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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1562 (Rear Drive Axle) >> Repair Instructions >> Differential Replacement (Automatic Transmission) >> Removal Procedure

Removal Procedure

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Fig 1: Rear Driveline & Rear Transaxle Assembly
GM321407Courtesy of GENERAL MOTORS CORP.
NOTE: Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
NOTE: When tilting down the rear of the driveline, observe the clearance between the rear of the engine and the composite dash panel. Do not allow the engine to rest unsupported against the composite dash panel, or vehicle damage may result.
NOTE: When lowering and removing the rear of the driveline, observe the clearance between the rear of the transaxle assembly and the underbody to prevent damage.
    Fig 2: Driveline Tunnel Closeout Panel & Muffler Assemblies
    GM180595Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable.
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  4. Remove the catalytic converters. Refer to Catalytic Converter Replacement in Engine Exhaust.
  5. Tie off the LH muffler assembly to the underbody to support the muffler out of the way.
  6. Remove the RH muffler assembly. Refer to Muffler Replacement - Right in Engine Exhaust.
  7. Remove the driveline tunnel closeout panel. Refer to Driveline Tunnel Closeout Panel Replacement in Propeller Shaft.
    8. Fig 3: Propeller Input Shaft Front Bearing Positioning Bolts
    GM173638Courtesy of GENERAL MOTORS CORP.
  8. Remove the two plug bolts from the front of driveline support assembly.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The propeller input shaft front bearing positioning bolts are intended to remain torqued to specification and in place UNTIL INSTRUCTED in the installation procedure.
    IMPORTANT: Failure to use the minimum length fastener specified will prevent proper retention of the propeller input shaft front bearing during disassembly or installation.
  9. Install two bolts, M10 - 1.5 X 55 mm, or longer, in place of the plug bolts.

    (The long bolts are located to maintain the propeller input shaft front bearing in original position during removal and installation.)

    Tighten:  Tighten the propeller input shaft front bearing positioning bolts to 35 N.m (26 lb ft).

    10. Fig 4: Engine Flywheel Housing Access Plug
    GM71455Courtesy of GENERAL MOTORS CORP.
  10. Using a flat bladed screwdriver, remove the engine flywheel housing access plug.
    11. Fig 5: View Of Propeller Shaft Hub Clamp Bolt
    GM173641Courtesy of GENERAL MOTORS CORP.
  11. Loosen the propeller shaft hub clamp bolt (1).

    Rotate the engine at the flywheel, if necessary for alignment.

    12. Fig 6: Transmission Shift Cable Bracket & Bolts
    GM71443Courtesy of GENERAL MOTORS CORP.
  12. Remove the nuts retaining the transmission shift cable bracket to the transmission.
    13. Fig 7: Transmission Shift Lever
    GM173669Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the transmission shift control cable from the transmission shift lever.

    Unsnap to release the cable.

  14. Reposition the transmission shift cable and bracket.
    15. Fig 8: View Of Shock Absorber Mounting To Control Arm
    GM180606Courtesy of GENERAL MOTORS CORP.
  15. Remove the rear transverse spring. Refer to Rear Transverse Spring Replacement in Rear Suspension.
  16. Support the lower control arm with a straight jack.
  17. Disconnect the outer tie rod end from the suspension knuckle. Refer to Tie Rod Replacement (Outer End) or Tie Rod Replacement (Suspension Link) in Rear Suspension.
  18. Remove the shock absorber lower mounting bolt.
  19. Disconnect the lower ball joint from the suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  20. Remove the straight jack from the control arm.
  21. Repeat steps 18 through 22 for the other side of the vehicle.
    22. Fig 9: Install J 42055 To Transmission Jack
    GM196197Courtesy of GENERAL MOTORS CORP.
  22. Assemble the J 42055  .
  23. Install the J 42055  to a transmission jack.
  24. Position and firmly secure the J 42055  with the transmission jack to the transmission.
    25. Fig 10: View Of Transaxle Mount-To-Rear Crossmember Nuts
    GM180633Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  26. Remove the differential to transmission lower nut.

    Removing the nut at this time will aid in separating the differential from the transmission after the driveline has been removed from the vehicle.

  27. Remove the transaxle mount to rear crossmember nuts.
    28. Fig 11: View Of Jack Supports
    GM180637Courtesy of GENERAL MOTORS CORP.
  28. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
  29. Using ONLY HAND TOOLS, remove the rear suspension crossmember retaining nuts.
    30. Fig 12: View Of Rear Suspension Crossmember
    GM180638Courtesy of GENERAL MOTORS CORP.
  30. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
    31. Fig 13: View Of Transaxle Mount Bracket & Bolts
    GM71501Courtesy of GENERAL MOTORS CORP.
  31. Remove the transaxle mount bracket to differential bolts.
  32. Remove the transaxle mount with bracket.

    Removing the transaxle mount will allow for greater stability on a workbench after the driveline is removed.

    33. Fig 14: LH Axle Shaft & Differential
    GM196201Courtesy of GENERAL MOTORS CORP.
  33. Using a pry bar, CAREFULLY release the axle shafts from the differential.
  34. Tie off the axle shafts to the underbody to support the shafts out of the way.

    The LH muffler assembly pipe toward the rear provides a good location to help support the LH axle shaft (1).

    35. Fig 15: Wiring Harness & Driveline Support Assembly
    GM71407Courtesy of GENERAL MOTORS CORP.
  35. Release the retainer (1) securing (and positioning) the wiring harness to the L-shaped brackets along the driveline support assembly, then slide the harness up out of the brackets and position out of the way.
    36. Fig 16: Vehicle Speed Sensor (VSS) Electrical Connector
    GM180649Courtesy of GENERAL MOTORS CORP.
  36. SLOWLY lower the driveline approximately 50 mm (2 in), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.
  37. Disconnect the vehicle speed sensor (VSS) electrical connector.
    38. Fig 17: Wiring Harness Retainer To Stud At Differential Rear Cover
    GM71409Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  39. Disconnect the wiring harness retainer clip from the top of the differential.
    40. Fig 18: View Of Transmission Harness 20-Way Connector
    GM173659Courtesy of GENERAL MOTORS CORP.
  40. Disconnect the transmission harness 20-way connector.

    Depress both tabs on the connector and pull straight up; do not pry the connector.

    41. Fig 19: Park/Neutral Position Switch Electrical Connectors
    GM205288Courtesy of GENERAL MOTORS CORP.
  41. Disconnect the park/neutral position switch electrical connectors.
  42. Remove the bolt retaining the transmission wiring harness to the LH side of the transmission case.
    43. Fig 20: Supporting Transmission Using Jackstand
    GM196198Courtesy of GENERAL MOTORS CORP.
  43. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt, and observe the relationship between the top rear of the differential and the lowest part of the rear compartment panel floor (the center storage compartment between the frame rails); the differential should not be lowered more than approximately EVEN with the specified body point of reference.

    (The engine positive crankcase ventilation (PCV) pipes which route along the rear of the engine intake manifold will likely contact the dash panel.)

  44. Release the wiring harness from the harness retainer along the top of the transmission.
  45. Check to be sure that the wiring harness is free from the driveline being removed.
    46. Fig 21: Locating Cooler Fittings
    GM71418Courtesy of GENERAL MOTORS CORP.
  46. Disconnect the transmission oil cooler rear pipes from the junction fittings at the engine flywheel housing, then cap the pipes and plug the junction fittings to prevent contamination.
    47. Fig 22: Removing/Installing Driveline Support Assembly To Engine Flywheel Housing Bolts
    GM196199Courtesy of GENERAL MOTORS CORP.
  47. Using a block of wood to protect the engine oil pan, place a jack under the rear of the engine oil pan to support the engine and prevent contact with the composite dash panel.
  48. Remove the driveline support assembly to engine flywheel housing bolts.
    49. Fig 23: Wiring Harness Bracket
    GM71406Courtesy of GENERAL MOTORS CORP.
  49. Carefully bend the wiring harness bracket away from the driveline, toward the driveline tunnel wall in order to make a clear removal path for the driveline.
    50. Fig 24: Separating Edge Of Driveline Support Assembly & Engine Flywheel Housing Using Flat Bladed Tool
    GM196200Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The aid of an assistant will be necessary for the remaining steps.
  50. Have an assistant insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the engine flywheel housing, then begin to pry the driveline loose from the engine.
    51. Fig 25: Propeller Input Shaft
    GM71466Courtesy of GENERAL MOTORS CORP.
  51. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  52. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt and pulling the driveline away from the engine UNTIL the propeller input shaft at the front of the driveline support assembly just clears the engine flywheel housing.
  53. SLOWLY lower the driveline completely out of the vehicle.
    54. Fig 26: J 42055, Driveline Support Assembly And The Differential
    GM196196Courtesy of GENERAL MOTORS CORP.
  54. Position the chainfall, or equivalent lifting device, in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly.
  55. Using the lifting device, raise the driveline to relieve the weight from the transmission jack.
  56. Disconnect the J 42055  from the transmission jack ONLY, the J 42055  will provide stability to the driveline components while working on a bench.
  57. Position the driveline on a workbench with the lifting device still attached.
  58. Support the driveline support assembly and the differential for additional balance.
  59. Remove the lifting device from the driveline.
    60. Fig 27: Differential, Transmission Bolts & Nuts
    GM71505Courtesy of GENERAL MOTORS CORP.
  60. Remove the differential to transmission bolts and nuts.
    61. IMPORTANT: Use care when separating the differential from the transmission to not damage the transmission output shaft seal in the differential plate.
  61. SLOWLY slide the differential from the transmission.
    62. Fig 28: Differential Plate & Differential
    GM71504Courtesy of GENERAL MOTORS CORP.
  62. Remove the differential plate from the differential.
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