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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 879 (Front Drive Axle - 4WD) >> Repair Instructions >> Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing Brake Rotors
    G01468013Courtesy of GENERAL MOTORS CORP.
  1. Raise the vehicle. Refer to JACKING AND LIFTING 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 SINGLE PISTON or BRAKE CALIPER -- FRONT DUAL PISTON in Disc Brakes.
  4. Remove the brake rotors.
  5. Remove the front differential carrier assembly shield, if equipped. Refer to SHIELD REPLACEMENT  .
  6. Remove the left front differential carrier assembly shield bracket.
  7. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.
  8. Remove the yoke retainer bolts and the yoke retainers from the front axle pinion yoke.
    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 joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint.
  9. Disconnect the propeller shaft from the front axle pinion yoke.

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

  10. Support the propeller shaft and move out of the way as necessary.
  11. 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 carrier bearings
    • The axle bearings
    • The axle seals
    Fig 2: Measuring Torque Required In Order To Rotate Pinion
    G01468014Courtesy of GENERAL MOTORS CORP.
  12. Scribe a line (1) on the pinion shaft and the pinion yoke (2). Record the number of exposed threads on the pinion shaft.
    Fig 3: Scribing A Line On Pinion Shaft And Pinion Yoke
    G01468015Courtesy of GENERAL MOTORS CORP.
  13. Install the J 8614-01  onto the pinion as shown.
  14. Remove the pinion nut while holding the J 8614-01  .
    Fig 4: Removing Pinion Nut
    G01468016Courtesy of GENERAL MOTORS CORP.
  15. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 
  16. Remove the pinon yoke 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.

  17. Remove the oil seal using a flat-bladed tool.
  18. Remove the dust deflector from the pinion yoke by doing the following:
    • Tap the deflector off the pinion yoke.
    • Clean up the stake points on the pinion yoke.
    Fig 5: Removing Oil Seal
    G01468017Courtesy of GENERAL MOTORS CORP.
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