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Disassembly Procedure

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    Fig 1: Removing Upper Differential Carrier Assembly Bushing Using J 36616-2, J 33791-1, Thrust Bearing, J 21474-18 & Forcing Screw
    GM893247Courtesy of GENERAL MOTORS CORP.
  1. Using the J 36616-2 (1), J 33791-1 (2), thrust bearing (3), and the J 21474-18 (4), remove the upper differential carrier assembly bushing.
    2. Fig 2: Removing Lower Differential Carrier Assembly Bushingj 21474-18, Thrust Bearing, J 33791-1, J 36616-2, & Forcing Screw
    GM892847Courtesy of GENERAL MOTORS CORP.
  2. Using the J 21474-18 (1), thrust bearing (2), J 33791-1 (3), and the J 36616-2 (4), remove the lower differential carrier assembly bushing.
    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
    GM2047154Courtesy of GENERAL MOTORS CORP.
  6. Remove the following components from the inner axle shaft housing (4):
    1. The clutch fork inner spring (9)
    2. The clutch fork assembly (10)
    3. The clutch shaft shim (9)
    4. The clutch shaft sleeve (7)
    5. The retainer ring (6)
    6. The thrust washers (5)
    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: Removing Inner Axle Shaft Seal And/Or Inner Axle Shaft Bearing Usingj 29369-2 & J 2619-01
    GM834245Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: To remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps.
  8. Install the inner axle shaft housing into a vise.
  9. Clamp only on the mounting flange of the inner axle shaft housing.
  10. Using the J 29369-2  (1) and the J 2619-01  (2), remove the inner axle shaft bearing and the seal.
  11. Remove the inner axle shaft housing from the vise.
  12. Remove the front drive axle clutch shaft.
    13. Fig 8: Identifying Clutch Shaft Pilot Bearing - Front Drive Axle
    GM680254Courtesy of GENERAL MOTORS CORP.
  13. Use the J 34011  , remove the clutch shaft bearing. See Special Tools .
    14. Fig 9: Removing Inner Axle Shaft Seal/Bearing Using J 29369-2 & J 2619-01 - Front Drive Axle
    GM1332786Courtesy of GENERAL MOTORS CORP.
  14. Clamp only on the mounting flange of the differential carrier assembly, install the differential carrier assembly into a vise.
  15. Using a hammer and a brass drift, remove the inner axle shaft.
  16. Using the J 2619-01  (2) and the J 29369-2  (1), remove the inner axle shaft bearing and the inner axle seal bearing and the seal. See Special Tools .
  17. Remove the differential carrier assembly from the vise.
    18. Fig 10: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  18. Remove the vent connector.
  19. Remove the differential carrier assembly bolts.
    20. Fig 11: Identifying Differential Carrier Assembly Bolts
    GM205917Courtesy of GENERAL MOTORS CORP.
  20. Using a hammer and a brass drift, separate the left carrier case half from the right carrier case half.
  21. Remove the differential case assembly.
  22. Disconnect the right side differential bearing adjuster nut lock from the differential bearing adjuster nut by prying up on the lock.
    23. Fig 12: Left Side Differential Bearing Adjuster Nut Lock & Bolt (9.25 Inch Axle)
    GM685960Courtesy of GENERAL MOTORS CORP.
  23. Remove the left side differential bearing adjuster nut lock and the bolt.
    24. Fig 13: Identifying Left Side Differential Bearing Adjuster (9.25 Inch Axle)
    GM680888Courtesy of GENERAL MOTORS CORP.
  24. Using the J 36615  and turning it counterclock wise, remove the left side differential bearing adjuster. See Special Tools .
    25. Fig 14: Identifying Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
    GM680101Courtesy of GENERAL MOTORS CORP.
  25. Using the J 36599-A  and turning it counterclock wise, remove the right side differential bearing adjuster. See Special Tools .
  26. Using a hammer and brass drift, remove the right side differential bearing adjuster nut sleeve.
    27. Fig 15: Holding Pinion Flange Using Special Tool
    GM664065Courtesy of GENERAL MOTORS CORP.
  27. Using the J 8614-01  to hold the differential yoke, remove the pinion nut and washer. See Special Tools .
    28. Fig 16: Removing Pinion Yoke
    GM664070Courtesy of GENERAL MOTORS CORP.
  28. Using the J 8614-01  (1), (2) and turning (3) clockwise, remove the differential yoke. See Special Tools .
    29. Fig 17: Installing J 45765 To Left Side Differential Carrier Case (9.25 Inch Axle)
    GM847067Courtesy of GENERAL MOTORS CORP.
  29. Using the J 45765  and turning the bolt clockwise, remove the drive pinion gear, pinion gear selectable shim, inner pinion bearing, and the collapsible spacer. See Special Tools .
  30. Using a suitable tool, remove the drive pinion seal.
  31. Remove the outer pinion bearing from the differential carrier case half.
    32. Fig 18: Installing J 45754-3 Over Inner Pinion Bearing Cup (9.25 Inch Axle)
    GM866062Courtesy of GENERAL MOTORS CORP.
  32. Position the J 45754-3 over the inner pinion bearing cup.
    33. Fig 19: Installing J 45754 Forcing Screw Into J 45754-3 (9.25 Inch Axle)
    GM866059Courtesy of GENERAL MOTORS CORP.
  33. Using the J 45754  , bolt (1), plate (2) and by tapping the bolt (1) with a hammer, remove the inner pinion bearing cup. See Special Tools .
    34. Fig 20: Forcing Screw, J 45754-2 & J 45754-4 (9.25 Inch Axle)
    GM866067Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Before removing the outer pinion bearing cup, ensure that the tool is evenly seated behind the outer pinion bearing cup bore and over the outer pinion bearing cup bore.
  34. Using the J 45754  (1), (2), and turning the (3) clockwise, remove the outer pinion bearing cup. See Special Tools .
    35. Fig 21: Removing Inner Pinion Bearing Using Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  35. Using the J 22912-B  and a press, remove the inner pinion bearing. See Special Tools .
  36. Remove the pinion gear selectable shim.
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