Disassembly Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 21551 Output Shaft Bearing Remover
J 22912-O1 Pinion Bearing Remover
J 23907 Slide Hammer
J 29369-1 Bushing/Bearing Remover
J 29369-2 Bushing/Bearing Remover (2-3 inches)
J 33791 Bushing Remover and Installer Set
J 33792 Side Bearing Adjuster Socket
J 33837 Pinion Bearing Cup Remover and Installer
J 34011 Pilot Bearing Remover
J 36611 Output Shaft Bearing Remover
J 42213 Side Bearing Adjuster Socket
J 8092 Driver Handle
J 8614-01 Pinion Flange Holder

Remove the 2 remaining inner axle shaft housing bolts.
Remove the inner axle shaft housing with the inner axle shaft.
Remove the following components from the inner axle shaft housing:
1. The clutch cable retainer spring
2. The clutch fork assembly
3. The clutch fork inner spring
4. The clutch fork sleeve
5. The thrust washer
6. The clutch gear by doing the following:
  1. Clamp the inner shaft housing in a vise.
    Clamp only on the mounting flange.
  2. Strike the inside surface of the axle shaft with a hammer and a brass drift in order to dislodge the front drive axle clutch gear from the inner axle shaft.
  3. Remove the front drive axle clutch gear.
7. Remove the thrust washer.
Remove the inner axle shaft.
Remove the clutch fork seal. Use a punch to drive out the seal.
Remove the inner axle shaft seal and the bearing by doing the following:
1. Install the J 23907 (1) and the J 29369-1 (2) as shown.
2. Remove the inner axle shaft seal and the bearing by pulling on the J 23907 (1).
Remove the front drive axle clutch shaft.
Remove the thrust washer from the right side differential carrier assembly case half.

Fig 1: Removing Inner Axle Shaft Seal And Bearing
Courtesy of GENERAL MOTORS CORP.
Remove the clutch shaft bearing using the J 34011 .
Remove the inner axle shaft seal cover and the seal.
Remove the inner axle shaft seal by doing the following:
1. Install the inner axle shaft seal cover in a vise.
2. Install the J 29369-1 to the backside of the inner axle shaft seal.
3. Install the J 23907 to the J 29369-1 .
4. Remove the inner axle shaft seal by pulling on the J 23907 .
Remove the differential carrier assembly bolts.

Fig 2: Removing Clutch Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
Separate the left carrier case half from the right carrier case half by inserting a screwdriver into the slots provided and prying the case apart.
Remove the differential case assembly.

Fig 3: Removing Differential Case Assembly
Courtesy of GENERAL MOTORS CORP.
Remove the differential bearing adjuster nut lock bolts and the differential bearing adjuster nut locks.

Fig 4: Removing Differential Bearing Adjuster Nut Lock Bolts
Courtesy of GENERAL MOTORS CORP.
Remove the left differential bearing adjuster and the differential case bearing cup by doing the following:
1. Install the J 42213 onto the differential bearing adjuster nut.
2. Turn the J 42213 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
Fig 5: Removing Left Differential Bearing Adjuster
Courtesy of GENERAL MOTORS CORP.
Remove the right differential bearing adjuster and the differential case bearing cup by doing the following:
1. Install the J 33792 onto the differential bearing adjuster nut.
2. Turn the J 33792 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
Fig 6: Removing Right Differential Bearing Adjuster
Courtesy of GENERAL MOTORS CORP.
Remove the left inner shaft bearing using the J 36611 (2) and the J 8092 (1).

Fig 7: Removing Left Inner Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
Remove the right inner shaft bearing using the J 21551 (2) and the J 8092 (1).

Fig 8: Removing Right Inner Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
Install the J 8614-01 as shown.
Remove the pinion nut while holding the J 8614-01 .
Remove the washer.

Fig 9: Removing Pinion Nut
Courtesy of GENERAL MOTORS CORP.
Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Remove the dust deflector from the pinion yoke by doing the following:
1. Tap the deflector off the pinion yoke.
2. Clean up the stake points on the pinion yoke.
Fig 10: Removing Pinion Yoke
Courtesy of GENERAL MOTORS CORP.
Mount the left side differential carrier case in the J 33837-1.
Install the J 33837-3.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 counterclockwise to remove the following components:
- The drive pinion
- The drive pinion selectable shim
- The inner pinion bearing
- The collapsible spacer
Remove the collapsible spacer from the pinion.

Fig 11: Removing Collapsible Spacer From Pinion
Courtesy of GENERAL MOTORS CORP.
Remove the inner pinion bearing by installing the J 22912-O1 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
Remove the pinion gear selectable shim.

Fig 12: Removing Inner Pinion Bearing
Courtesy of GENERAL MOTORS CORP.
Install the J 33837-6 (2) onto the J 33837-3 between the inner and the outer bearing cup.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 clockwise in order to remove the following components:
- The pinion oil seal
- The pinion outer bearing
- The pinion outer bearing cup
Install the J 33837-6 (2) onto the J 33837-3 on the inside surface of the outer bearing cup.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 counterclockwise in order to press the inner pinion bearing cup out from the differential carrier case.

Fig 13: Installing J 33837-6 Onto The J 33837-3 On Inside Surface Of Outer Bearing Cup
Courtesy of GENERAL MOTORS CORP.
Install the J 33791 onto the differential carrier assembly bushings.
Remove the bushings using the J 33791 .

Fig 14: Removing Bushing
Courtesy of GENERAL MOTORS CORP.