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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1014 (Rear Drive Axle) >> Repair Instructions >> Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). Refer to Brake Caliper Replacement - Rear (1500 Series) or Brake Caliper Replacement - Rear (2500/3500 Series) in Disc Brakes.
  4. Remove the brake rotors (8.6 inch, 9.5 inch axles). Refer to Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) or Brake Rotor Replacement - Rear (W/Dual Wheels) or Brake Rotor Replacement - Rear (W/NYS) in Disc Brakes.
  5. Remove the axle shafts (10.5 inch, 11.5 inch axle). Refer to Rear Axle Shaft and/or Gasket Replacement .
  6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4).
    7. Fig 1: Identifying Driveshaft Pinion, Yoke Retainers & Bolts
    GM361391Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the propeller shaft from the axle.

    Wrap the bearing caps with tape in order to prevent the loss of bearing rollers.

    Support the propeller shaft as necessary.

  8. 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:
    • The pinion bearings
    • The pinion pilot bearing (10.5 inch axle)
    • The pinion oil seal
    • The differential case bearings
    • The axle bearings (8.6 inch, 9.5 inch axles)
    • The axle seals (8.6 inch, 9.5 inch axles)
    9. Fig 2: Measuring Pinion Rotating Torque
    GM661077Courtesy of GENERAL MOTORS CORP.
  9. Place an alignment mark between the pinion and the pinion yoke.
    10. Fig 3: View Of Pinion Shaft & Pinion Yoke Alignment Marks
    GM788905Courtesy of GENERAL MOTORS CORP.
  10. Install the J 8614-01  as shown.
    11. Fig 4: Holding Pinion Yoke With Special Tool
    GM661080Courtesy of GENERAL MOTORS CORP.
  11. Remove the pinion nut while holding the J 8614-01  .
  12. Remove the washer.
  13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
  14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).

    Use a container in order to retrieve the lubricant.

    15. Fig 5: Holding Pinion Yoke With Special Tool
    GM661074Courtesy of GENERAL MOTORS CORP.
  15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.
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