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Disassembly Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the upper differential carrier assembly bushing by performing the following steps:
    1. 1.1. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown.
    2. 1.2. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
    Fig 1: Thrust Bearing, J 36616-2, J 33791-1 & J 21474-18
    G01480474Courtesy of GENERAL MOTORS CORP.
  2. Remove the lower differential carrier assembly bushing by performing the following steps:
    1. 2.1. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown.
    2. 2.2. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
  3. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift.
  4. Remove the inner axle shaft housing to differential carrier assembly bolts.
  5. Carefully remove the inner axle shaft and inner axle shaft housing.
  6. Remove the inner axle shaft from the inner axle shaft housing.
    Fig 2: Thrust Bearing, J 21474-18, J 33791-1 & J 36616-2
    G01480475Courtesy of GENERAL MOTORS CORP.
  7. Install the inner axle shaft housing into a vise.

    Clamp only on the mounting flange of the inner axle shaft housing.

  8. Install the J 29369-1  behind the inner axle shaft bearing.
  9. Install the J 2619-01  to the J 29369-1. 
  10. Remove the inner axle shaft seal and the inner axle shaft bearing using the J 2619-01. 
  11. Place the differential carrier assembly into a vise.

    Clamp only on the mounting flange of the differential carrier assembly case.

  12. Remove the inner axle shaft using a hammer and a brass drift.
  13. Install the J 29369-1  behind the inner axle shaft bearing.
  14. Install the J 2619-01  to the J 29369-1. 
  15. Remove the inner axle shaft seal and the inner axle shaft bearing using the J 2619-01. 
  16. Remove the differential carrier assembly from the vise.
  17. Remove the vent connector.
  18. Remove the differential carrier assembly bolts.
  19. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case with a hammer and a brass drift.
  20. Remove the differential case assembly.

    Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks.

    Fig 3: Remove Vent Hose Connector
    G01480476Courtesy of GENERAL MOTORS CORP.
  21. Remove the differential bearing adjuster nuts and the bearing cups by doing the following:
    1. 21.1. Install the J 36599-A  onto the differential bearing adjuster nut.
    2. 21.2. Turn the J 36599-A  clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore.
    Fig 4: Differential Bearing Adjuster Nut & Cups Using J 36599-A
    G01480477Courtesy of GENERAL MOTORS CORP.
  22. Install the J 8614-01  as shown.

    Remove the pinion nut while holding the J 8614-01. 

  23. Remove the washer.
    Fig 5: Remove Pinion Nut Using J 8614-01
    G01480478Courtesy of GENERAL MOTORS CORP.
  24. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
  25. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
    Fig 6: Remove Pinion Yoke Using J 8614-2, J 8614-3 & J 8614-01
    G01480479Courtesy of GENERAL MOTORS CORP.
  26. Install the J 36598  into a vise.
  27. Install the left differential carrier case half onto the J 36598  and the J 36598-6.
  28. While holding the forcing screw of the J 36598,  turn the handle of the J 36598  counterclockwise in order to remove the pinion with the following components:
    • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer
  29. Remove the collapsible spacer from the pinion.
    Fig 7: Installing J 36598 In Vise
    G01480480Courtesy of GENERAL MOTORS CORP.
  30. Remove the inner pinion bearing by installing the J 22912-O1  between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
  31. Remove the pinion gear selectable shim.
    Fig 8: Remove Inner Pinion Bearing Using J 22912-01
    G01480481Courtesy of GENERAL MOTORS CORP.
  32. Install the J 36598-5 (3) behind the inner pinion bearing cup.
  33. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3).
  34. While holding the forcing screw of the J 36598  (1), turn the handle of the J 36598  (2) counterclockwise and press the inner bearing cup out from the differential carrier case.
    Fig 9: Remove Inner Pinion Bearing Cup Using J 36598-5 & J 36598
    G01480482Courtesy of GENERAL MOTORS CORP.
  35. Install the J 36598-5 (2) behind the outer pinion bearing cup.
  36. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2).
  37. While holding the forcing screw of the J 36598,  turn the handle of the J 36598  clockwise in order to remove the following components:
Fig 10: Remove Outer Pinion Bearing, Cup & Oil Seal Using J 36598 & J 36598-5
G01480483Courtesy of GENERAL MOTORS CORP.
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