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Home >> GMC >> 1991 >> Value Van 7.4 N >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Drive Axle - DANA Full-Floating >> Overhaul >> Differential Assembly >> Disassembly

Differential Assembly: Disassembly

  1. Properly support rear axle assembly. Remove differential cover bolts and cover. Drain lubricant from axle. Remove axle shafts. See AXLE SHAFTS  under REMOVAL & INSTALLATION.
  2. Remove bearing cap bolts. Note letters on caps and drive axle housing for reassembly reference. Remove differential bearing caps. See Fig 2 or Fig 3 . Mount dial indicator on differential housing. See Fig 1. Preload dial indicator to .020" (.51 mm), then rotate gauge to zero dial.
    CAUTION: DO NOT  spread housing more than .015" (.38 mm) as housing will be damaged.
  3. Use Drive Axle Housing Spreader (J-24385-01) to spread drive axle housing out .015" (.38 mm). See Fig 1. Using 2 prybars, pry differential case out of housing.
  4. Remove drive axle housing spreader. Use Differential Bearing Remover (J-29721), Adapters (J-29721-70), and Removal Plug (J-8107-03) to remove differential bearings and shims. Store bearings with matching bearing cups. Mark bearing sets and shims left or right for reassembly reference.
  5. Place differential case in soft-jawed vise and remove ring gear bolts. Using a soft-faced hammer, tap ring gear off differential case. Remove pinion shaft lock pin. Remove pinion shaft, pinion gears and thrust washers. Remove differential side gears and thrust washers. Mark gears and washers for reassembly reference.
  6. Check drive pinion bearing preload. If drive pinion bearings need to be replaced, mark pinion flange and drive pinion nut for reassembly reference. Using Pinion Flange Holder/Remover (J-8614-01), remove drive pinion nut and pinion flange.
  7. Install differential cover with 2 bolts to keep drive pinion from falling out of housing during removal. Tap drive pinion out of differential housing. Remover cover and retrieve drive pinion and shims. Save shims for reassembly.
  8. Pry drive pinion oil seal from bore, being careful not to damage machined surfaces. Remove outer drive pinion bearing and oil slinger. Remove drive pinion bearing cups from drive axle housing.
  9. Remove drive pinion adjustment shims and baffle. Keep shims and baffle together for reassembly. Using Differential Bearing Remover (J-29721) and Adapters (J-29721-70), remove inner drive pinion bearing.
    Fig 1: Spreading Drive Axle Housing
    G121080Courtesy of GENERAL MOTORS CORP.
    Fig 2: Exploded View of Dana 9 3/4" Ring Gear Full-Floating Axle Assembly
    G121081Courtesy of GENERAL MOTORS CORP.
    Fig 3: Exploded View of Dana 10 1/2" Full-Floating Axle Assembly
    G121082Courtesy of GENERAL MOTORS CORP.
    NOTE: DO NOT  steam clean any parts having a ground and polished surface, such as bearings, gears and shafts.
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