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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Front Drive Axle - 4WD >> Repair Instructions >> Differential Drive Pinion Flange/Yoke, Seal and Dust Deflector Replacement-Front >> Removal Procedure

Removal Procedure

  1. Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  2. Remove the tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  3. Remove the brake calipers. Refer to BRAKE CALIPER (FRONT) in Disc Brakes.
  4. Reference mark the relationship of the propeller shaft to the front axle pinion flange.
  5. Remove the pinion flange bolts from the front axle pinion flange.
    NOTE: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joints may fracture and lead to premature failure of the joint.
    Fig 1: Removing Pinion Flange Bolts From Front Axle Pinion Flange
    G01642985Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the propeller shaft from the front axle pinion flange.
  7. Support the propeller shaft and move out of the way as necessary.
  8. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components:
    • The pinion bearings
    • The pinion seal
    • The axle bearings
    • The axle seals
    Fig 2: Measuring Required Torque For Pinion Rotation
    G01642986Courtesy of GENERAL MOTORS CORP.
  9. Scribe an alignment line between the pinion and the pinion flange.
    Fig 3: Marking Alignment Line Between Pinion & Pinion Flange
    G01642987Courtesy of GENERAL MOTORS CORP.
  10. Install the J 8614-01 onto the pinion as shown.
    Fig 4: Installing J 8614-01 Onto Pinion
    G01642988Courtesy of GENERAL MOTORS CORP.
  11. Remove the pinion nut while holding the J 8614-01.
  12. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
  13. Remove the pinon flange by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).

    Important  Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.

    Fig 5: Removing Pinon Flange Using Special Tools
    G01642989Courtesy of GENERAL MOTORS CORP.
  14. Remove the oil seal using a flat-bladed tool.
  15. Remove the dust deflector from the pinion flange by doing the following:
    • Tap the deflector off the pinion flange.
    • Clean up the stake points on the pinion flange.
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