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Home >> GMC >> 1993 >> C3500 HD 5.7 K, Automatic >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Drive Axle - DANA 9.75", 10.5" & 11" (Full-Floating) >> Overhaul >> Differential Assembly >> Disassembly

Differential Assembly: Disassembly

  1. Remove axle housing. See REAR AXLE HOUSING ASSEMBLY  under REMOVAL & INSTALLATION. Remove differential cover bolts and cover. Remove axle shafts. See AXLE SHAFTS  under REMOVAL & INSTALLATION.
  2. Note letters on bearing caps and drive axle housing for reassembly reference. Remove differential bearing caps. See Fig 2. Mount dial indicator on differential housing. See Fig 1. Preload dial indicator to .020" (.51 mm), then return dial to zero.
    CAUTION: DO NOT  spread housing more than .015" (.38 mm), or damage may result.
  3. Mount Axle Housing Spreader (J-24385-01 ) to differential housing. See Fig 1. Spread drive axle housing to maximum of .015" (.38 mm). Using 2 pry bars, pry differential case out of axle housing.
    Fig 1: Spreading Drive Axle Housing
    G121080Courtesy of GENERAL MOTORS CORP.
  4. Remove axle housing spreader. Using Differential Bearing Remover (J-29721 ), Adapters (J-29721-70 ) and Removal Plug (J-8107-03 ), remove differential case side bearings and shims. Mark bearing, race, and shims left or right side for reassembly reference.
  5. Using shop towels, place differential case in soft-jawed vise. Remove ring gear bolts. Ring gear bolts are right-hand thread. Using a soft-faced hammer, tap ring gear off differential case.
  6. Using hammer and punch, remove pinion shaft roll pin and pinion shaft. Remove pinion gears and thrust washers. Remove differential side gears and thrust washers. Mark all gears and washers for reassembly reference.
  7. Using Pinion Flange Holder/Remover (J-8614-01 ), remove drive pinion nut. See Figure. Using Pinion Flange Remover (J-8614-1 , J-8614-2 and J-8614-3 ), remove pinion flange. See Figure.
  8. Install differential cover with 2 bolts (to prevent drive pinion from falling out of housing). Tap out drive pinion. Remover cover, drive pinion and small diameter pinion preload shims. Save shims for reassembly.
  9. Pry out drive pinion oil seal. Remove outer drive pinion bearing and oil slinger. Remove drive pinion bearing races from drive axle housing.
  10. Remove drive pinion adjustment shims and baffle (if equipped). Keep shims and baffle together for reassembly. Using Differential Side Bearing Remover (J-29721 ) and 4 Adapters (J-29721-70 ), remove inner drive pinion bearing.
    Fig 2: Exploded View Of Dana 9 3/4", 10 1/2" & 11" Ring Gear Full-Floating Axle Assembly
    G121081Courtesy of GENERAL MOTORS CORP.
    NOTE: DO NOT  steam clean any parts having a ground and polished surface, such as bearings, gears or shafts.
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