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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. Drain the axle lubricant. Refer to Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) , Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) .
  3. Remove the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
  4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4).
    5. Fig 1: Identifying Driveshaft Pinion, Yoke Retainers & Bolts
    GM361391Courtesy of GENERAL MOTORS CORP.
  5. 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.

  6. Measure the amount of torque required to rotate the pinion and the ring gear. 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
    • The pinion oil seal
    • The differential case bearings
    7. Fig 2: Measuring Pinion Rotating Torque
    GM661077Courtesy of GENERAL MOTORS CORP.
  7. Place an alignment mark between the pinion and the pinion yoke.
    8. Fig 3: View Of Pinion Shaft & Pinion Yoke Alignment Marks
    GM788905Courtesy of GENERAL MOTORS CORP.
  8. Remove the pinion gear bearing retainer bolts.
  9. Remove the pinion gear bearing retainer and the pinion.
  10. Remove the selective shim.
  11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly.
  12. Install the J 8614-01  as shown.
    13. Fig 4: Installing J 8614-01 To Pinion Yoke
    GM694814Courtesy of GENERAL MOTORS CORP.
  13. Remove the pinion nut while holding the J 8614-01  .
  14. Remove the washer.
  15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01  (3) as shown.
    16. Fig 5: Installing J 8614-3, J 8614-2 & J 8614-01 To Pinion Yoke
    GM694825Courtesy of GENERAL MOTORS CORP.
  16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01  (3).
  17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.
  18. Remove the outer pinion bearing.
  19. Remove the pinion.
    20. Fig 6: Removing Pinion
    GM694822Courtesy of GENERAL MOTORS CORP.
  20. Remove the collapsible spacer.
    21. Fig 7: Removing Collapsible Spacer
    GM739955Courtesy of GENERAL MOTORS CORP.
  21. Remove the inner pinion bearing from the pinion using the J 22912-01  and a hydraulic press.
    22. Fig 8: Removing Inner Pinion Bearing Using Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.

    Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly.

    23. Fig 9: Removing Outer Pinion Bearing Cup
    GM739944Courtesy of GENERAL MOTORS CORP.
  23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.

    Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly.

    24. Fig 10: Removing Inner Pinion Bearing Cup
    GM739945Courtesy of GENERAL MOTORS CORP.
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