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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 >> Removal Procedure

Removal 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. Raise the vehicle. Refer to Lifting and Jacking the Vehicle 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 Replacement - Front in Disc Brakes.
  4. Remove the differential carrier assembly shield, if equipped. Refer to Shield Replacement .
  5. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.
  6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1).
    7. 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.
  7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1).

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

    8. Fig 1: Front Axle Pinion Yoke, Propeller Shaft Universal Joint, Yoke Retainer & Bolts
    GM363785Courtesy of GENERAL MOTORS CORP.
  8. Support the propeller shaft and move out of the way as necessary.
  9. 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
    10. Fig 2: Measuring Pinion Rotation Torque - Front Axle
    GM157174Courtesy of GENERAL MOTORS CORP.
  10. Scribe an alignment line between the pinion shaft and the pinion yoke.
    11. Fig 3: View Of Pinion Shaft & Pinion Yoke Alignment Marks
    GM788905Courtesy of GENERAL MOTORS CORP.
  11. Install the J 8614-01  onto the pinion as shown.
    12. Fig 4: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS CORP.
  12. Remove the pinion nut while holding the J 8614-01  .
  13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
  14. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
    15. Fig 5: Removing Pinion Yoke
    GM664070Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case.
  15. Remove the oil seal using a suitable seal removal tool.
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