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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 987 (Front Drive Axle) >> Repair Instructions >> Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front >> Installation Procedure

Installation 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.
  1. Install the oil seal by doing the following:
    1. Position the oil seal over the seal bore.
    2. Install the J 36366 over the oil seal.
    3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface.
    2. Fig 1: Installing Oil Seal Using J 36366 - Front Axle
    GM664080Courtesy of GENERAL MOTORS CORP.
  2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke.
  3. Install the pinion yoke.

    Align the reference marks made during removal.

    4. NOTE: Refer to Pinion Flange/Yoke Installation Notice in Cautions and Notices.
  4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
  5. Install the washer and a new pinion nut.
  6. Install the J 8614-01  onto the pinion yoke as shown.
    7. Fig 2: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
  7. Tighten the pinion nut while holding the J 8614-01  .

    Tighten:  Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

  8. Measure the rotating torque of the pinion using an inch-pound torque wrench.

    Compare the measurement with the rotating torque recorded earlier.

    Tighten:  Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal.

  9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
  10. Install the propeller shaft universal joint (2) to the pinion yoke (1).

    Align the reference marks made during removal.

  11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1).

    Tighten:  Tighten the yoke retainer bolts to 25 N.m (18 lb ft).

    12. Fig 3: Front Axle Pinion Yoke, Propeller Shaft Universal Joint, Yoke Retainer & Bolts
    GM363785Courtesy of GENERAL MOTORS CORP.
  12. Inspect the axle lubricant level, and add, if necessary. Refer to Lubricant Level Inspection - Front Drive Axle .
  13. Install the differential carrier assembly shield, if equipped. Refer to Shield Replacement .
  14. Install the brake calipers. Refer to Brake Caliper Replacement - Front in Disc Brakes.
  15. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  16. Lower the vehicle.
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