Rear Axle - Disassemble

Tools Required

• J 22536  Pinion Driver
• J 2619-O1  Slide Hammer
• J 34178  Spreader Gage Adapter
• J 44685  Rear Axle Seal and Bearing Remover
• J 45222  Axle Housing Spreader
• J 8001  Dial Indicator Set
• J 8614-O1  Flange and Pulley Holding Tool

1. Remove the rear axle fill plug.
Fig 1: Removing Rear Axle Fill Plug
Courtesy of GENERAL MOTORS CORP.
2. Remove the rear axle drain plug.
Fig 2: Removing Rear Axle Drain Plug
Courtesy of GENERAL MOTORS CORP.
3. Drain the lubricant into a suitable container.
4. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear.
5. Remove the rear axle housing cover bolts (1).
Fig 3: Removing Rear Axle Housing Cover Bolts
Courtesy of GENERAL MOTORS CORP.
6. Remove the rear axle housing cover (2) from the axle housing.
7. Remove the pinion shaft locking bolt.
Fig 4: Removing Pinion Shaft Locking Bolt
Courtesy of GENERAL MOTORS CORP.
8. On axles without a locking differential, remove the pinion shaft.
Fig 5: Removing Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
9. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
Fig 6: Partially Removing Shaft
Courtesy of GENERAL MOTORS CORP.
10. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2).
Fig 7: Rotating Lock Until Lock Aligns With Thrust Block
Courtesy of GENERAL MOTORS CORP.
11. Push the flange of the axle shaft toward the differential.
12. Remove the lock from the button end of the axle shaft.
Fig 8: Removing Lock From Button End Of Axle Shaft
Courtesy of GENERAL MOTORS CORP.
13. Remove the axle shaft from the axle housing.
14. Measure the amount of torque required to rotate the pinion. Use an inch- pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components:
    Fig 9: Measuring Amount Of Torque Required To Rotate Pinion

    Courtesy of GENERAL MOTORS CORP.
    • The pinion bearings
    • The pinion seal
    • The differential case bearings
15. Scribe an alignment mark between the pinion yoke and the pinion stem.
Fig 10: Scribing An Alignment Mark Between Pinion Yoke And Pinion Stem
Courtesy of GENERAL MOTORS CORP.
16. Install the J 8614-O1 as shown.
Fig 11: Installing J 8614-O1
Courtesy of GENERAL MOTORS CORP.
17. Remove the pinion nut while holding the J 8614-O1.
18. Remove the washer.
19. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-O1 (1) as shown.
Fig 12: Installing J 8614-2 And J 8614-3 Into 8614-O1
Courtesy of GENERAL MOTORS CORP.
20. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-O1 (1).
21. Remove the axle shaft seal and the bearing from the axle shaft tube using the J 44685 (1) and the J 2619-O1 (2).
Fig 13: Removing Axle Shaft Seal And Bearing From Axle Shaft Tube
Courtesy of GENERAL MOTORS CORP.
22. Install the J 45222 to the axle housing as shown.
Fig 14: Installing J 45222 To Axle Housing
Courtesy of GENERAL MOTORS CORP.
23. Install the J 8001-1 (2), the J 8001-2 (3), the J 34178 (4, 6), and the J 8001-1 (5) as shown.
Fig 15: Installing J 8001-1, J 8001-2, J 34178, And J 8001-1
Courtesy of GENERAL MOTORS CORP.
24. Preload the J 8001-1 (5) approximately 1 revolution.
25. Move the housing of the J 8001-1 (5) until the needle indicates zero.
26. Spread the axle housing by turning the clevis screw of the J 34178 until the needle of the J 8001-1 indicates 1.02 mm (0.040 in).
Fig 16: Spreading Axle Housing
Courtesy of GENERAL MOTORS CORP.
27. Remove the bearing caps bolts and the caps. Mark the bearing caps left and right.
    CAUTION: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.
    NOTE: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.
28. Remove the differential from the axle housing using a pry bar and a block of wood.
Fig 17: Removing Differential From Axle Housing
Courtesy of GENERAL MOTORS CORP.
29. Remove the bearing cups, the shims, and the spacers as necessary.

    Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

30. Remove the J 8001-1, the J 8001-2, the J 34178, and the J 8001-1.
31. Remove the J 45222.
32. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
33. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
34. Install the J 22536 as shown.

    Make sure the J 22536 is firmly seated on the pinion.

Fig 18: Installing J 22536
Courtesy of GENERAL MOTORS CORP.
35. Drive the pinion out using the J 22536 and a hammer.

    Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.

36. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.
37. Remove the collapsible spacer from the pinion. Discard the spacer.
Fig 19: Removing Collapsible Spacer From Pinion
Courtesy of GENERAL MOTORS CORP.
38. Remove the drive pinion bearing cups from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.