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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1375 (Rear Drive Axle) >> Repair Instructions >> Differential Overhaul >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2004 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Place a pan under the differential assembly.
  2. Remove the fill plug and drain plug from differential carrier.
  3. Remove the differential from the vehicle. Refer to Differential Carrier Assembly Replacement .
  4. Remove the 4 coupling cover bolts.
  5. Remove the coupling cover from the differential assembly.
  6. Remove the washer and spacer from the differential assembly.
    7. Fig 1: Differential Preload Wrench
    GM832890Courtesy of GENERAL MOTORS CORP.
  7. Install the J 8001  against the a ring gear tooth.
  8. Hold the pinion gear stationary.
  9. Using J 35405  (1), move the ring gear back and forth as far as it will travel without turning the pinion gear. See Special Tools and Equipment .
    10. IMPORTANT: Check the differential backlash at 3 different positions on the ring gear to obtain an accurate reading.
  10. Observe the J 8001  while moving the ring gear as previously described. Differential backlash should be within 0.10-0.15 mm (0.0039-0.0059 in).
    11. Fig 2: Measuring Drive Pinion Starting Preload Using Torque Wrench
    GM832891Courtesy of GENERAL MOTORS CORP.
  11. Using a torque wrench (1) and J 46004  , measure and record the drive pinion starting preload. See Special Tools and Equipment . Preload should be between 0.4-0.7 N.m (3-6 lb in).
    12. Fig 3: Bushing Bearing Remover And Slide Hammer With Bearing Adapter
    GM832893Courtesy of GENERAL MOTORS CORP.
  12. Remove the differential carrier side oil seals using the J 29369-2  (1) and the J 23907  (2). See Special Tools and Equipment .
    13. Fig 4: Removing Drive Pinion Nut
    GM832897Courtesy of GENERAL MOTORS CORP.
  13. Using a hammer and punch, unstick the drive pinion nut.
  14. Using J 46004  and J 46002  , remove the pinion nut. See Special Tools and Equipment .
  15. Remove the differential carrier front oil seal using the J 22888-20A  . See Special Tools and Equipment .
  16. Remove the front bearing from the drive pinion.
    17. Fig 5: Differential Carrier And Vent Hose
    GM832907Courtesy of GENERAL MOTORS CORP.
  17. Remove the vent hose from the differential carrier.
    18. Fig 6: Elbows And Differential Carrier Reference Marks
    GM832910Courtesy of GENERAL MOTORS CORP.
  18. Place reference marks (1) on the elbows and differential carrier.
  19. Remove the 2 elbows using a screwdriver.
  20. Remove the 10 differential cover bolts.
    21. Fig 7: Removing Differential Cover
    GM832913Courtesy of GENERAL MOTORS CORP.
  21. Using a brass drift and a hammer, remove the differential cover from the differential carrier.
  22. Remove the differential case from the differential carrier.
  23. Remove the drive pinion and sleeve from the differential carrier.
    24. Fig 8: Removing Drive Pinion Rear Bearing
    GM833752Courtesy of GENERAL MOTORS CORP.
  24. Remove the drive pinion rear bearing from drive pinion using J 22912-01 (1) and a press.
    25. Fig 9: Removing Differential Case Side Bearings
    GM832939Courtesy of GENERAL MOTORS CORP.
  25. Remove the differential case side bearings from the differential case using J 22912-01 (1) and a press.
    26. Fig 10: Reference Mark At Ring Gear And Differential Case
    GM832941Courtesy of GENERAL MOTORS CORP.
  26. Place a reference mark (1) on the ring gear and differential case.
  27. Remove the 10 ring gear retaining bolts.
  28. Using a soft faced hammer, tap the ring gear to remove it from the differential case.
    29. Fig 11: Removing Pinion Shaft Roll Pin
    GM832944Courtesy of GENERAL MOTORS CORP.
  29. Use a punch and a hammer in order to remove the pinion shaft roll pin from the differential case.
  30. Remove the following components from the differential case:
    • The pinion shaft
    • The pinion gears
    • The pinion washers
    • The differential side gears
    • The side gear thrust washers
  31. Clean all the components thoroughly with clean solvent. Dry the components.
  32. Inspect all of the gears for the following conditions. Replace as necessary:
    • Cracks
    • Chipped teeth
    • Broken teeth
    • Other damage
  33. Inspect the differential side bearing surfaces. Replace as necessary:
    • Roughness
    • Excessive wear
  34. Inspect the differential case gear and bearing surfaces for cracks and blue discoloration. These conditions indicate overheating or other damage. Replace as necessary.
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