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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1893 (Drive Axles - Front) >> Repair Instructions >> Differential Carrier Assembly - Disassemble (8.25 Inch Axles) >> 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 Upper Differential Carrier Assembly Bushing (8.25 inch Axles)
    G01455893Courtesy 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  .
    Fig 2: Remove the lower differential carrier assembly bushing (8.25 inch Axles)
    G01455894Courtesy of GENERAL MOTORS CORP.
  3. Remove the front axle actuator, S4WD axle only.
    Fig 3: Removing Front Axle Actuator
    G01455895Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift, F4WD axle only.
  5. Remove the inner axle shaft, F4WD axle only.
  6. Remove the inner axle shaft housing to differential carrier assembly bolts.
  7. Remove the inner axle shaft housing, F4WD axle only.
  8. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly, S4WD axle only.
    Fig 4: Removing Inner Axle Shaft Housing With Inner Axle Shaft And Clutch Fork Components
    G01455896Courtesy of GENERAL MOTORS CORP.
  9. Remove the following components from the inner axle shaft housing:
    1. The clutch fork inner spring (10)
    2. The clutch fork assembly (11, 12, 13, 14)
    3. The clutch shaft shim (9)
    4. The clutch shaft sleeve (8)
    5. The front drive axle clutch gear (6) by doing the following:
      1. Clamp the inner axle shaft housing (4) in a vise.

        Clamp only on the mounting flange.

      2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
    6. Remove the thrust washer (5)
    Fig 5: Removing Components From Inner Axle Shaft Housing
    GM695177Courtesy of GENERAL MOTORS CORP.
  10. 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 29369-1  (1) behind the inner axle shaft bearing.
    3. Install the J 2619-01  (2) to the J 29369-1  (1).
    4. Remove the inner axle shaft bearing and the seal using the J 2619-01  .
    Fig 6: Removing The Inner Axle Shaft Seal And/Or The Inner Axle Shaft Bearing Using 29369-2 & J 2619-01
    GM834245
  11. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Place the differential carrier assembly into a vise.

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

    2. Install the J 29369-1  (1) behind the inner axle shaft bearing.
    3. Install the J 2619-01  (2) to the J 29369-1  .
    4. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01  .
    Fig 7: Removing Inner Axle Shaft Seal/Bearing Using J 29369-2 & J 2619-01 -- Front Drive Axle
    GM1332786
  12. Remove the differential carrier assembly from the vise.
  13. Remove the front drive axle clutch shaft, S4WD axle only.
  14. Use the J 34011  in order to remove the clutch shaft bearing, S4WD axle only.
    Fig 8: Removing Clutch Shaft Pilot Bearing -- Front Drive Axle
    GM680254
  15. Remove the vent connector.
    Fig 9: Removing Vent Hose Connector -- Front Drive Axle
    GM847064
  16. Remove the differential carrier assembly bolts.
    Fig 10: Identifying Differential Carrier Assembly Bolts
    GM1332740Courtesy of GENERAL MOTORS CORP.
  17. 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.
    Fig 11: Removing Differential Case Assembly (8.25 Inch Axles)
    GM1332738
  18. Remove the differential case assembly.

    Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, S4WD axle - both sides, F4WD axle - left side.

  19. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following, S4WD axle - both sides, F4WD axle - left side:
    1. Install the J 36599-A  onto the differential bearing adjuster nut.
    2. Turn the J 36599-A  clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore.
    Fig 12: Removing Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
    GM680101
  20. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift, S4WD axle - both sides, F4WD axle - left side.
  21. Install the J 8614-2  (2) and the J 8614-3  (3) into the J 8614-01  (1) as shown.
    Fig 13: Installing The J 8614-01 Onto The Pinion -- Front Axle
    GM664065
  22. Remove the washer.
  23. Install the J 8614-2  (2) and the J 8614-3  (3) into the J 8614-01  (1) as shown.
    Fig 14: Removing Pinion Yoke -- Front Axle
    GM664070
  24. Remove the pinion yoke by turning the J 8614-3  (3) clockwise while holding the J 8614-01  (1).
  25. The steps below explain how to remove the drive pinion and pinion bearing cups using the J 36598  or the J 45765  and the J-45858  . Follow the appropriate steps depending on what tool is available.
  26. Install the J 36598  into a vise.
  27. Install the left differential carrier case half onto the J 36598  and the J 36598-6  .
    Fig 15: Removing Pinion (8.25 Inch Axles)
    GM680106
  28. While holding the forcing screw of the J 36598  , turn the handle of the J 36598  counterclockwise in order to remove the pinion with the following components:
    1. The pinion gear selectable shim.
    2. The inner pinion bearing.
    3. The collapsible spacer.
  29. Install the J 36598-5  (3) behind the inner pinion bearing cup.
    Fig 16: Installing J 39598-5 Behind Inner Pinion Bearing Cup
    GM890234
  30. Thread the forcing screw of the J 36598  (1) onto the J 36598-5  (3) until fully seated.
  31. While holding the forcing screw of the J 36598  (1), turn the handle of the J 36598  (2) counterclockwise and press the inner bearing cup out from the differential carrier case.
  32. Install the J 36598-5  (2) behind the outer pinion bearing cup.
    Fig 17: Installing J 36598-5 Behind Outer Pinion Bearing Cup
    GM680114
  33. Install the forcing screw of the J 36598  (1) to the J 36598-5  (2).
  34. While holding the forcing screw of the J 36598  , turn the handle of the J 36598  clockwise in order to remove the following components:
    1. The pinion oil seal
    2. The pinion outer bearing
    3. The pinion outer bearing cup
  35. Install the J 45765  to the left side differential carrier case half over the drive pinion as shown.
    Fig 18: Removing Pinion Components Using J 45765 (8.25 Inch Axles)
    GM1486597
  36. Turn the forcing screw of the J 45765  clockwise to remove the following components from the left side differential carrier case half:
    1. The drive pinion gear
    2. The pinion gear selectable shim
    3. The inner pinion bearing
    4. The collapsible spacer
  37. Remove the drive pinion seal using a suitable seal remover.
  38. Remove the outer pinion bearing from the differential carrier case half.
  39. Install the J 45858-4  over the inner pinion bearing cup.
    Fig 19: Installing J 45858-4 Over Inner Pinion Bearing Cup (8.25 Inch Axles)
    GM1486598
  40. Install the forcing screw (1) of the J 45858  into the J 45858-4  (2).
    Fig 20: Installing Forcing Screw Of J 45858 Into J 45858-4 (8.25 Inch Axles)
    GM1486602
  41. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
  42. Install the J 45858-3  (3), the thrust bearing and the washer (2), and the forcing screw (1) over the outer pinion bearing cup bore.
    Fig 21: Installing J 45858-3, Thrust Bearing & Washer, & Forcing Screw (8.25 Inch Axles)
    GM1486596
  43. Install the J 45858-5  into the pinion bearing bore behind the outer pinion bearing cup.

    Slowly turn the forcing screw clockwise until the J 45858-5  is evenly seated behind the outer pinion bearing cup bore and the J 45858-3  is evenly seated over the outer pinion bearing cup bore.

    Fig 22: Installing J 45858-5 Into Pinion Bearing Bore (8.25 Inch Axles)
    GM1486591
  44. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
  45. Remove the collapsible spacer from the drive pinion.
  46. Install the J 22912-B  between the pinion bearing and the drive pinion.
    Fig 23: Removing The Inner Pinion Bearing Using J 22912-01 (8.25 Inch Axles)
    GM680110
  47. Remove the inner pinion bearing using the J 22912-B  and a hydraulic press.
  48. Remove the pinion gear selectable shim.
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