LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 225 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly - Disassemble >> Disassembly Procedure

Disassembly Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required 

  1. Remove the inner housing to differential carrier assembly bolts.
    Fig 1: Removing Inner Shaft Housing To Differential Carrier Assembly Bolts
    G01216421Courtesy of GENERAL MOTORS CORP.
  2. Remove the inner housing and inner shaft from the differential carrier assembly.
    Fig 2: Removing Inner Housing & Inner Shaft From Differential Carrier Assembly
    G01216422Courtesy of GENERAL MOTORS CORP.
  3. Remove the inner shaft.
  4. Install the inner shaft housing into a vise.
    Fig 3: Removing Inner Shaft
    G01216423Courtesy of GENERAL MOTORS CORP.
  5. Install the J-29369-1  (2) and the J-2619-01  (1) behind the inner shaft bearing.
  6. Remove the inner shaft bearing and inner shaft seal using the J-2619-01  .
    Fig 4: Installing J-29369-1 & J-2619-01 Behind Inner Shaft Bearing
    G01216424Courtesy of GENERAL MOTORS CORP.
  7. Install the J-45850-2 (2), J-45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the upper inner shaft housing bushing as shown.
  8. Remove the upper inner shaft housing bushing using the J-45850  .
  9. Remove the inner shaft housing from the vise.
    Fig 5: Installing J-45850-2, J-45850-3 & Components Over Upper Inner Shaft Housing Bushing
    G01216425Courtesy of GENERAL MOTORS CORP.
  10. Install the inner shaft housing into a vise so that the lower inner shaft bushing bore is flush with the jaws of the vise.
    Fig 6: Installing Inner Shaft Housing Into Vise
    G01216426Courtesy of GENERAL MOTORS CORP.
  11. Install the J-45850-2 (2), J-45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the lower inner shaft housing bushing as shown.
  12. Remove the lower inner shaft housing bushing using the J-45850  .
  13. Remove the inner shaft housing from the vise.
  14. Install the differential carrier assembly into a vise.

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

    Fig 7: Installing J-45850-2, J-45850-3 & Components Over Lower Inner Shaft Housing Bushing
    G01216427Courtesy of GENERAL MOTORS CORP.
  15. Remove the left inner shaft using a hammer and a brass drift.
    Fig 8: Removing Left Inner Shaft
    G01216428Courtesy of GENERAL MOTORS CORP.
  16. Remove the inner shaft seal cover bolts.
    Fig 9: Removing Inner Shaft Seal Cover Bolts
    G01216429Courtesy of GENERAL MOTORS CORP.
  17. Remove the inner shaft seal cover.
    Fig 10: Removing Inner Shaft Seal Cover
    G01216430Courtesy of GENERAL MOTORS CORP.
  18. Remove the left side differential bearing adjuster lock bolt.
    Fig 11: Removing Left Side Differential Bearing Adjuster Lock Bolt
    G01216431Courtesy of GENERAL MOTORS CORP.
  19. Remove the left side differential bearing adjuster lock.
    Fig 12: Removing Left Side Differential Bearing Adjuster Lock
    G01216432Courtesy of GENERAL MOTORS CORP.
  20. Remove the right side differential bearing adjuster lock bolt.
    Fig 13: Removing Right Side Differential Bearing Adjuster Lock Bolt
    G01216433Courtesy of GENERAL MOTORS CORP.
  21. Remove the right side differential bearing adjuster lock.
  22. Remove the differential carrier assembly from the vise.
    Fig 14: Removing Right Side Differential Bearing Adjuster Lock
    G01216434Courtesy of GENERAL MOTORS CORP.
  23. Remove the differential carrier assembly bolts.
    Fig 15: Removing Differential Carrier Assembly Bolts
    G01216435Courtesy of GENERAL MOTORS CORP.
  24. Separate the right carrier case half from the left carrier case half by tapping on the carrier case using a hammer and a brass drift.
  25. Remove the differential case assembly.
    Fig 16: Separating Right Carrier Case Half From Left Carrier Case Half Using Hammer & Brass Drift
    G01216436Courtesy of GENERAL MOTORS CORP.
  26. Remove the left differential bearing adjuster by doing the following:
    1. Install the J-45224  onto the differential bearing adjuster.
    2. Turn the J-45224  counterclockwise in order to remove the differential bearing adjuster.
  27. Remove the differential bearing cup.
    Fig 17: Installing J-45224 Onto Differential Bearing Adjuster
    G01216437Courtesy of GENERAL MOTORS CORP.
  28. Remove the right differential bearing adjuster by doing the following:
    1. Install the J-45224  onto the differential bearing adjuster.
    2. Turn the J-45224  counterclockwise in order to remove the differential bearing adjuster.
  29. Remove the differential bearing cup.
    Fig 18: Installing J-45224 Onto Differential Bearing Adjuster
    G01216438Courtesy of GENERAL MOTORS CORP.
  30. Remove the left inner shaft bearing using the J-45232  (2) and the J-8092  (1).
    Fig 19: Removing Left Inner Shaft Bearing Using J-45232 & J-8092
    G01216439Courtesy of GENERAL MOTORS CORP.
  31. Install the J-8614-01  onto the pinion yoke as shown.

    Remove the pinion nut while holding the J-8614-01  .

  32. Remove the washer.
    Fig 20: Installing J-8614-01 Onto Pinion Yoke
    G01216440Courtesy of GENERAL MOTORS CORP.
  33. Install the J-8614-2 (2) and the J-8614-3 (3) into the J-8614-01  (1) as shown.
  34. Remove the pinion yoke by turning the J-8614-3 (3) clockwise while holding the J-8614-01  (1).
    Fig 21: Installing J-8614-2 & J-8614-3 Into J-8614-01
    G01216441Courtesy of GENERAL MOTORS CORP.
  35. Install the J-45234  onto the left differential carrier case and over the drive pinion as shown.
  36. Remove the drive pinion by turning the forcing screw of the J-45234  clockwise.
  37. Remove the pinion oil seal using a suitable seal removal tool.
    Fig 22: Installing J-45234 Onto Left Differential Carrier Case & Over Drive Pinion
    G01216442Courtesy of GENERAL MOTORS CORP.
  38. Remove the outer pinion bearing.
    Fig 23: Removing Outer Pinion Bearing
    G01216443Courtesy of GENERAL MOTORS CORP.
  39. Remove the collapsible spacer from the pinion.
    Fig 24: Removing Collapsible Spacer From Pinion
    G01216444Courtesy of GENERAL MOTORS CORP.
  40. Remove the inner pinion bearing by installing the J-22912-01  between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
  41. Remove the pinion gear selectable shim.
    Fig 25: Removing Inner Pinion Bearing By Installing J-22912-01
    G01216445Courtesy of GENERAL MOTORS CORP.
  42. Install the J-45228-4 to the outer pinion bearing cup as shown.
    Fig 26: Installing J-45228-4 To Outer Pinion Bearing Cup
    G01216446Courtesy of GENERAL MOTORS CORP.
  43. Install the J-45228-1 (2) and the J-45228-5 (1) to the J-45228-4.

    Seat the ridge of the J-45228-1 (2) into the outer pinion bearing cup bore.

  44. Remove the outer pinion bearing cup by turning the J-45228-5 (1) clockwise.
    Fig 27: Installing J-45228-1 & J-45228-5 To J-45228-4
    G01216447Courtesy of GENERAL MOTORS CORP.
  45. Install the J-45228-4 to the inner pinion bearing cup as shown.
    Fig 28: Installing J-45228-4 To Inner Pinion Bearing Cup
    G01216448Courtesy of GENERAL MOTORS CORP.
  46. Install the J-45228-1 (1) and the J-45228-5 (2) to the J-45228-4.
  47. Remove the outer pinion bearing cup by turning the J-45228-5 (2) clockwise.
    Fig 29: Installing J-45228-1 & J-45228-5 To J-45228-4
    G01216449Courtesy of GENERAL MOTORS CORP.
  48. Remove the upper differential carrier assembly bushing by performing the following steps:
    1. Install the J-45850-2 (2), the J-45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown.
    2. Remove the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J-45850  .
      Fig 30: Installing J-45850-2, J-45850-3 & Components Over Differential Carrier Assembly Bushing
      G01216450Courtesy of GENERAL MOTORS CORP.
  49. Remove the lower differential carrier assembly bushing by performing the following steps:
    1. Install the J-45850-2 (2), the J-45850-3 (1), the forcing screw, the thrust bearing, and the nuts (3) over the differential carrier assembly bushing as shown.
    2. Remove the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J-45850  .
      Fig 31: Installing J-45850-2, J-45850-3 & Components Over Differential Carrier Assembly Bushing
      G01216451Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals