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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 COMPANY
  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 COMPANY
  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 COMPANY
  3. Remove the front axle actuator.
  4. Remove the inner axle shaft housing to differential carrier assembly bolts.
    5. Fig 4: Identifying Inner Axle Shaft Housing Assembly - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM893259Courtesy of GENERAL MOTORS COMPANY
  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 COMPANY
  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 COMPANY
  7. Remove the inner axle shaft (2).
    8. Fig 7: Installing J 2619-01 To J 29369
    GM834245Courtesy of GENERAL MOTORS COMPANY
  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  bushing and bearing remover (1) behind the inner axle shaft bearing.
  9. Install the J-2619-01  slide hammer (2) to the J-29369-2  bushing and bearing remover (1).
  10. Remove the inner axle shaft bearing and the inner axle shaft bearing and the seal using the J-2619-01  slide hammer.
  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 COMPANY
  13. Use the J-34011  pilot bearing remover in order to remove the clutch shaft bearing.
    14. Fig 9: Removing Inner Axle Shaft Seal/Bearing - Front Drive Axle
    GM1332786Courtesy of GENERAL MOTORS COMPANY
  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  bushing and bearing remover (1) behind the inner axle shaft bearing.
  17. Install the J-2619-01  slide hammer (2) to the J-29369-2  bushing and bearing remover (1).
  18. Remove the inner axle shaft bearing and the inner axle seal bearing and the seal using the J-2619-01  slide hammer.
  19. Remove the differential carrier assembly from the vise.
    20. Fig 10: View Of Vent Hose Connector
    GM847064Courtesy of GENERAL MOTORS COMPANY
  20. Remove the vent connector.
  21. Remove the differential carrier assembly bolts.
    22. Fig 11: Identifying Differential Carrier Assembly Bolts
    GM205917Courtesy of GENERAL MOTORS COMPANY
  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 COMPANY
  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 COMPANY
  25. Remove the left side differential bearing adjuster by doing the following:
    1. Install the J-36615  side bearing nut wrench onto the differential bearing adjuster nut as shown.
    2. Turn the J-36615  side bearing nut wrench counterclockwise in order to remove the differential bearing adjuster nut and the O-ring.
    26. Fig 14: Identifying Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
    GM680101Courtesy of GENERAL MOTORS COMPANY
  26. Remove the right side differential bearing adjuster by doing the following:
    1. Install the J-36599-A  side bearing nut wrench onto the differential bearing adjuster nut.
    2. Turn the J-36599-A  side bearing nut wrench 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 COMPANY
  28. Install the J-8614-01  flange and pulley holding tool as shown in the garphic.

    Remove the pinion nut while holding the J-8614-01  flange and pulley holding tool.

  29. Remove the washer.
    30. Fig 16: Identifying Special Tools J 8614-2, J 8614-3 & J 8614-01
    GM664070Courtesy of GENERAL MOTORS COMPANY
  30. Install the J-8614-2 (2) and the J-8614-3 (3) into the J-8614-01  flange and pulley holding tool (1) as shown.
  31. Remove the pinion yoke by turning the J-8614-3 (3) clockwise while holding the J-8614-01  flange and pulley holding tool (1).
    32. Fig 17: View Of J 45765 Installed To Left Side Differential Carrier Case Half
    GM847067Courtesy of GENERAL MOTORS COMPANY
  32. Install the J-45765  pinion remover to the left side differential carrier case half over the drive pinion as shown.
  33. Turn the forcing screw of the J-45765  pinion remover 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: View Of J 45754-3 Over Inner Pinion Bearing Cup
    GM866062Courtesy of GENERAL MOTORS COMPANY
  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 COMPANY
  37. Install the forcing screw (1) of the J-45754  pinion bearing race remover/installer 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: Installing J 45754-2 & Forcing Screw (9.25 Inch Axle)
    GM866064Courtesy of GENERAL MOTORS COMPANY
  39. Install the J-45754-2 (2) and the forcing screw (1) over the outer pinion bearing cup bore.
    40. Fig 21: Forcing Screw, J 45754-2 & J 45754-4 (9.25 Inch Axle)
    GM866067Courtesy of GENERAL MOTORS COMPANY
  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 COMPANY
  42. Install the J-22912-B  split-plate bearing puller between the pinion bearing and the drive pinion.
  43. Remove the inner pinion bearing using the J-22912-B  split-plate bearing puller and a hydraulic press.
  44. Remove the pinion gear selectable shim.
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