.
  5. Remove the bearing caps. Mark the bearing caps left and right.
  6. For the 8.6 inch axle, install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.
    7. Fig 3: Pinion Shaft Contacting Axle Housing Top
    GM156411Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Differential Housing Cover and Gasket Removal Notice in Cautions and Notices.
  7. For the 8.6 inch axle, rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.
  8. For the 9.5 inch axle, loosen the differential bearing adjuster nut using the J 24429  .
  9. Remove the differential assembly.
  10. Remove the bearing cups, the shims, and the spacers as necessary.

    Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

  11. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement (All Except 9.75 Inch Axle)  or Differential Side Bearings Replacement (9.75 Inch Axle) .
  12. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) , Drive Pinion and Ring Gear Replacement (9.75 Inch Axle)  or Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) .
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