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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 372 (Front Drive Axle) >> Repair Instructions >> Differential Carrier Assembly Disassemble (9.25 Inch Axle) >> Disassembly Procedure

Disassembly Procedure

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    Fig 1: Upper Differential Carrier Assembly Bushing And Special Tool
    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: Lower Differential Carrier Assembly Bushing And Remover
    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
    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: Installing Inner Shaft Housing
    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 Shaft Housing Components (9.25 Inch Axle)
    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: Inner Axle Shaft And Housing
    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 And Special Tools
    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.
  9. Install the J 2619-01 (2) to the J 29369-2  (1).
  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: 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.
    14. Fig 9: Removing Inner Axle Shaft Seal/Bearing
    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.
  17. Install the J 2619-01 (2) to the J 29369-2  (1).
  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: Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS CORP.
  20. Remove the vent connector.
  21. Remove the differential carrier assembly bolts.
    22. Fig 11: Differential Carrier Assembly Bolts
    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: Left Side Differential Bearing Adjuster Nut Lock & Bolt (9.25 Inch Axle)
    GM685960Courtesy of GENERAL MOTORS CORP.
  24. Remove the left side differential bearing adjuster nut lock and the bolt.
    25. Fig 13: 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.
    2. Turn the J 36615  counterclockwise in order to remove the differential bearing adjuster nut and the O-ring.
    26. Fig 14: Differential Bearing Adjuster Nuts & Bearing Cups
    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.
    2. Turn the J 36599-A  clockwise in order to push the bearing cup out of the bore.
  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.

    Remove the pinion nut while holding the J 8614-01 .

  29. Remove the washer.
    30. Fig 16: Pinion Yoke
    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.
  31. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
    32. Fig 17: Special Tool 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.
  33. Turn the forcing screw of the J 45765  clockwise to remove the following components from the left side differential carrier case half:
    • 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: Special Tool 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: Installing Forcing Screw Into Special Tool
    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: Special Tool And Forcing Screw (9.25 Inch Axle)
    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: Forcing Screw And Special Tools (9.25 Inch Axle)
    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: Removing Inner Pinion Bearing Using Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  42. Install the J 22912-B between the pinion bearing and the drive pinion.
  43. Remove the inner pinion bearing using the J 22912-B and a hydraulic press.
  44. Remove the pinion gear selectable shim.
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