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Disassembly Procedure

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  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: Remove Upper Differential Carrier Assembly Bushing Using J 36616-2, J 33791-1 & J 21474-18
    G01480454Courtesy 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.
    Fig 2: Remove Lower Differential Carrier Assembly Bushing Using J 21474-18, J 33791-1 & J 36616-2
    G01480455Courtesy of GENERAL MOTORS CORP.
  3. Remove the front axle actuator.
  4. Remove the inner axle shaft housing to differential carrier assembly bolts.
    Fig 3: Remove Front Axle Actuator
    G01480456Courtesy of GENERAL MOTORS CORP.
  5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly.
    Fig 4: Remove Inner Axle Shaft Housing
    G01480457Courtesy of GENERAL MOTORS CORP.
  6. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
    1. 6.1. The clutch fork inner spring (10)
    2. 6.2. The clutch fork assembly (11)
    3. 6.3. The clutch shaft shim (9)
    4. 6.4. The clutch shaft sleeve (8)
    5. 6.5. The front drive axle clutch gear (6) by doing the following:
      1. 6.5.1. Clamp the inner axle shaft housing (4) in a vise.

        Clamp only on the mounting flange.

      2. 6.5.2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
    6. 6.6. Remove the thrust washer (5)
    Fig 5: Remove Inner Axle Shaft Housing & Components (8.25 Inch Axle)
    G01480458Courtesy of GENERAL MOTORS CORP.
  7. For the 9.25 inch axle, remove the following components from the inner axle shaft housing (4):
    1. 7.1. The clutch fork inner spring (10)
    2. 7.2. The clutch fork assembly (11)
    3. 7.3. The clutch shaft shim (9)
    4. 7.4. The clutch shaft sleeve (8)
    5. 7.5. The retainer ring (7)
    6. 7.6. The thrust washers (5, 6)
    Fig 6: Remove Inner Axle Shaft Housing & Components (9.25 Inch Axle)
    G01480459Courtesy of GENERAL MOTORS CORP.
  8. Remove the inner axle shaft (2).
    Fig 7: Remove Inner Axle Shaft
    G01480460Courtesy of GENERAL MOTORS CORP.
  9. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
  10. Install the J 29369-1,  8.25 inch axle, or the J 29369-2,  9.25 inch axle, behind the inner axle shaft bearing.
  11. Install the J 2619-01  (2) to the J 29369-1  or the J 29369-2  (1).
  12. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01. 
  13. Remove the front drive axle clutch shaft.
    Fig 8: Install J 2619-01 & J 29369-2
    G01480461Courtesy of GENERAL MOTORS CORP.
  14. Use the J 34011  in order to remove the clutch shaft bearing.
  15. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case.
  16. Remove the inner axle shaft using a hammer and a brass drift.
  17. Install the J 29369-1,  8.25 inch axle, or the J 29369-2,  9.25 inch axle, behind the inner axle shaft bearing.
  18. Install the J 2619-01  to the J 29369-1  or the J 29369-2. 
  19. Remove the inner axle shaft seal and the inner axle shaft bearing using the J 2619-01. 
  20. Remove the differential carrier assembly from the vise.
    Fig 9: Remove Clutch Shaft Bearing
    G01480462Courtesy of GENERAL MOTORS CORP.
  21. Remove the vent connector.
  22. Remove the differential carrier assembly bolts.
    Fig 10: Remove Vent Hose Connector
    G01480463Courtesy of GENERAL MOTORS CORP.
  23. 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.
  24. Remove the differential case assembly.

    Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, 8.25 inch axle-both sides, 9.25 inch axle-right side.

    Fig 11: Remove Differential Case Assembly
    G01480464Courtesy of GENERAL MOTORS CORP.
  25. Remove the differential bearing adjuster nut lock bolt and the lock from the differential bearing adjuster nut, 9.25 inch axle-left side.
    Fig 12: Remove Differential Bearing Adjuster Nut Lock Bolt
    G01480465Courtesy of GENERAL MOTORS CORP.
  26. Remove the differential bearing adjuster by doing the following, 8.25 inch axle-both sides, 9.25 inch axle-right side:
    1. 26.1. Install the J 36599-A  onto the differential bearing adjuster nut.
    2. 26.2. Turn the J 36599-A  clockwise in order to push the bearing cup out of the bore.
    Fig 13: Remove Differential Bearing Adjuster Nut (8.25 Inch Axle) Using J 36599-A
    G01480466Courtesy of GENERAL MOTORS CORP.
  27. For the 9.25 inch axle-left side, remove the differential bearing adjuster by doing the following:
    1. 27.1. Install the J 36615  onto the differential bearing adjuster nut as shown.
    2. 27.2. Turn the J 36615  counterclockwise in order to remove the differential bearing adjuster nut and the O-ring.
    Fig 14: Remove Differential Bearing Adjuster Nut (9.25 Inch Axle) Using J 36615
    G01480467Courtesy of GENERAL MOTORS CORP.
  28. Install the J 8614-01  as shown.

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

  29. Remove the washer.
    Fig 15: Remove Pinion Nut Using J 8614-01
    G01480468Courtesy of GENERAL MOTORS CORP.
  30. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
  31. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
    Fig 16: Removing Pinion Yoke
    G01480469Courtesy of GENERAL MOTORS CORP.
  32. Install the J 36598  into a vise.
  33. Install the left differential carrier case half onto the J 36598  and the J 36598-6, 8.25 in axle, or the J 36598,  9.25 inch axle.
  34. 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
  35. Remove the collapsible spacer from the pinion.
    Fig 17: Installing J 36509 In Vise
    G01480470Courtesy of GENERAL MOTORS CORP.
  36. 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.
  37. Remove the pinion gear selectable shim.
    Fig 18: Remove Inner Pinion Bearing Using J 22912-01
    G01480471Courtesy of GENERAL MOTORS CORP.
  38. Install the J 36598-5 (3) behind the inner pinion bearing cup.
  39. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3) until fully seated.
  40. 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 19: Remove Inner Pinion Bearing Cup Using J 36598-5 & J 36598
    G01480472Courtesy of GENERAL MOTORS CORP.
  41. Install the J 36598-5 (2) behind the outer pinion bearing cup.
  42. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2).
  43. While holding the forcing screw of the J 36598,  turn the handle of the J 36598  clockwise in order to remove the following components:
    • The pinion oil seal
    • The pinion outer bearing
    • The pinion outer bearing cup
    Fig 20: Remove Outer Pinion Bearing, Cup & Oil Seal Using J 36598 & J 36598-5
    G01480473Courtesy of GENERAL MOTORS CORP.
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