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Disassembly Procedure

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  1. Remove the upper differential carrier assembly bushing by performing the following steps:
    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. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
    2. Fig 1: Removing Upper Differential Carrier Assembly Bushing Using J 36616-2, J 33791-1, Thrust Bearing, J 21474-18, & Forcing Screw (8.25 Inch Axles)
    GM893247Courtesy of GENERAL MOTORS CORP.
  2. Remove the lower differential carrier assembly bushing by performing the following steps:
    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. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
    3. Fig 2: Remove The Lower Differential Carrier Assembly Bushing Using J 21474-18, Thrust Bearing, J 33791-1, J 36616-2, & Forcing Screw (8.25 Inch Axles)
    GM892847Courtesy of GENERAL MOTORS CORP.
  3. Remove the front axle actuator, S4WD axle only.
  4. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift, F4WD axle only.
  5. Remove the inner axle shaft, F4WD axle only.
  6. Remove the inner axle shaft housing to differential carrier assembly bolts.
  7. Remove the inner axle shaft housing, F4WD axle only.
    8. Fig 3: Removing Inner Axle Shaft (8.25 Inch Axles)
    GM893264Courtesy of GENERAL MOTORS CORP.
  8. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly, S4WD axle only.
    9. Fig 4: Removing Inner Axle Shaft Housing (8.25 Inch Axles)
    GM893259Courtesy of GENERAL MOTORS CORP.
  9. Remove the following components from the inner axle shaft housing, S4WD axle only:
    1. The clutch fork inner spring (10)
    2. The clutch fork assembly (11)
    3. The clutch shaft shim (9)
    4. The clutch shaft sleeve (8)
    5. The front drive axle clutch gear (6) by doing the following:
      1. Clamp the inner axle shaft housing (4) in a vise.

        Clamp only on the mounting flange.

      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. Remove the front drive axle clutch gear (6)
    7. Remove the thrust washer (5)
    8. Remove the inner axle shaft (1)
    10. Fig 5: Inner Axle Shaft Housing Components (S4WD Axle Only)
    GM892810Courtesy of GENERAL MOTORS CORP.
  10. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Install the inner axle shaft housing into a vise.

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

    2. Install the J 29369-1  (1) behind the inner axle shaft bearing.
    3. Install the J 2619-01  (2) to the J 29369-1  (1).
    4. Remove the inner axle shaft bearing and the seal using the J 2619-01  .
    11. Fig 6: Removing Inner Axle Shaft Bearing & Inner Axle Shaft Seal From Inner Axle Shaft Housing (8.25 Inch Axles)
    GM834245Courtesy of GENERAL MOTORS CORP.
  11. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Place the differential carrier assembly into a vise.

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

    2. Install the J 29369-1  (1) behind the inner axle shaft bearing.
    3. Install the J 2619-01  (2) to the J 29369-1  .
    4. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01  .
    12. Fig 7: Removing Inner Axle Shaft Bearing & Inner Axle Shaft Seal From Differential Carrier (8.25 Inch Axles)
    GM1332786Courtesy of GENERAL MOTORS CORP.
  12. Remove the differential carrier assembly from the vise.
  13. Remove the front drive axle clutch shaft, S4WD axle only.
  14. Use the J 34011  in order to remove the clutch shaft bearing, S4WD axle only.
    15. Fig 8: Removing Clutch Shaft Bearing (S4WD)
    GM680254Courtesy of GENERAL MOTORS CORP.
  15. Remove the vent connector.
    16. Fig 9: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  16. Remove the differential carrier assembly bolts.
    17. Fig 10: Differential Carrier Assembly Bolts (8.25 Inch Axles)
    GM1332740Courtesy of GENERAL MOTORS CORP.
  17. 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.
  18. Remove the differential case assembly.

    Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, S4WD axle - both sides, F4WD axle - left side.

    19. Fig 11: Removing Differential Case Assembly (8.25 Inch Axles)
    GM1332738Courtesy of GENERAL MOTORS CORP.
  19. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following, S4WD axle - both sides, F4WD axle - left side:
    1. Install the J 36599-A  onto the differential bearing adjuster nut.
    2. Turn the J 36599-A  clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore.
    20. Fig 12: Removing Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
    GM680101Courtesy of GENERAL MOTORS CORP.
  20. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift, S4WD axle - both sides, F4WD axle - left side.
  21. Install the J 8614-01  as shown.

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

    22. Fig 13: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS CORP.
  22. Remove the washer.
  23. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
    24. Fig 14: Removing Pinion Yoke
    GM664070Courtesy of GENERAL MOTORS CORP.
  24. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
  25. The steps below explain how to remove the drive pinion and pinion bearing cups using the J 36598  or the J 45765  and the J-45858  . Follow the appropriate steps depending on what tool is available.
  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. Fig 15: Removing Pinion (8.25 Inch Axles)
    GM680106Courtesy of GENERAL MOTORS CORP.
  29. Install the J 36598-5 (3) behind the inner pinion bearing cup.
  30. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3) until fully seated.
  31. 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.
    32. Fig 16: Pressing The Inner Bearing Cup Out From The Differential Carrier Case Using J 36598 Forcing Screw, J 36598 Handle & J 36598-5 (8.25 Inch Axles)
    GM890234Courtesy of GENERAL MOTORS CORP.
  32. Install the J 36598-5 (2) behind the outer pinion bearing cup.
  33. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2).
    34. Fig 17: Removing Pinion Oil Seal & Bearing Using Forcing Screw J 36598 To J 36598-5 (8.25 Inch Axles)
    GM680114Courtesy of GENERAL MOTORS CORP.
  34. 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
  35. Install the J 45765  to the left side differential carrier case half over the drive pinion as shown.
  36. Turn the forcing screw of the J 45765  clockwise to remove the following components from the left side differential carrier case half:
    • The drive pinion gear
    • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer
    Fig 18: Removing Pinion Components Using J 45765 (8.25 Inch Axles)
    GM1486597Courtesy of GENERAL MOTORS CORP.
  37. Remove the drive pinion seal using a suitable seal remover.
  38. Remove the outer pinion bearing from the differential carrier case half.
  39. Install the J 45858-4 over the inner pinion bearing cup.
    40. Fig 19: Installing J 45858-4 Over Inner Pinion Bearing Cup (8.25 Inch Axles)
    GM1486598Courtesy of GENERAL MOTORS CORP.
  40. Install the forcing screw (1) of the J 45858 into the J 45858-4 (2).
    41. Fig 20: Installing Forcing Screw Of J 45858 Into J 45858-4 (8.25 Inch Axles)
    GM1486602Courtesy of GENERAL MOTORS CORP.
  41. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
  42. Install the J 45858-3 (3), the thrust bearing and the washer (2), and the forcing screw (1) over the outer pinion bearing cup bore.
    43. Fig 21: Installing J 45858-3, Thrust Bearing & Washer, & Forcing Screw (8.25 Inch Axles)
    GM1486596Courtesy of GENERAL MOTORS CORP.
  43. Install the J 45858-5 into the pinion bearing bore behind the outer pinion bearing cup.

    Slowly turn the forcing screw clockwise until the J 45858-5 is evenly seated behind the outer pinion bearing cup bore and the J 45858-3 is evenly seated over the outer pinion bearing cup bore.

    44. Fig 22: Installing J 45858-5 Into Pinion Bearing Bore (8.25 Inch Axles)
    GM1486591Courtesy of GENERAL MOTORS CORP.
  44. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
  45. Remove the collapsible spacer from the drive pinion.
  46. Install the J 22912-01  between the pinion bearing and the drive pinion.
  47. Remove the inner pinion bearing using the J 22912-01  and a hydraulic press.
    Fig 23: Removing Inner Pinion Bearing Using Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  48. Remove the pinion gear selectable shim.
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