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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1770 (Rear Drive Axle) >> Repair Instructions >> Differential Housing Assembly Disassemble

Differential Housing Assembly Disassemble

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

    Fig 1: RDM Drain Plug
    GM693541Courtesy of GENERAL MOTORS CORP.
  1. Remove the drain plug and the drain the fluid.
    2. Fig 2: Fill Plug
    GM792776Courtesy of GENERAL MOTORS CORP.
  2. Remove the fill plug.
    3. Fig 3: Rear Mounting Bracket & Bolts
    GM693545Courtesy of GENERAL MOTORS CORP.
  3. Remove the rear mounting bracket (2) and the bolts (3).
    4. Fig 4: Installing J44873 On Pinion Flange
    GM1265096Courtesy of GENERAL MOTORS CORP.
  4. Install J 44873  to the pinion flange (2) using 2 prop shaft bolts. See Special Tools . Attach half drive breaker bar in order to hold the pinion flange to remove nut.
    5. Fig 5: Inspecting Dust Deflector For Cracks
    GM693550Courtesy of GENERAL MOTORS CORP.
  5. Remove the nut (1) and the flange (2). Discard the used nut.
  6. Remove the dust deflector (2) from the flange (1), if required.
    7. Fig 6: Removing Input Flange Oil Seal From Clutch Cover
    GM693554Courtesy of GENERAL MOTORS CORP.
  7. Remove the input flange oil seal (1) from the clutch cover.
    8. Fig 7: Removing Bolts & Clutch Cover From Differential Housing
    GM792777Courtesy of GENERAL MOTORS CORP.
  8. Remove the bolts (1) and the clutch cover (2) from the differential housing.
    9. Fig 8: Filter Assembly
    GM735400Courtesy of GENERAL MOTORS CORP.
  9. Remove the filter assembly.
  10. Remove the dowel pins.
    11. Fig 9: Removing Clutch Drum From Housing Cover
    GM693566Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not submerge the clutch drum in solvent. This will damage friction material and geroter pump.
    IMPORTANT: The clutch drum is not serviceable. If inoperative conditions are found, replace the unit.
  11. Remove the clutch drum (2) from the clutch cover (1).
    12. Fig 10: Removing Snap Ring From Clutch Cover
    GM693569Courtesy of GENERAL MOTORS CORP.
  12. Remove the snap ring (1) from the clutch cover.
    13. Fig 11: Remove Bearing If It's Going To Be Replaced
    GM1253118Courtesy of GENERAL MOTORS CORP.
  13. Remove the bearing (1). Only remove the bearing if it is going to be replaced. It must be pressed out by the inner race.
    14. Fig 12: Clutch Drum Rear Oil Seal
    GM936277Courtesy of GENERAL MOTORS CORP.
  14. Remove the clutch drum rear oil seal (1) from the housing.
    15. Fig 13: Installing Differential Housing On J44869 Using 4 Clutch Cover Bolts
    GM1547599Courtesy of GENERAL MOTORS CORP.
  15. Attach the assembly holding fixture J 44869  to the housing, using 4 clutch cover bolts. See Special Tools .
  16. Install the housing (1) and the fixture into J 43964  (2) adapter. See Special Tools .
    17. Fig 14: 4 (M10) Cover Bolts
    GM792780Courtesy of GENERAL MOTORS CORP.
  17. Remove the rear cover bolts, 4 M8 and 4 M10.
    18. Fig 15: Removing Rear Cover By Prying It Off At Pry Point Locations
    GM792783Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use the pry point only. Do not pry on the sealing surface.
    IMPORTANT: The rear differential carrier may come out with the cover.
  18. Remove the rear cover by prying it off at the pry point locations.
    19. Fig 16: Right & Left Axle Shaft Oil Seals
    GM734836Courtesy of GENERAL MOTORS CORP.
  19. Remove the right and the left axle shaft oil seals.
    20. Fig 17: Differential Carrier
    GM792784Courtesy of GENERAL MOTORS CORP.
  20. Remove the differential carrier. Place a screw driver in the axle differential bore and pry up.
    21. Fig 18: Carrier Assembly, Bearing Races & Shims
    GM693575Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Mark or tag the bearing races and the shims for assembly.
  21. Remove the carrier assembly (1), bearing races (2), and shims (3).
    22. Fig 19: Removing Bolts & Ring Gear From Carrier
    GM693576Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The ring gear bolts are not to be reused. Use new bolts during assembly.
  22. Remove the bolts (3) and the ring gear (1) from the carrier (2).
    23. Fig 20: Identifying Lock Pin Location
    GM693578Courtesy of GENERAL MOTORS CORP.
  23. Identify the lock pin location (1) within the differential case.
    24. Fig 21: Identifying Pinion Shaft Roll Pin
    GM693579Courtesy of GENERAL MOTORS CORP.
  24. Drive the pinion shaft roll pin from the access hole (3) until the pinion shaft (2) can be removed from the differential case (1).
    25. Fig 22: Washers, Pinion Gears & Side Gears
    GM748624Courtesy of GENERAL MOTORS CORP.
  25. Remove the washers (1), pinion gears (2) and side gears (3) from the differential case.
    26. Fig 23: Using J44854
    GM734838Courtesy of GENERAL MOTORS CORP.
  26. Using J 44854  (3), . See Special Tools .J 22912-01  (2), and J 44855  (1), place the carrier into a press and press off the bearing. See Special Tools .
  27. Turn the carrier over, using the same; remove the right side differential bearing.
    28. Fig 24: Using Punch Bend Out Flat On Both Sides Of Pinion
    GM693580Courtesy of GENERAL MOTORS CORP.
  28. Using a punch, bend out the flat on both sides of the pinion nut.
    29. Fig 25: Placing J44864 Over Pinion Shaft
    GM1547602Courtesy of GENERAL MOTORS CORP.
  29. Place J 44864  (1) over the pinion shaft. See Special Tools . Turn the shaft to align the hex nut with the flat on the assembly holding fixture J 44869  (2). See Special Tools .
    30. Fig 26: Placing J44865 & Breaker Bar Over Pinion Splines
    GM1547603Courtesy of GENERAL MOTORS CORP.
  30. Place J 44865  (1) and the breaker bar over the pinion splines. See Special Tools . Remove the nut.
    31. Fig 27: Removing Pinion Nut On Pinion Shaft
    GM1547604Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The pinion nut is not reusable.
  31. Remove J 44864  (1) and the nut. See Special Tools .
  32. Remove the 4 bolts from J 44869  , and remove from the housing. See Special Tools .
    33. Fig 28: Inspecting Press Bar Surface
    GM693586Courtesy of GENERAL MOTORS CORP.
    NOTE: Inspect the press bar surface. Do not press the housing against a rough surface. Sealing surfaces could be damaged.
  33. Position the differential housing into a press in order to remove the pinion shaft.
    34. Fig 29: Front Bearing, Collapsible Spacer & Pinion Shaft
    GM693590Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The collapsible spacer is not reusable.
  34. Remove the front bearing (1), the collapsible spacer (2) and the pinion shaft (3).
    35. Fig 30: Placing J3940 Behind Bearing Race
    GM792798Courtesy of GENERAL MOTORS CORP.
    NOTE: If dowel pins are still in the housing, remove them before pressing. Pressing on dowels will damage the housing.
    IMPORTANT: The bolt is left-hand threaded on J 3940.
  35. Place J 3940  behind the front bearing race in the grooves. See Special Tools . Spread the arms and tighten the lock bolt.
  36. Place the housing in a press and remove the race.
    37. Fig 31: Placing J3940 Behind Rear Pinion Bearing Race
    GM792796Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The bolt is left-hand threaded on J 3940.
  37. Place J 3940  behind the rear pinion bearing race in the grooves. See Special Tools . Spread the arms and tighten the lock bolt.
  38. Place the housing in a press and remove the race.
    39. Fig 32: Using J44858
    GM693592Courtesy of GENERAL MOTORS CORP.
  39. Using J 44858  (2), and . See Special Tools .J 22912-01  (1), place the V of the split plate in the groove of J 44858  (2). See Special Tools . Tighten the nuts.
    40. IMPORTANT: The pinion shim is located under the bearing. Measure and mark or tag when removed.
  40. Place the pinion shaft and the tools in a press; then remove the bearing and the shim.
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