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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 946 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly Disassemble (8.25 Inch Axle Lock Tab Style) >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the differential carrier assembly in a vise.
    2. Fig 1: View Of Front Axle Actuator
    GM1866174Courtesy of GENERAL MOTORS CORP.
  2. Remove the front axle actuator, S4WD axle only.
    3. Fig 2: Removing The Inner Axle Shaft Seal And/Or The Inner Axle Shaft Bearing Using J 29369-2 & J 2619-01
    GM834245Courtesy of GENERAL MOTORS CORP.
  3. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Install the J 29369-1  (1) behind the inner axle shaft bearing. See Special Tools .
    2. Install the J 2619-01  (2) to the J 29369-1  (1). See Special Tools .
    3. Using the J 2619-01  , remove the inner axle shaft bearing and the seal.
  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: View Of Inner Axle Shaft Housing Assembly To Differential Carrier Assembly
    GM893259Courtesy 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: View Of Inner Axle Housing Bolt, Axle Shaft Housing & Gasket
    GM1866194Courtesy of GENERAL MOTORS CORP.
  9. Remove the inner axle housing bolt (1), axle shaft housing (2), and gasket (3).
    10. Fig 5: Inner Axle Shaft Housing Components (8.25 Inch)
    GM892810Courtesy of GENERAL MOTORS CORP.
  10. 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)
    11. Fig 6: View Of Differential Carrier Assembly Special Tools
    GM1865771Courtesy 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. See Special Tools .
    3. Install the J 2619-01  (2) to the J 29369-1  . See Special Tools .
    4. Using the J 2619-01  , remove the inner axle shaft bearing and the inner axle shaft seal.
  12. Remove the differential carrier assembly from the vise.
  13. Remove the front drive axle clutch shaft.
    14. Fig 7: Removing Clutch Shaft Pilot Bearing - Front Drive Axle
    GM680254Courtesy of GENERAL MOTORS CORP.
  14. Using the J 34011  , remove the clutch shaft bearing. See Special Tools .
    15. Fig 8: View Of Vent Connector
    GM1904008Courtesy of GENERAL MOTORS CORP.
  15. Remove the vent connector.
    16. Fig 9: View Of Differential Carrier Housing, Gasket & Bolts
    GM1865718Courtesy of GENERAL MOTORS CORP.
  16. Remove the differential carrier assembly bolts (1).
  17. Separate the left carrier case half from the right carrier case half (2) by tapping on the on the carrier case with a hammer and a brass drift.
  18. Remove the differential carrier housing (2) and the differential carrier housing gasket (3).
  19. Remove the differential case assembly.

    Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks.

    20. Fig 10: Identifying Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
    GM680101Courtesy of GENERAL MOTORS CORP.
  20. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following:
    1. Install the J 36599-A  onto the differential bearing adjuster nut. See Special Tools .
    2. Turn the J 36599-A  clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore. See Special Tools .
  21. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift.
    22. Fig 11: View Of J 8614-01
    GM1865961Courtesy of GENERAL MOTORS CORP.
  22. Install the J 8614-01  as shown. See Special Tools .

    Remove the pinion nut while holding the J 8614-01  . See Special Tools .

  23. Remove the washer.
    24. Fig 12: View Of Pinion Yoke Removal Tools
    GM1865770Courtesy of GENERAL MOTORS CORP.
  24. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown. See Special Tools .
  25. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1). See Special Tools .
  26. 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  . See Special Tools . Follow the appropriate steps depending on what tool is available.
  27. Install the J 36598  into a vise. See Special Tools .
    28. Fig 13: Identifying Holding Fixture & Pinion Tool J 36598
    GM680106Courtesy of GENERAL MOTORS CORP.
  28. Install the left differential carrier case half onto the J 36598  and the J 36598-6. See Special Tools .
  29. 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. See Special Tools .
    • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer
    30. Fig 14: 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.
  30. Install the J 36598-5 (3) behind the inner pinion bearing cup.
  31. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3) until fully seated. See Special Tools .
  32. 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. See Special Tools .
    33. Fig 15: Identifying Pinion Oil Seal & Bearing Using Forcing Screw J 36598 To J 36598-5 (8.25 Inch Axles)
    GM680114Courtesy of GENERAL MOTORS CORP.
  33. Install the J 36598-5 (2) behind the outer pinion bearing cup.
  34. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2). See Special Tools .
  35. While holding the forcing screw of the J 36598  , turn the handle of the J 36598  clockwise in order to remove the following components: See Special Tools .
    • The pinion oil seal
    • The pinion outer bearing
    • The pinion outer bearing cup
    36. Fig 16: Identifying Pinion Components Using J 45765 (8.25 Inch Axles)
    GM1486597Courtesy of GENERAL MOTORS CORP.
  36. Install the J 45765  to the left side differential carrier case half over the drive pinion as shown. See Special Tools .
  37. Turn the forcing screw of the J 45765  clockwise to remove the following components from the left side differential carrier case half:. See Special Tools .
    • The drive pinion gear
    • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer
  38. Remove the drive pinion seal using a suitable seal remover.
  39. Remove the outer pinion bearing from the differential carrier case half.
    40. Fig 17: Installing J 45858-4 Over Inner Pinion Bearing Cup (8.25 Inch Axles)
    GM1486598Courtesy of GENERAL MOTORS CORP.
  40. Install the J 45858-4 over the inner pinion bearing cup.
    41. Fig 18: Installing Forcing Screw Of J 45858 Into J 45858-4 (8.25 Inch Axles)
    GM1486602Courtesy of GENERAL MOTORS CORP.
  41. Install the forcing screw (1) of the J 45858 into the J 45858-4 (2).
  42. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
    43. Fig 19: Installing J 45858-3, Thrust Bearing & Washer, & Forcing Screw (8.25 Inch Axles)
    GM1486596Courtesy of GENERAL MOTORS CORP.
  43. 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.
    44. Fig 20: Installing J 45858-5 Into Pinion Bearing Bore (8.25 Inch Axles)
    GM1486591Courtesy of GENERAL MOTORS CORP.
  44. 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.

  45. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
  46. Remove the collapsible spacer from the drive pinion.
    47. Fig 21: View Of Inner Pinion Bearing & Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  47. Install the J 22912-B  between the pinion bearing and the drive pinion. See Special Tools .
  48. Using the J 22912-B  and a hydraulic press, remove the inner pinion bearing. See Special Tools .
  49. Remove the pinion gear selectable shim.
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