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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 103 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly - Disassemble (9.25 Inch Axle) >> Disassembly Procedure

Disassembly Procedure

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    Fig 1: View Of Special Tools J 36616-2, J 33791-1, Thrust Bearing, J 21474-18 & Forcing Screw
    GM893247Courtesy of GENERAL MOTORS CORP.
  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 2: View Of Special Tools 21474-18, Thrust Bearing, J 33791-1, J 36616-2, & Forcing Screw
    GM892847Courtesy 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 3: Inner Axle Shaft (8.25 Inch Axles)
    GM893264Courtesy of GENERAL MOTORS CORP.
  3. Remove the front axle actuator.
  4. Remove the inner axle shaft housing to differential carrier assembly bolts.
    5. Fig 4: View Of Inner Axle Shaft Housing Assembly To Differential Carrier Assembly
    GM893259Courtesy of GENERAL MOTORS CORP.
  5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly.
    6. Fig 5: Inner Axle Shaft Housing Components (9.25 Inch)
    GM892812Courtesy of GENERAL MOTORS CORP.
  6. Remove the following components from the inner axle shaft housing (4):
    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 retainer ring (7)
    6. The thrust washers (5, 6)
    7. Fig 6: Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM615683Courtesy of GENERAL MOTORS CORP.
  7. Remove the inner axle shaft (2).
    8. Fig 7: Inner Axle Shaft Seal And/Or The Inner Axle Shaft Bearing & J 29369-2 & J 2619-01
    GM834245Courtesy of GENERAL MOTORS CORP.
  8. 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 29369-2  (1) behind the inner axle shaft bearing. See Special Tools .
  9. Install the J 2619-01  (2) to the J 29369-2  (1). See Special Tools .
  10. Remove the inner axle shaft bearing and the inner axle shaft bearing and the seal using the J 2619-01  .
  11. Remove the inner axle shaft housing from the vise.
  12. Remove the front drive axle clutch shaft.
    13. Fig 8: Removing Clutch Shaft Pilot Bearing - Front Drive Axle
    GM680254Courtesy of GENERAL MOTORS CORP.
  13. Use the J 34011  in order to remove the clutch shaft bearing. See Special Tools .
    14. Fig 9: Inner Axle Shaft Seal/Bearing & J 29369-2 & J 2619-01 - Front Drive Axle
    GM1332786Courtesy of GENERAL MOTORS CORP.
  14. Place the differential carrier assembly into a vise.

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

  15. Remove the inner axle shaft using a hammer and a brass drift.
  16. Install the J 29369-2  (1) behind the inner axle shaft bearing. See Special Tools .
  17. Install the J 2619-01  (2) to the J 29369-2  (1). See Special Tools .
  18. Remove the inner axle shaft bearing and the inner axle seal bearing and the seal using the J 2619-01  .
  19. Remove the differential carrier assembly from the vise.
    20. Fig 10: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  20. Remove the vent connector.
  21. Remove the differential carrier assembly bolts.
    22. Fig 11: View Of Clutch Shaft To Differential Carrier Case Half
    GM205917Courtesy of GENERAL MOTORS CORP.
  22. 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.
  23. Remove the differential case assembly.

    Disconnect the right side differential bearing adjuster nut lock from the differential bearing adjuster nut by prying up on the lock.

    24. Fig 12: View Of Left Side Differential Bearing Adjuster Nut Lock & Bolt
    GM685960Courtesy of GENERAL MOTORS CORP.
  24. Remove the left side differential bearing adjuster nut lock and the bolt.
    25. Fig 13: View Of J 36615 On Left Side Differential Bearing Adjuster Nut
    GM680888Courtesy of GENERAL MOTORS CORP.
  25. Remove the left side differential bearing adjuster by doing the following:
    1. Install the J 36615  onto the differential bearing adjuster nut as shown. See Special Tools .
    2. Turn the J 36615  counterclockwise in order to remove the differential bearing adjuster nut and the O-ring. See Special Tools .
    26. Fig 14: View Of J 36599-A On Right Side Differential Bearing Adjuster Nut
    GM680101Courtesy of GENERAL MOTORS CORP.
  26. Remove the right side differential bearing adjuster 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 bearing cup out of the bore. See Special Tools .
  27. Remove the right side differential bearing adjuster nut sleeve using a hammer and brass drift.
    28. Fig 15: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS CORP.
  28. Install the J 8614-01  as shown. See Special Tools .

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

  29. Remove the washer.
    30. Fig 16: Identifying Special Tools J 8614-2, J 8614-3 & J 8614-01
    GM664070Courtesy of GENERAL MOTORS CORP.
  30. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown. See Special Tools .
  31. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1). See Special Tools .
    32. Fig 17: View Of J 45765 Installed To Left Side Differential Carrier Case Half
    GM847067Courtesy of GENERAL MOTORS CORP.
  32. Install the J 45765  to the left side differential carrier case half over the drive pinion as shown. See Special Tools .
  33. 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
  34. Remove the drive pinion seal using a suitable seal remover.
  35. Remove the outer pinion bearing from the differential carrier case half.
    36. Fig 18: View Of J 45754-3 Over Inner Pinion Bearing Cup
    GM866062Courtesy of GENERAL MOTORS CORP.
  36. Install the J 45754-3 over the inner pinion bearing cup.
    37. Fig 19: View Of Forcing Screw Installed Into J 45754-3
    GM866059Courtesy of GENERAL MOTORS CORP.
  37. Install the forcing screw (1) of the J 45754 into the J 45754-3 (2).
  38. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
    39. Fig 20: View Of J 45754-2 & Forcing Screw Installed Over Outer Pinion Bearing Cup Bore
    GM866064Courtesy of GENERAL MOTORS CORP.
  39. Install the J 45754-2 (2) and the forcing screw (1) over the outer pinion bearing cup bore.
    40. Fig 21: View Of J 45754-4 Installed In Pinion Bearing Bore
    GM866067Courtesy of GENERAL MOTORS CORP.
  40. Install the J 45754-4 (3) into the pinion bearing bore behind the outer pinion bearing cup.

    Slowly turn the forcing screw (1) until the J 45754-4 is evenly seated behind the outer pinion bearing cup bore and the J 45754-2 (2) is evenly seated over the outer pinion bearing cup bore.

  41. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
    42. Fig 22: View Of Inner Pinion Bearing & Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  42. Install the J 22912-01  between the pinion bearing and the drive pinion. See Special Tools .
  43. Remove the inner pinion bearing using the J 22912-01  and a hydraulic press. See Special Tools .
  44. Remove the pinion gear selectable shim.
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