Drive Axle - Front Cadillac Escalade GMT400

SPECIFICATIONS

Fastener Tightening Specifications

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Begin the system diagnosis by reviewing the system Description and Operation. Refer to DESCRIPTION AND OPERATION . Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exist. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to SYMPTOMS - FRONT DRIVE AXLE in order to identify the correct procedure for diagnosing the system and where the procedure is located.

SYMPTOMS - FRONT DRIVE AXLE

Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system functions. Refer to FRONT DRIVE AXLE DESCRIPTION AND OPERATION .

Noise Diagnosis

Any gear-driven unit produces a certain amount of noise that is normal and that conventional repairs or adjustment cannot eliminate. Slight noise that is heard only at a certain speed or under unusual or remote conditions is acceptable. For example, this noise tends to reach a peak at speeds from 60-100 km/h (40-60 mph) depending upon road and load conditions, or upon gear ratio and tire size. Noise of this kind does not indicate trouble in the axle assembly.

When an axle is suspected of being noisy, make a thorough test in order to determine whether the noise originates in the tires, road surface, wheel bearings, engine, transmission, propeller shaft, or axle assembly.

Classifying the Symptom

Front Drive Axle symptoms can usually be classified into the following categories

1. Leaks
2. Noises
3. Vibrations

Leak and noise related symptoms are diagnosed within the Front Drive Axle section.

Visual/Physical Inspection

1. Inspect the system for loose or missing fasteners.
2. Inspect the system for loose or leaking components.
3. Inspect the system for obvious damage or conditions which may cause the symptom.

Symptoms List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom.

1. «FRONT DRIVE AXLE NOISES»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front)
2. «NOISY IN DRIVE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front)
3. «NOISY WHEN COASTING»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front)
4. «INTERMITTENT NOISE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front)
5. «CONSTANT NOISE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front)
6. «NOISY ON TURNS»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front)
7. «FRONT AXLE LUBRICANT LEAK DIAGNOSIS»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front__front-axle-lubricant-leak-diagnosis)

Gear Noise

Gear noise or whine is audible from 32-89 km/h (20-55 mph) under 4 driving conditions

1. Drive - Acceleration or heavy pull
2. Road Load - Vehicle driving load or constant speed
3. Float - Using enough throttle to keep the vehicle from driving the engine, the vehicle slows down gradually but the engine still pulls slightly
4. Coast - Throttle is closed and the vehicle is in gear

Gear noise most frequently has periods where the noise is more prominent, usually between 48-64 km/h (30-40 mph) and 80-85 km/h (50-53 mph). Gear whine is corrected by ring and pinion gear replacement or adjustment, depending on the mileage of the gear set.

Bearing Noise

Faulty bearings produce a rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise (hum) will pulsate at a constant vehicle speed. This indicates a bad pinion or a bad front axle side bearing. This noise can be confused with front wheel bearing noise. Inspect and replace the bearings and the affected components as required.

Front Wheel Bearing Noise

A rough front wheel bearing produces a noise which continues with the car coasting at low speed and the transmission in neutral. The noise may diminish some when the brakes are gently applied. The noise may also change when performing side-to-side maneuvers with the vehicle.

A rough and/or noisy wheel bearing can be heard by spinning the wheels by hand and listening at the hubs for the noise. Inspect and replace the bearings and the affected components as needed.

Knock at Low Speeds

A low speed knock can be caused by a differential case side gear bore that has worn oversize. Inspect the side gears and the differential case assembly and replace the components as necessary.

Backlash Clunk

Excessive backlash clunk under acceleration or de-acceleration can be caused by any of the following

1. Worn differential pinion shaft
2. Worn differential pinion and/or side gear teeth
3. Worn thrust washers
4. Excessive clearance between the side gears and the axle shafts
5. Excessive clearance between differential side gears and the bore in the case
6. Excessive drive pinon and ring gear backlash

Inspect, adjust or replace the affected components as necessary.

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Straight Roller Bearing Diagnosis

Consider the following factors when diagnosing a bearing condition

1. Note the general condition of all parts during disassembly and inspection.
2. Classify the failure with the aid of the illustrations.
3. Determine the cause.
4. Make all repairs following recommended procedures.

Scheme 15

Light pattern on races and rollers can be caused by fine abrasives. Clean all of the parts including the housings. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 16

Heavy pattern on races and rollers can be caused by fine abrasives. Clean all of the parts including the housing. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 17

Surface indentations in the raceway can be caused by roll either under impact loading or vibration while the bearing is not rotating. Replace the bearing if rough or noisy. Replace the shaft if damaged.

Scheme 18

Surface depressions on race and rollers can be caused by hard particles of foreign material. Clean all of the parts, including the housing. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 19

Flaking of surface metal results from fatigue, usually at one edge of race and rollers. Replace the bearing. Clean all related parts. Replace the shaft if damaged.

Scheme 20

Flaking of surface metal results from fatigue, usually at both edges of the race and rollers. Replace the bearing. Clean all related parts. Replace the shaft if damaged.

Scheme 21

Outer misalignment due to a foreign object. Replace the bearing. Ensure races are properly seated. Replace the shaft if the bearing operating surface is damaged.

Scheme 22

Corrosion set up by a small relative movement of parts with no lubrication. Replace the bearing. Clean all the relative parts. Check the seals. Check for proper fit and lubrication. Replace the shaft if damaged.

Scheme 23

Smearing of metal due to slippage. Slippage can be caused by poor fits, lack of lubrication, overheating, overloads or handling damage. Replace the bearing. Clean all the related parts. Check for proper fit and lubrication.

Tapered Roller Bearing Diagnosis

Consider the following factors when diagnosing bearing condition

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1. General condition of all parts during disassembly and inspection.
2. Classify the failure with the aid of the illustrations.
3. Determine the cause.
4. Make all repairs following recommended procedures. Pattern on the races and the rollers caused by fine abrasives. Clean all of the parts and the housings. Check the seals and the bearings. Replace any leaky, rough, or noisy bearings.

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Pattern on the roller ends caused by fine abrasives. Clean all of the parts and the housings. Check the seals and the bearings. Replace any leaky, rough, or noisy bearings.

Scheme 26

Metal smears on the roller ends due to overheating, lubricant failure, or lubricant overload. Replace the bearing. Check the seals. Check for proper lubrication.

Scheme 27

Bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. Replace the bearings. Check the seals. Check for proper lubrication.

Scheme 28

A damaged cage due to improper handling or improper tool usage. Replace the bearing.

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Wear around the outside diameter of the cage and the roller pockets caused by abrasive material. Wear caused from inefficient lubrication. Clean the related parts and the housings. Check the seals. Replace the bearings.

Scheme 30

Surface depressions on the race and the rollers caused by hard particles of foreign matter. Clean all the parts and the housings. Check the seals. Replace rough or noisy bearings.

Scheme 31

Corrosion caused by small relative movement of parts with no lubrication. Replace the bearing. Clean the related parts. Check the seals. Check for proper lubrication.

Scheme 32

Smearing of the metal due to slippage. Slippage can be caused by the following factors

1. Poor fits
2. Lubrication
3. Overheating
4. Overloads
5. Handling damage

Replace the bearings. Clean the related parts. Check for proper fit and lubrication.

Scheme 33

Discoloration ranging from light brown to black. This discoloration is caused from incorrect lubrication or moisture. Reuse the bearing if you can remove the stains with light polishing. Reuse the bearing if there is no evidence of overheating. Check the seals and the related parts for damage.

Scheme 34

Heat discoloration ranges from faint yellow to dark blue. This discoloration results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal. A file drawn over a hard part will glide readily with no metal cutting. Replace the bearings if overheating damage is indicated. The tempered part will fail the file test. Check the seals and the other related parts.

Scheme 35

A misaligned outer race due to a foreign object. Clean the related parts. Replace the bearing. Ensure the races are properly sealed.

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Cracked race due to improper fit, cocking, or poor bearing seats. Replace the bearing. Correct bearing seats.

Scheme 37

Flaked surface metal that results from fatigue. Replace the bearing. Clean all related parts.

Scheme 38

Surface indentations in the race way caused by the rollers under impact loading or caused from vibration while the bearing is not rotating. Replace a rough or noisy bearing.

FRONT AXLE LUBRICANT LEAK DIAGNOSIS

Front axle lubricant leaks can occur at the following locations

1. Axle shaft oil seals
2. Differential carrier assembly mating surface
3. Drain plug
4. Fill plug
5. Inner axle tube assembly to differential carrier assembly mating surface
6. Pinion yoke oil seal
7. Vent tube and/or connector

Determining the Cause

While most front axle leaks may be easy to find, determining the cause may not be. A thorough inspection of the area around the leak may assist in determining the cause of the leak.

Oil Seals

Lubricant leaks from a oil seal may be caused by any of the following

1. An improperly installed seal
2. A distorted seal
3. A worn seal
4. A worn shaft
5. A brittle seal lip
6. A hardened seal lip

To determine the actual cause of the leak, clean the area around the leak. Observe the area of the leak and determine the if the seal or another component is causing the leak. A worn seal surface will cause a leak at the sealing lip while a misaligned seal or a seal installed into a housing with an excessive bore will cause the seal to leak at the outside surface of the seal. Hardened or cracked seal lips usually indicate the axle is operating beyond the normal temperature limits for the axle. A seal whose sealing surface has been nicked or cut may indicate that the shaft has a rough, burred, or gouged surface and will need to be inspected before the seal can be replaced.

Sealing Surfaces

Front axles components are assembled using specific sealers. A leak at a surface sealed with sealant is usually caused by a poor fit of the components but can also be caused by the use of the wrong sealant. When correcting a sealant leak, inspect each component for distortion and for nicks or gouges that may prohibit the sealant from sealing properly and when re-assembling the component, use the proper sealant.

Differential Carrier Assembly

Lubricant leaks at the differential carrier assembly can occur at the following locations

1. Drain Plug
2. Fill Plug
3. Vent tube

Drain and fill plug leaks are usually caused by a loose plug. A vent tube leak can be cause by a loose fitting vent hose or by a vent tube assembly whose interior shield is stuck in the upside down position. Inspect the vent plug's interior shield for unrestricted movement, repair or replace the plug as necessary. Drain or fill plug leaks can be repaired by either tightening the plug or by using an approved sealer on the threads on the plug.

Scheme 39

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
2. Make sure the vehicle is level.
3. Inspect the front axle for leaks. Repair as necessary.
4. Remove the front differential carrier shield (if equipped). Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
5. Clean the area around the front axle fill plug.
6. Remove the front axle fill plug (1).
7. Inspect the oil level. Specification The oil level should be between 0-13 mm (0-0.5 in) below the fill plug opening.
8. If the level is low, add oil until the level is even with the bottom edge of the fill plug opening. Use the proper fluid.
9. Install the fill plug. Tighten Tighten the plug to 33 N.m (24 lb ft).
10. Install the front differential carrier shield (if equipped). Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
11. Lower the vehicle.

Scheme 40

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
2. Remove the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
3. Clean the area around the front axle fill plug and the drain plug.
4. Remove the fill plug.
5. Remove the drain plug.
6. Drain the fluid from the front differential carrier assembly.

Scheme 41

1. Install the drain plug. Tighten Tighten the drain plug to 33 N.m (24 lb ft).
2. Fill the differential carrier assembly with axle lubricant. Use the proper fluid.
3. Install the fill plug. Tighten Tighten the fill plug to 33 N.m (24 lb ft).
4. Install the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
5. Lower the vehicle.

Scheme 42

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
2. Remove the front differential carrier shield bolts.
3. Remove the front differential carrier shield.

Scheme 43

1. Install the front differential carrier shield.
2. Install the front differential carrier shield bolts. Tighten Tighten the front differential carrier shield bolts to 20 N.m (15 lb ft).
3. Lower the vehicle.

Scheme 44

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
2. Remove the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
3. Disconnect the electrical connector from the actuator (3).
4. Remove the electric motor actuator (3) by turning the actuator counterclockwise.

Scheme 45

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the electric motor actuator.
2. Install the electric motor actuator (3). Tighten Tighten the actuator to 20 N.m (15 lb ft).
3. Connect the electrical connector to the actuator.
4. Install the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
5. Lower the vehicle.

Removal Procedure

1. Remove the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
2. Remove the clamp at differential housing.
3. Remove the vent hose from the axle.
4. Remove the bolt on the frame.
5. Remove the clip on radiator support.
6. Remove the vent hose.

Installation Procedure

1. Install the vent hose to the vehicle. Route the vent hose the same way as when removed. Ensure the hose is free of kinks and routes clear of sharp components. Ensure the vent hose is not plugged.
2. Install the clip on the radiator support.
3. Install the bolt and the clamp on the frame.
4. Install the vent hose to the axle fitting.
5. Install the clamp.
6. Install the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .

Scheme 46

Scheme 47

1. Raise the vehicle. Refer «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
2. Disconnect the vent hose from the vent hose connector.
3. Remove the vent hose connector from the differential carrier assembly.

Scheme 48

Scheme 49

1. Install the vent hose connector into the differential carrier assembly. Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent onto the threads. Tighten the vent hose connector. Tighten Tighten the vent hose connector to 28 N.m (21 lb ft).
2. Connect the vent hose to the vent hose connector.
3. Lower the vehicle.

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Scheme 56

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting).
2. Drain the differential carrier assembly. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
3. Disconnect the electrical connector from the electric motor actuator.
4. Disconnect the wire harness from the inner axle shaft housing.
5. Remove the stabilizer shaft link assembly. Refer to «STABILIZER BAR»(/cadillac/escalade/gmt400-1998-2000/remont/suspension-front/#front-suspension-4wd-torsion-bar).
6. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft. Disconnect the wheel drive shaft from the inner axle shaft.
7. Remove the inner axle shaft housing nuts from the bracket.
8. Remove the inner axle shaft housing bolts from the differential carrier case.
9. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.
10. For the 8.25 inch axle, remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly components (14, 13, 12, 11) The clutch shaft shim (9) Remove the clutch sleeve (8) Remove the clutch gear (6) by doing the following: Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange. 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). Remove the thrust washer (5) (Scheme 56): Inner Axle Shaft Housing Components
11. For the 9.25 inch axle, remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly components (14, 13, 12, 11) The clutch shaft shim (9) The clutch sleeve (8) The retainer ring (7) The thrust washers (5, 6) (Scheme 57): Inner Axle Shaft Housing Components
12. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet.
13. Remove the inner axle seal and the bearing from the axle housing. Refer to «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).

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Scheme 63

1. Install the new inner axle shaft bearing and the seal to the axle housing. Refer to «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
2. Install the inner axle shaft (2) into the inner axle shaft housing (1). Carefully tap the inner axle shaft into place with a soft-faced mallet.
3. For the 8.25 inch axle, install the following components into the inner axle shaft housing: The thrust washer (5). Use chassis grease in order to hold the thrust washer in place. Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The retainer ring (7) into the clutch gear (6). The clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (14, 13, 12, 11) The clutch fork inner spring (10) into the differential carrier case. (Scheme 58): Inner Axle Shaft Housing Components
4. For the 9.25 inch axle, install the following components into the inner axle shaft housing: The thrust washer (5). Use chassis grease in order to hold the thrust washer in place. Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The second thrust washer (6) The retainer ring (7) onto the inner axle shaft (1) Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (14, 13,12, 11) The clutch fork inner spring (10) into the differential carrier case. (Scheme 59): Inner Axle Shaft Housing Components
5. Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
6. Install the inner axle shaft housing assembly to the differential carrier assembly.
7. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
8. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft).
9. Connect the wheel drive shaft inboard flange to the inner axle shaft.
10. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).
11. Install the stabilizer shaft link assembly. Refer to «STABILIZER BAR»(/cadillac/escalade/gmt400-1998-2000/remont/suspension-front/#front-suspension-4wd-torsion-bar).
12. Connect the wire harness to the inner axle shaft housing.
13. Connect the electrical connector to the front axle actuator.
14. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
15. Lower the vehicle.

Scheme 64

1. Remove the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
2. Remove the clutch fork assembly (2) from the inner axle shaft housing (1).
3. Remove the clutch fork inner spring from the differential carrier case assembly, if necessary. Take care not to dislodge the inner axle clutch shim from the inner axle shaft.

Disassembly Procedure

1. Remove the clip (4) from the clutch fork lever (1).
2. Remove the clutch fork (3) and the clutch fork outer spring (2) from the clutch fork shaft (1).

Assembly Procedure

1. Install the clutch fork outer spring (2) and the clutch fork (3) onto the clutch fork shaft (1).
2. Install the clip (4) onto the clutch fork shaft (1). Ensure the clip fully seats into the groove on the clutch fork shaft.

Scheme 65

1. Install the clutch fork inner spring into the differential carrier case assembly, if necessary.
2. Install the clutch fork assembly (2) into the inner axle shaft housing (1).
3. Install the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .

CLUTCH FORK INSPECTION - FRONT DRIVE AXLE

1. Inspect the carrier connector for damaged splines and teeth. Replace as required.
2. Inspect the shift fork for wear, scoring, and damage to the thrust surfaces. Replace as required.
3. Inspect the differential sleeve and the inner output shaft for damaged splines and teeth. Replace as required.
4. Inspect the damper spring for breakage. Replace or repair the damper spring as needed.
5. Inspect the differential actuator and the engagement switch for damage and frayed wiring.

Tools Required

1. J 34011 Pilot Bearing Remover
2. J 33842 Pilot Bearing Installer

Scheme 66

1. Remove the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
2. Remove the clutch shaft from the differential carrier assembly.
3. Remove the clutch shaft pilot bearing using the J 34011 .

Scheme 67

1. Lubricate the bearing with axle lubricant. Use the proper fluid. (Scheme 6)
2. Install the clutch shaft pilot bearing using the J 33842.
3. Install the clutch shaft to the differential carrier assembly.
4. Install the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 2619-01 Slide Hammer
3. J 29369-1 Bushing and Bearing Remover
4. J 29369-2 Bushing and Bearing Remover (2-3 inch)
5. J 36609 Axle Tube Bearing Installer
6. J 45225 Axle Seal Installer

Scheme 68

Scheme 69

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting).
2. Drain the differential carrier assembly. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
3. If replacing the right side seal and/or bearing, perform the following steps: Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front). Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front). Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01.
4. If only replacing the left side seal, perform the following steps: Place an alignment mark between the inner axle shaft and the wheel drive shaft. Disconnect the wheel drive shaft from the inner axle shaft. Remove the inner axle shaft using a hammer and a brass drift. Remove the inner axle shaft seal using a suitable seal remover tool. (Scheme 72): Removing Inner Axle Shaft Seal/Bearing
5. If replacing the left side seal and/or bearing, perform the following steps: Remove the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front). Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. Remove the inner axle shaft using a hammer and a brass drift. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. (Scheme 73): Removing Inner Axle Shaft Seal/Bearing Install the J 2619-01 to the J 29369-1 or the J 29369-2. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01.

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Scheme 75

1. If installing the right side bearing, perform the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). (Scheme 75): Installing New Axle Shaft Seal
3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
4. Install the inner axle shaft and clutch fork assembly components into the inner axle housing. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). (Scheme 76): Install The Left Side Bearing
7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). (Scheme 77): Install The New Axle Shaft Seal
8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. (Scheme 78): Installing Seal Using
11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. (Scheme 79): Axle Shaft Inner Flange
12. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft.
13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft to inner axle shaft bolts to 79 Nm (58 lb ft).
14. Fill the differential carrier assembly. Use the proper fluid. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
15. Lower the vehicle.

1. J 34672 Depth Micrometer
2. J34673 Flat Gage Bar
3. J 8001 Dial Indicator Set

Adjustment Method

The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced

1. The inner axle shaft
2. The inner axle shaft housing
3. The clutch shaft
4. The differential carrier case
5. The ring and pinion gears
6. The differential case assembly
7. The bearings
8. The carrier connector

Front drive axle clutch shims are available in the following sizes

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
2. Install the following components into the inner axle shaft housing: Install the inner axle shaft (1) into the front drive axle housing (4). Install the thrust washer (with tabs) (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. Install the thrust washer (without tabs) (6). Install the retaining ring (7) into the front drive axle clutch gear (6).
3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. IMPORTANT: In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.
4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.
5. Install the J 34673 (1) and the J 34672 (2) onto the inner shaft housing as shown.
6. Using the J 34672 , measure the distance from the edge of the inner axle shaft to the surface of the J 34673 . Ensure the base of the J 34672 is flat against the inner axle shaft.
7. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7. This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J 34673 .
9. Using a micrometer, measure the thickness of the J 34673 .
10. Subtract the thickness of the J 34673 , measured in step 9, from the measurement determined in step 8. This is the shim thickness for the front axle without having any axle shaft endplay.
11. The correct shim size will be one size smaller than the figure obtained in the previous step. Note the following examples: If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim. If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim.

Alternate Adjustment Method

Important: Use this method only if the proper tools for calculating the shim size are unavailable.

Scheme 80

1. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place.
2. Install the assembled axle tube and the shaft to the carrier. Do not use sealer at this time.
3. Install the bolts. Tighten Tighten the bolts to 40 N.m (30 lb ft).
4. Measure the shaft end play using the following procedure: Install the J 8001 or the equivalent on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange. Move the shaft back and forth and read the end play. The correct end play is 0.03-0.51 mm (0.001-0.020 in). If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.

1. J 8614-01 Flange and Pulley Holding Tool
2. J 36366 Pinion Oil Seal Installer

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
2. Remove the tire and wheel assemblies.
3. Remove the brake calipers. Refer to «FRONT BRAKE CALIPER»(/cadillac/escalade/gmt400-1998-2000/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__front-brake-caliper) .
4. Remove the differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
5. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.
6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). NOTE: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint.
7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers.
8. Support the propeller shaft and move out of the way as necessary.
9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: The pinion bearings The pinion seal The carrier bearings The axle bearings The axle seals
10. Scribe an alignment line between the pinion shaft and the pinion yoke.
11. Install the J 8614-01 onto the pinion as shown.
12. Remove the pinion nut while holding the J 8614-01 .
13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
14. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case.
15. Remove the oil seal using a suitable seal removal tool.

Scheme 86

Scheme 87

Scheme 88

1. Install the oil seal by doing the following: Position the oil seal over the seal bore. Install the J 36366 over the oil seal. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke.
3. Install the pinion yoke. Align the reference marks made during removal.
4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
5. Install the washer and a new pinion nut.
6. Install the J 8614-01 onto the pinion yoke as shown. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
7. Tighten the pinion nut while holding the J 8614-01 . Tighten Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement with the rotating torque recorded earlier. Tighten Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal.
9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
10. Install the propeller shaft universal joint (2) to the pinion yoke (1). Align the reference marks made during removal.
11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). Tighten Tighten the yoke retainer bolts to 25 N.m (18 lb ft).
12. Inspect the axle lubricant level, and add, if necessary. Refer to «LUBRICANT LEVEL INSPECTION - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
13. Install the differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
14. Install the brake calipers. Refer to «FRONT BRAKE CALIPER»(/cadillac/escalade/gmt400-1998-2000/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__front-brake-caliper) .
15. Install the tire and wheel assemblies.
16. Lower the vehicle.

1. J 33791 Carrier Bushing Remover/Installer
2. J 36616 Axle Mount Bushing Remover/Installer

Scheme 89

Scheme 90

1. Remove the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
2. Remove the upper differential carrier assembly bushing by performing the following steps: 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 . Remove the upper differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18 .
3. Remove the lower differential carrier assembly bushing by performing the following steps: 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. Remove the lower differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18 .

Scheme 91

Scheme 92

1. Install the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
2. Install the upper differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
3. Install the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Turn the steering wheel all the way to the left.
2. Raise the vehicle. Refer to «JACKING & HOISTING»(/cadillac/escalade/gmt400-1998-2000/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__jacking-hoisting) .
3. Place jack or utility stands at the rear end of the vehicle.
4. Remove the engine protection shield.
5. Remove the front differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
6. Drain the differential carrier assembly, if necessary. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
7. Disconnect the front propeller shaft from the differential carrier assembly.
8. Remove the relay rod. Refer to «RELAY ROD»(/cadillac/escalade/gmt400-1998-2000/remont/manual-power-steering/#power-recirculating-ball-steering) .
9. Support the differential carrier assembly with a transmission jack or equivalent.
10. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft, both sides.
11. Disconnect the electrical connector from the front axle actuator, S4WD axle only.
12. Disconnect the wire harness from the inner axle shaft housing, S4WD axle only.
13. Disconnect the wire harness from the differential carrier assembly, S4WD axle only.
14. Disconnect the vent hose from the differential carrier assembly.
15. Remove the inner axle housing nuts and washers from the bracket.
16. Remove the differential carrier assembly upper mounting bolt and the nut.
17. Pivot the differential carrier assembly forward and down on the lower mount bolt while it is being supported by the transmission jack.
18. Secure the differential carrier assembly to the jack.
19. Remove the differential carrier assembly lower mounting bolt and the nut.
20. Remove the differential carrier assembly.

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

1. Install the differential carrier assembly.
2. Install the differential carrier assembly lower mounting bolt and the nut. Do not tighten the bolt at this time.
3. Pivot the differential carrier assembly up and back on the lower mount bolt while it is being supported by the transmission jack.
4. Install the differential carrier assembly upper mounting bolt and the nut.
5. Install the inner axle housing washers and nuts to the bracket. Tighten Tighten the inner axle housing nuts to 100 N.m (75 lb ft). Tighten the upper and the lower differential carrier assembly bolts to 100 N.m (75 lb ft).
6. Connect the vent hose to the differential carrier assembly.
7. Remove the transmission jack.
8. Connect the wire harness to the differential carrier assembly, S4WD axle only.
9. Connect the wire harness to the inner axle shaft housing, S4WD axle only.
10. Connect the electrical connector to the front axle actuator, S4WD axle only.
11. Install the wheel drive shaft inboard flange to inner axle shaft bolts, both sides. Tighten Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).
12. Install the relay rod. Refer to «RELAY ROD»(/cadillac/escalade/gmt400-1998-2000/remont/manual-power-steering/#power-recirculating-ball-steering) .
13. Install the front propeller shaft to the differential carrier assembly.
14. Check the differential carrier assembly fluid level. Refer to «LUBRICANT LEVEL INSPECTION - FRONT DRIVE AXLE»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
15. Install the front differential carrier assembly shield, if equipped. Refer to «SHIELD REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .
16. Install the engine protection shield.
17. Remove the utility stands.
18. Lower the vehicle.

THRUST WASHERS, SHIMS, AND ADJUSTER SLEEVES INSPECTION

1. Inspect the shims and the thrust washers for cracks and chips. The damaged shims should be replaced with an equally sized service shim.
2. Inspect the adjuster sleeves for damaged threads. Replace if required.

1. J 22888-D Side Bearing Remover Kit
2. J 36597 Side Bearing Puller Pilot - 9.25 in axle

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

1. Remove the differential side bearing by performing the following steps: Place the differential case in a vise. Install the J 22888-20A (2) and the J 8107-2 (1), 8.25 inch axle, or the J 36597, 9.25 inch axle as shown. Remove the differential side bearings using the J22888-20A.
2. Remove the ring gear bolts. Discard the bolts.
3. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary.
4. On the 8.25 inch axle, remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin.
5. On the 9.25 inch axle, remove the pinion shaft lock bolt. (Scheme 117): Removing Pinion Shaft Lock Bolt
6. Remove the pinion shaft.
7. For the 8.25 inch axle, remove the differential pinion gears and the differential side gears by performing the following steps: Roll the differential pinion gears out of the case with the pinion gear thrust washers. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right.
8. For the 9.25 inch axle, remove the differential pinion gears and the differential side gears by performing the following steps: Remove the differential side gear spacers. Drive the pinion gear thrust washers out from the differential case using a hammer and a brass drift. Roll the differential pinion gears out of the differential case. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right.

DIFFERENTIAL CASE BEARINGS INSPECTION

1. Inspect the bearings for smooth rotation after oiling.
2. Inspect the bearing rollers for wear.
3. Inspect the bearing cups for the following conditions: Wear Cracks Brinelling Scoring

DIFFERENTIAL CASE AND GEARS INSPECTION

1. Inspect the following components for excessive wear and/or fit: The pinion gear shaft The thrust washers The differential case for wear, cracks and scoring The fit of the pinion gear shaft in the differential case The fit of the differential side gears in the differential case The fit of the side gears on the axle shafts
2. Inspect the teeth of the pinion gears and the differential side gears for the following conditions: Wear Cracks Scoring Spalling
3. Replace any worn or poor fitting components as necessary.

PINION AND RING GEAR INSPECTION

1. The ring and pinion gears are matched sets and must be replaced any time a replacement of either is necessary.
2. Inspect the pinion and the ring gear teeth for the following conditions: Cracking Chipping Scoring Excessive wear
3. Inspect the pinion gear splines for wear.
4. Inspect the pinion flange splines for wear.
5. Inspect the fit of the pinion flange on the pinion gear.
6. Inspect the sealing surface of the pinion flange for nicks, burrs, or rough tool marks which will damage the inside diameter of the pinion seal and result in an oil leak.
7. Inspect all of the parts for wear and replace as necessary.

1. J 22912-B Split-Plate Bearing Puller
2. J 2619-01 Slide Hammer
3. J 29369-1 Bushing and Bearing Remover
4. J 33791 Carrier Bushing Remover/Installer
5. J 34011 Pilot Bearing Remover
6. J 36598 Holding Fixture
7. J 36599-A Side Bearing Nut Wrench
8. J 36616 Axle Mount Bushing Remover/Installer
9. J 45765 Pinion Remover
10. J 45858 Front Axle Bearing Race Remover/Installer
11. J 8614-01 Flange and Pulley Holding Tool

Inspection Procedure

Perform the following before disassembling the axle

1. Remove the drain plug from the axle.
2. Drain the axle lubricant.
3. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
4. Check the ring gear backlash. Refer to «BACKLASH INSPECTION AND ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .

This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and Preloading the differential case.

Determine the cause of the axle problem before disassembly, if possible.

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

1. Remove the upper differential carrier assembly bushing by performing the following steps: 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. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
2. Remove the lower differential carrier assembly bushing by performing the following steps: 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. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
3. Remove the front axle actuator, S4WD axle only.
4. Remove the inner axle shaft housing to differential carrier assembly bolts.
5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly, S4WD axle only.
6. Remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly (11, 12, 13, 14) The clutch shaft shim (9) The clutch shaft sleeve (8) The front drive axle clutch gear (6) by doing the following: Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange. 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). Remove the thrust washer (5)
7. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the J 29369-1 (1) behind the inner axle shaft bearing. Install the J 2619-01 (2) to the J 29369-1 (1). Remove the inner axle shaft bearing and the seal using the J 2619-01. (Scheme 123): Removing The Inner Axle Shaft Seal And/Or The Inner Axle Shaft Bearing Using 29369-2 & J 2619-01
8. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps: Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. Install the J 29369-1 (1) behind the inner axle shaft bearing. Install the J 2619-01 (2) to the J 29369-1. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01. (Scheme 124): Removing Inner Axle Shaft Seal/Bearing Using J 29369-2 & J 2619-01 -- Front Drive Axle
9. Remove the differential carrier assembly from the vise.
10. Remove the front drive axle clutch shaft, S4WD axle only.
11. Use the J 34011 in order to remove the clutch shaft bearing, S4WD axle only. (Scheme 125): Removing Clutch Shaft Pilot Bearing -- Front Drive Axle
12. Remove the vent connector. (Scheme 126): Removing Vent Hose Connector -- Front Drive Axle
13. Remove the differential carrier assembly bolts.
14. 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. (Scheme 128): Removing Differential Case Assembly (8.25 Inch Axles)
15. Remove the differential case assembly. Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, S4WD axle - both sides, F4WD axle - left side.
16. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following, S4WD axle - both sides, F4WD axle - left side: Install the J 36599-A onto the differential bearing adjuster nut. Turn the J 36599-A clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore. (Scheme 129): Removing Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
17. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift, S4WD axle - both sides, F4WD axle - left side.
18. Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01. (Scheme 130): Installing The J 8614-01 Onto The Pinion -- Front Axle
19. Remove the washer.
20. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. (Scheme 131): Removing Pinion Yoke -- Front Axle
21. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
22. 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. Follow the appropriate steps depending on what tool is available.
23. Install the J 36598 into a vise.
24. Install the left differential carrier case half onto the J 36598 and the J 36598-6. (Scheme 132): Removing Pinion (8.25 Inch Axles)
25. 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: The pinion gear selectable shim. The inner pinion bearing. The collapsible spacer.
26. Install the J 36598-5 (3) behind the inner pinion bearing cup. (Scheme 133): Installing J 39598-5 Behind Inner Pinion Bearing Cup
27. Thread the forcing screw of the J 36598 (1) onto the J 36598-5 (3) until fully seated.
28. 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.
29. Install the J 36598-5 (2) behind the outer pinion bearing cup. (Scheme 134): Installing J 36598-5 Behind Outer Pinion Bearing Cup
30. Install the forcing screw of the J 36598 (1) to the J 36598-5 (2).
31. While holding the forcing screw of the J 36598, turn the handle of the J 36598 clockwise in order to remove the following components: The pinion oil seal The pinion outer bearing The pinion outer bearing cup
32. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown. (Scheme 135): Removing Pinion Components Using J 45765 (8.25 Inch Axles)
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. Install the J 45858-4 over the inner pinion bearing cup. see scheme 137: Installing J 45858-4 Over Inner Pinion Bearing Cup (8.25 Inch Axles)
37. Install the forcing screw (1) of the J 45858 into the J 45858-4 (2). see scheme 138: Installing Forcing Screw Of J 45858 Into J 45858-4 (8.25 Inch Axles)
38. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
39. 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. see scheme 139: Installing J 45858-3, Thrust Bearing & Washer, & Forcing Screw (8.25 Inch Axles)
40. 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. see scheme 140: Installing J 45858-5 Into Pinion Bearing Bore (8.25 Inch Axles)
41. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
42. Remove the collapsible spacer from the drive pinion.
43. Install the J 22912-B between the pinion bearing and the drive pinion. see scheme 141: Removing The Inner Pinion Bearing Using J 22912-01 (8.25 Inch Axles)
44. Remove the inner pinion bearing using the J 22912-B and a hydraulic press.
45. Remove the pinion gear selectable shim.

1. J 22912-B Split-Plate Bearing Puller
2. J 2619-01 Slide Hammer
3. J 29369-2 Bushing and Bearing Remover (2-3 in)
4. J 33791 Carrier Bushing Remover/Installer
5. J 34011 Pilot Bearing Remover
6. J 36598 Holding Fixture
7. J 36599-A Side Bearing Nut Wrench
8. J 36615 Side Bearing Nut Wrench
9. J 36616 Axle Mount Bushing Remover/Installer
10. J 45754 Pinion Bearing Race Remover/Installer - 9.25 inch Axle
11. J 45765 Pinion Remover
12. J 8614-01 Flange and Pulley Holding Tool

Perform the following before disassembling the axle

1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
5. Check the ring gear backlash. Refer to «BACKLASH INSPECTION AND ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front) .

This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and Preloading the differential case.

Determine the cause of the axle problem before disassembly, if possible.

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

1. Remove the upper differential carrier assembly bushing by performing the following steps: 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. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
2. Remove the lower differential carrier assembly bushing by performing the following steps: 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. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.
3. Remove the front axle actuator.
4. Remove the inner axle shaft housing to differential carrier assembly bolts.
5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly.
6. Remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly (11, 12, 13, 14) The clutch shaft shim (9) The clutch shaft sleeve (8) The retainer ring (7) The thrust washers (5, 6) see scheme 146: Inner Axle Shaft Housing Components (9.25 Inch Axle)
7. Remove the inner axle shaft (2).
8. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the J 29369-2 (1) behind the inner axle shaft bearing. Install the J 2619-01 (2) to the J 29369-2 (1). Remove the inner axle shaft bearing and the seal using the J 2619-01. see scheme 148: Removing The Inner Axle Shaft Seal And/Or The Inner Axle Shaft Bearing Using 29369-2 & J 2619-01
9. Remove the differential carrier assembly from the vise.
10. Remove the front drive axle clutch shaft.
11. Use the J 34011 in order to remove the clutch shaft bearing. see scheme 149: Removing Clutch Shaft Pilot Bearing -- Front Drive Axle
12. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. see scheme 150: Removing Inner Axle Shaft Seal/Bearing Using J 29369-2 & J 2619-01 -- Front Drive Axle
13. Remove the inner axle shaft using a hammer and a brass drift.
14. Install the J 29369-2 (1) behind the inner axle shaft bearing.
15. Install the J 2619-01 (2) to the J 29369-2 (1).
16. Remove the inner axle shaft bearing and the inner axle seal bearing and the seal using the J 2619-01.
17. Remove the differential carrier assembly from the vise.
18. Remove the vent connector. see scheme 151: Removing Vent Hose Connector -- Front Drive Axle
19. Remove the differential carrier assembly bolts.
20. 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.
21. Remove the differential case assembly. Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the lock.
22. Remove the left side differential bearing adjuster nut lock and the bolt.
23. Remove the left side differential bearing adjuster by doing the following: Install the J 36615 onto the differential bearing adjuster nut as shown. Turn the J 36615 counterclockwise in order to remove the differential bearing adjuster nut and the O-ring. see scheme 153: Removing Left Side Differential Bearing Adjuster (9.25 Inch Axle)
24. Remove the right side differential bearing adjuster by doing the following: Install the J 36599-A onto the differential bearing adjuster nut. Turn the J 36599-A clockwise in order to push the bearing cup out of the bore. (Scheme 137): Removing Differential Bearing Adjuster Nuts & Bearing Cups (8.25 Inch Axles)
25. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift.
26. Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01. (Scheme 138): Installing The J 8614-01 Onto The Pinion -- Front Axle
27. Remove the washer.
28. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. (Scheme 139): Removing Pinion Yoke -- Front Axle
29. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
30. 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-45754. Follow the appropriate steps depending on what tool is available.
31. Install the J 36598 into a vise.
32. Install the left differential carrier case half onto the J 36598. (Scheme 140): Removing Pinion
33. 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: The pinion gear selectable shim. The inner pinion bearing. The collapsible spacer.
34. Install the J 36598-5 (3) behind the inner pinion bearing cup. (Scheme 141): Installing J 39598-5 Behind Inner Pinion Bearing Cup
35. Thread the forcing screw of the J 36598 (1) onto the J 36598-5 (3) until fully seated.
36. 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.
37. Install the J 36598-5 (2) behind the outer pinion bearing cup. see scheme 159: Installing J 36598-5 Behind Outer Pinion Bearing Cup
38. Install the forcing screw of the J 36598 (1) to the J 36598-5 (2).
39. While holding the forcing screw of the J 36598, turn the handle of the J 36598 clockwise in order to remove the following components: The pinion oil seal The pinion outer bearing The pinion outer bearing cup
40. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown. (Scheme 142): Installing J 45765 To The Left Side Differential Carrier Case (9.25 Inch Axle)
41. 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
42. Remove the drive pinion seal using a suitable seal remover.
43. Remove the outer pinion bearing from the differential carrier case half.
44. Install the J 45754-3 over the inner pinion bearing cup. (Scheme 143): Installing J 45754-3 Over The Inner Pinion Bearing Cup (9.25 Inch Axle)
45. Install the forcing screw (1) of the J 45754 into the J 45754-3 (2). (Scheme 144): Installing J 45754 Forcing Screw Into J 45754-3 (9.25 Inch Axle)
46. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
47. Install the J 45754-2 (3) and the forcing screw (1) over the outer pinion bearing cup bore. (Scheme 145): Installing J 45754-2 & Forcing Screw (9.25 Inch Axle)
48. Install the J 45754-4 (3) into the pinion bearing bore behind the outer pinion bearing cup. Slowly turn the forcing screw clockwise until the J 45754-4 is evenly seated behind the outer pinion bearing cup bore and the J 45754-2 is evenly seated over the outer pinion bearing cup bore. (Scheme 146): Forcing Screw, J 45754-2 & J 45754-4 (9.25 Inch Axle)
49. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
50. Install the J 22912-B between the pinion bearing and the drive pinion. (Scheme 147): Removing The Inner Pinion Bearing Using J 22912-01
51. Remove the inner pinion bearing using the J 22912-B and a hydraulic press.
52. Remove the pinion gear selectable shim.

Tool Required

J 36598 Holding Fixture

Scheme 142

Scheme 143

Scheme 144

1. Before assembly, apply axle lubricant to the pinion bearing cups. (Scheme 6)
2. Install the J 36598 into a vise.
3. Install the left differential carrier case half into the J 36598 and the J 36598-6, 8.25 inch axle, or the J 36598 (1), 9.25 inch axle. Tighten the attaching bolts securely. (Scheme 148): Seating The Outer Pinion Bearing Cup Evenly Within The Outer Pinion Bearing Cup Bore J 36598 (8.25/9.25 Inch Axles)
4. Install the J 36598-3, 8.25 inch axle, or the J 36598-4, 9.25 inch axle (2), onto the forcing screw of the J 36598.
5. Install the outer pinion bearing cup into the differential carrier case.
6. Install the J 36598-3, 8.25 inch axle, or the J 36598-4, 9.25 inch axle (2) onto the outer pinion bearing cup. Rotate the J 36598-3 or the J 36598-4 and the outer pinion bearing cup several time in order to seat the outer pinion bearing cup evenly within the outer pinion bearing cup bore.
7. Install the outer pinion bearing cup into the differential carrier case half by holding the forcing screw of the J 36598 and turning the handle counterclockwise. Inspect the position of the outer pinion bearing cup as it is being installed into the outer pinion bearing cup bore to ensure the bearing cup is being installed evenly. If the pinion bearing cup is not being installed evenly, loosen the J 36598 and remove the outer pinion bearing cup. Reposition the outer pinion bearing cup over the outer pinion bearing cup bore and re-install.
8. Remove the J 36598-3 or the J 36598-4 from the forcing screw of the J 36598.
9. Install the J 36598-15 (2) into the outer pinion bearing cup. see scheme 167: Installing Inner Pinion Bearing Cup
10. Install the inner pinion bearing cup into the inner pinion bearing cup bore.
11. Place the J 36598-3, 8.25 inch axle, or the J 36598-4, 9.25 inch axle (2), over the inner pinion bearing cup. see scheme 168: Installing Inner Pinion Bearing Cup Into The Differential Carrier Case
12. Extend the forcing screw of the J 36598 (1) through the J 36598-15 and thread it into the J 36598-3 or the J 36598-4 (2) until fully seated.
13. Rotate the J 36598-3 or the J 36598-4 several times in order to ensure the inner pinion bearing cup is evenly seated and not mis-aligned in the bore.
14. Install the inner pinion bearing cup into the differential carrier case half by holding the forcing screw of the J 36598 and turning the handle clockwise. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being installed evenly. If the pinion bearing cup is not being installed evenly, loosen the J 36598 and remove the inner pinion bearing cup. Reposition the inner pinion bearing cup over the inner pinion bearing cup bore and re-install.
15. Remove the J 36598-3 or the J 36598-4 and the J 36598-15.
16. Remove the differential carrier case.
17. Remove the J 36598 from the vise.
18. Determine the selective shim thickness for the pinion. Refer to «PINION DEPTH ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front__pinion-depth-adjustment).

J 45754 Pinion Bearing Race Remover/Installer - 9.25 in Axle

Scheme 145

Scheme 146

Scheme 147

Scheme 148

1. Before assembly, apply axle lubricant to the pinion bearing cups. (Scheme 6) The pinion bearings The pinion and the differential gears The thrust washers The pinion bearing cups
2. Install the outer pinion bearing cup into the outer pinion bearing cup bore. (Scheme 149): Installing Outer Pinion Bearing Cup
3. Install the J 45754-1 over the outer pinion bearing cup. (Scheme 150): Installing J 45754-1 Over The Outer Pinion Bearing Cup (9.25 Inch Axle)
4. Install the forcing screw (1), the J 45754-2 (2) into the inner pinion bearing cup bore. (Scheme 151): Installing J 45754-2 Over Inner Pinion Bearing Cup Bore (9.25 Inch Axle)
5. Attach the forcing screw to the J 45754-1. Slowly turn the forcing screw until the J 45754-1 is evenly seated over the outer pinion bearing cup bore and the J 45754-2 with the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.
6. Turn the forcing screw clockwise slowly in order to draw the outer pinion bearing cup into the outer pinion bearing cup bore. Inspect the position of the outer pinion bearing cup as it is being drawn into the outer pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45754 and the outer pinion bearing cup and reposition the outer pinion bearing cup.
7. Tighten the forcing screw until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
8. Remove the J 45754.
9. Install the inner pinion bearing cup onto the J 45754-2 (2) and the forcing screw (1). (Scheme 152): Installing Inner Pinion Bearing Cup (9.25 Inch Axle)
10. Install the J 45754-2 (2), the forcing screw (1), and the inner pinion bearing cup into the pinion bearing cup bore.
11. Install the J 45754-1 over the outer pinion bearing cup. (Scheme 153): Installing J 45754-1 Over The Outer Pinion Bearing Cup (9.25 Inch Axle)
12. Attach the forcing screw to the J 45754-1. Slowly turn the forcing screw until the J 45754-1 is evenly seated over the outer pinion bearing cup bore and the J 45754-1 with the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.
13. Turn the forcing screw clockwise slowly in order to draw the inner pinion bearing cup into the inner pinion bearing cup bore. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45754 and the inner pinion bearing cup and reposition the inner pinion bearing cup.
14. Tighten the forcing screw clockwise until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
15. Remove the J 45754.
16. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to «PINION DEPTH ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front__pinion-depth-adjustment).

J-45858 Pinion Bearing Race Remover/Installer - 8.25 in Axle

Scheme 149

Scheme 150

Scheme 151

1. Before assembly, lubricate the following parts with axle lubricant. Use the proper fluid. (Scheme 6) The pinion bearings The pinion and the differential gears The thrust washers The pinion bearing cups
2. Install the J 45858-3 (3), the thrust bearing and the washer (2), and the J 45858-6 (1) over the outer pinion bearing cup bore. see scheme 174: Installing J 45858-3, Thrust Bearing & Washer, & Forcing Screw (8.25 Inch Axles)
3. Install the inner pinion bearing cup and the J 45858-2 (4) to the J 45858-6 (1). Slowly turn the J 45858-6 until the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore. (Scheme 155): Installing Inner Pinion Bearing Cup (8.25 Inch Axle)
4. Turn the J 45858-6 clockwise slowly in order to draw the inner pinion bearing cup into the inner pinion bearing cup bore. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J-45858 and the inner pinion bearing cup and reposition the inner pinion bearing cup.
5. Tighten the J 45858-6 until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
6. Remove the J-45858.
7. Install the outer pinion bearing cup and the J 45858-1 over the outer pinion bearing cup bore. (Scheme 156): Installing Outer Pinion Bearing Cup (8.25 Inch Axle)
8. Install the thrust bearing and the washer (2), the J 45858-6 (1), and the J 45858-2 (3) as shown. (Scheme 157): Install The Thrust Bearing And The Washer Using J 45858-6, Thrust Bearing & J 45858-2 (8.25 Inch Axle)
9. Slowly turn the J 45858-6 until the outer pinion bearing cup is evenly seated over the outer pinion bearing cup bore and the J 45858-2 is evenly seated within the inner pinion bearing cup.
10. Turn the J 45858-6 clockwise slowly in order to draw the outer pinion bearing cup into the outer pinion bearing cup bore. Inspect the position of the outer pinion bearing cup as it is being drawn into the outer pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J-45858 and the outer pinion bearing cup and reposition the outer pinion bearing cup.
11. Tighten the forcing screw until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
12. Remove the J-45858.
13. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to «PINION DEPTH ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front__pinion-depth-adjustment).

1. J 36601 Pinion Shim Selector
2. J 29763 Static Timing Gage

Scheme 152

Scheme 153

1. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. (Scheme 6)
2. Install the J 36601-4 or the J 36601-3 (4) to the J 36601-7 (1).
3. Install the J 21777-35 for the 8.25 inch axle or the J 21777-8 for the 9.25 inch axle (3) to the J 36601-7 (1).
4. Install the inner pinion bearing into the differential carrier case half.
5. Insert the J 36601-7 (1) with the J 21777-35 or the J 21777-8 (3) through the inner pinion bearing and the differential carrier case half.
6. Install the outer pinion bearing.
7. While holding the outer pinion bearing in position, install the J 36601-5 (2), the washer, and the nut to the J 36601-7 (1).
8. While holding the J 36601-7 (1) stationary with a wrench, tighten the nut on the J 36601-7 (1). Tighten Tighten the nut until all of the end play is removed from the J 36601.
9. Rotate the assembly several times in both directions in order to seat the pinion bearings.
10. While holding the J 36601-4 or the J 36601-3 (4) stationary, measure the rotating torque of the J 36601 using an inch-pound torque wrench. Specification The rotating torque of the J 36601 should be between 1.1-2.3 Nm (10-20 lb in).
11. If the torque is less than 1.0 Nm (10 lb in), continue to tighten the nut on the J 36601-7 until a rotating torque of 1.1-2.3 Nm (10-20 lb in) is obtained.
12. Install the adjustment screw and the lock nut of the J 29763 (2) to the J 36601-4 or the J 36601-3. see scheme 179: Using J 36601-3 & J 29763 To Measure Lowest Point In The Differential Side Bearing Bore
13. Install the J 29763 to the adjustment screw and lock nut assembly. Tighten the lock nut to hold the J 29763 in place.
14. Place the contact pad of the J 36601-4 or to the J 36601-3 into the differential side bearing bore.
15. Adjust the J 29763 to the differential bearing bore by doing the following: Loosen the lock nut on the J 29763. Place the contact pad of the J 36601-4 or the J 36601-3 onto the differential side bearing bore. With the contact pad of the J 36601-4 or the J 36601-3 touching the differential side bearing bore, push down on the J 29763 until the needle of the J 29763 has turned 3/4 of a turn clockwise. Tighten the lock nut of the J 29763.
16. Rotate the J 36601-4 or the J 36601-3 (1) back and forth until the needle of the J 29763 (2) indicates the lowest point in the differential side bearing bore.
17. At the lowest point of deflection, move the housing of the J 29763 until the needle indicates ZERO.
18. Move the J 36601-4 or the J 36601-3 back and forth again to verify the zero setting. Adjust the housing of the J 29763 as necessary to set the needle to ZERO.
19. After the ZERO setting is obtained and verified, grasp the J 36601-4 or the J 36601-3 (1) by the flats and move the J 36601-4 or the J 36601-3 out of the differential side bearing bore. (Scheme 158): Using J 36601-3 & J 29763 To Measure Thickness Of The Shim Needed In Order To Set The Depth Of The Pinion
20. The value indicated on the J 29763 (2) is the thickness of the shim needed in order to set the depth of the pinion.
21. Select the shim that indicates the correct thickness. Measure the shim with a micrometer in order to verify that the thickness is correct.
22. Remove the pinion depth setting tools.
23. Remove the pinion bearings.
24. Install the pinion shim between the drive pinion and the inner pinion bearing and assemble the differential carrier. Refer to Differential Carrier Assembly Assemble.

Differential Pinion Gear Shims Sizes. Scheme 154

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 22761 Differential Side Bearing Installer
3. J 22888-D Side Bearing Remover Kit

Scheme 155

Scheme 156

Scheme 157

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. (Scheme 6)
2. Install the thrust washers and the differential side gears into the differential case. If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations. (Scheme 159): Differential Side Gears & Thrust Washers
3. Install the differential pinion gears by performing the following steps: Position both pinion gears between the differential side gears directly opposite of each other. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening. (Scheme 160): Differential Pinion Gears & Thrust Washers
4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.
5. Install the pinion gear shaft.
6. Install the new pinion gear shaft lock pin using a hammer and a brass drift.
7. Install the ring gear onto the differential case.
8. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 Nm (88 lb ft).
10. Install the differential side bearings by performing the following steps: In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. Install the J 22761 and the J 8092 (1) onto the differential case bearing as shown. Drive the differential case bearing onto the case using the J 22761 and the J 8092.

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 29710 Differential Side Bearing Installer
3. J 36597 Side Bearing Puller Pilot - 9.25 in Axle

Scheme 158

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. (Scheme 6)
2. Install the thrust washers and the differential side gears into the differential case. If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations. (Scheme 162): Differential Side Gears & Thrust Washers
3. Install the differential pinion gears by performing the following steps: Position both pinion gears between the differential side gears directly opposite of each other. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening. (Scheme 163): Differential Pinion Gears & Thrust Washers (9.25 Inch Axle)
4. Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift.
5. Install the differential side gear spacers.
6. Install the pinion gear shaft. see scheme 188: Removing Pinion Shaft
7. Install the pinion shaft lock bolt. Tighten Tighten the pinion shaft lock bolt to 53 Nm (39 lb ft).
8. Install the ring gear onto the differential case.
9. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
10. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 138 Nm (102 lb ft).
11. Install the differential side bearings by performing the following steps: In order to protect the differential case, install the J 36597 in the case on the side opposite the bearing installation. Install the J 29710 (2) and the J 8092 (1) onto the differential case bearing as shown. Drive the differential case bearing onto the case using the J 29710 and the J 8092.

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 8614-01 Flange and Pulley Holding Tool
3. J 35512 Inner Pinion Bearing Installer
4. J 36366 Pinion Oil Seal Installer
5. J 36599-A Side Bearing Nut Wrench
6. J 36603 Side Bearing Cup Installer
7. J 36609 Axle Tube Bearing Installer
8. J 36612 Output Shaft Bearing Installer
9. J 36614 Inner Pinion Bearing Installer
10. J 36615 Side Bearing Nut Wrench (9.25 inch axle)

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

1. Install the pinion bearing cups into the differential carrier assembly. Refer to «PINION BEARING CUP INSTALLATION»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).
2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
3. Install the inner pinion bearing onto the pinion gear using the J 35512, 8.25 inch axle, or the J 36614, 9.25 inch axle.
4. Install the new collapsible spacer onto the pinion gear.
5. Install the outer pinion bearing into the differential carrier case half.
6. Install the pinion oil seal using J 36366. (Scheme 166): Installing Oil Seal Using J 36366
7. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
8. Lubricate the pinion bearings with axle lubricant. Use the correct sealant. (Scheme 6)
9. Install the pinion yoke.
10. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
11. Install the washer and a new pinion nut. If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed: Remove the pinion nut washer. Install the old pinion nut. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed. Remove the old pinon nut. Install the pinion nut washer. Install the new pinion nut.
12. Install the J 8614-01 onto the pinion yoke as shown. (Scheme 167): Installing The J 8614-01 Onto The Pinion -- Front Axle
13. Tighten the pinion nut while holding the J 8614-01. Tighten Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order to seat the bearings.
14. Remove the J 8614-01.
15. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.
16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, reinstall the J 8614-01 and continue to tighten the pinion nut. Specification The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.
17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
18. Remove the J 8614-01.
19. Assemble the differential adjuster nut into the differential nut sleeve until fully seated, 8.25 inch axle - left and right sides, 9.25 inch axle, right side.
20. Install the axle shaft bearings into the differential adjuster nut sleeve using the J 36612 (2) and the J 8092 (1), 8.25 inch S4WD axle - left and right sides, 8.25 inch F4WD axle - left side, 9.25 inch axle - right side. see scheme 194: Installing The Axle Shaft Bearings Into The Differential Adjuster Nut Sleeve Using J 8092 & J 36612
21. Install the axle shaft bearing into the differential adjuster nut sleeve using the J 36609 and the J 8092, 9.25 inch axle - left side.
22. Install the differential adjuster nut assembly and new adjuster lock nut tabs into the differential carrier case using the J 36609 and the J 8092, 8.25 inch axle - left and right sides, 9.25 inch axle - right side.
23. Install the differential adjuster nut assembly into the differential carrier case, 9.25 inch axle - left side.
24. Install the differential case side bearing cups to the differential carrier case using the J 36603 (2) and the J 8092 (1), 8.25 inch axle - left and right sides, 9.25 inch axle - right side. see scheme 195: Installing Differential Case Side Bearing Cups To The Differential Carrier Case Using J 8092 & J 36603
25. Install the differential case assembly into the left differential carrier case half. (Scheme 168): Installing Differential Case Assembly Into The Left Differential Carrier Case Half
26. Install the right differential carrier case half to the left differential carrier case half. Do not use sealer at this time. If the carrier case halves do not make complete contact, use the J 36599-A in order to back out the right differential adjuster nut sleeve until the differential carrier case halves make contact. (Scheme 169): Differential Case Assembly
27. Install the differential carrier case bolts. Tighten Tighten the differential carrier case bolts to 47 Nm (35 lb ft).
28. Install the differential carrier assembly into a vise.
29. Turn the right side differential adjuster nut sleeve clockwise 1 revolutions using the J 36599-A. (Scheme 170): Differential Bearing Adjuster Nuts & Bearing Cups
30. For the 8.25 inch axle, turn the left side differential adjuster nut sleeve clockwise using the J 36599-A in order to preload the differential side bearings against the differential side bearing cups. Tighten Tighten the differential adjuster nut to 75 Nm (55 lb ft). see scheme 199: Preloading Differential Side Bearings
31. For the 9.25 inch axle, turn the left side differential adjuster nut clockwise using the J 36615 in order to preload the differential side bearings against the differential side bearing cups. Tighten Tighten the differential adjuster nut to 75 Nm (55 lb ft).
32. Rotate the pinion several times in order to seat the pinion and differential side bearings.
33. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench. Specification The rotating torque of the pinion and differential assembly should be 3.4-6.2 Nm (30-55 lb in) for new bearings or 2.8-5.1 Nm (25-45 lb in) for used bearings.
34. If the rotating torque measurement is below 2.8 Nm (25 lb in) for used bearings, or 3.4 Nm (30 lb in) for new bearings, adjust the differential side bearing preload using the following steps: Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides. Using the J 36599-A or the J 36615, turn the left and the right side differential adjuster nut sleeves in or clockwise one notch. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications. (Scheme 171): Alignment Mark Between Differential Adjuster Nut Sleeve & Differential Carrier Case
35. If the rotating torque measurement is above 5.1 Nm (45 lb in) for used bearings, or 6.2 Nm (55 lb in) for new bearings, adjust the differential side bearing preload using the following steps: Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides. Using the J 36599-A or the J 36615, turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
36. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
37. Measure the drive pinion to ring gear backlash. Refer to «BACKLASH INSPECTION AND ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).

1. J 8001 Dial Indicator Set
2. J 36599-A Side Bearing Nut Wrench
3. J 36615 Side Bearing Nut Wrench

Scheme 166

1. Mark the location of the differential adjuster nut sleeves in relation to the differential carrier halves. Ensure that the notches can be counted when turned.
2. Install the J 8001-1 (1, 2), the J 8001-2 (3), and the J 8001-3 (4) as shown. Ensure that the button contacts the outer edge of the pinion yoke and that the plunger is at a right angle to the pinion yoke.
3. Move the pinion yoke back and forth through the pinion yoke's free play while not allowing the ring gear to move.
4. Record the dial indicator reading.
5. To determine the actual backlash, divide the dial indicator reading by 2. An actual dial indicator reading of 0.16 mm (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash. Specification The backlash between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred specification of 0.13-0.18 mm (0.005-0.007 in).
6. If the backlash is too small, increase the backlash by turning the left differential adjuster nut sleeve in one notch using the J 36599-A , 8.25 inch axle, or the J 36615 , 9.25 inch axle, and the right differential adjuster nut sleeve out one notch using the J 36599-A .
7. If the backlash is too large, decrease the backlash by turning the right differential adjuster nut sleeve in one notch using the J 36599-A and the left differential adjuster nut sleeve out one notch using the J 36599-A , 8.25 inch axle, or the J 36615 , 9.25 inch axle.
8. Recheck the backlash and adjust as necessary.
9. Recheck the rotating torque of the pinion and differential assembly and adjust as necessary.
10. Once the backlash and rotating torque of the pinion and differential assembly is correct, perform a gear tooth contact pattern check to ensure proper contact between the pinion and the ring gear. Refer to «GEAR TOOTH CONTACT PATTERN INSPECTION»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front__gear-tooth-contact-pattern-inspection) .

1. J 8092 Universal Driver Handle - 3/4 in -10
2. J 33842 Pilot Bearing Installer
3. J 36609 Axle Tube Bearing Installer
4. J 36616 Axle Mount Bushing Remover/Installer
5. J 45225 Axle Seal Installer

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

1. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
2. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 8.25 inch axle - both sides, 9.25 inch axle - right side.
3. Install the differential adjuster nut lock, 9.25 inch axle - left side.
4. Install the differential adjuster nut lock bolt. Tighten Tighten the differential adjuster lock nut bolt to 20 N.m (15 lb ft).
5. Remove the differential carrier assembly bolts. (Scheme 174): Differential Carrier Assembly Bolts
6. Remove the right differential carrier case half. (Scheme 175): Removing Differential Case Assembly
7. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
8. Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or equivalent to one differential carrier case half sealing surface. (Scheme 6)
9. Install the right differential carrier case half.
10. Install the differential carrier case bolts. Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft).
11. Lubricate the clutch shaft pilot bearing with axle lubricant. (Scheme 6)
12. Install the clutch shaft pilot bearing using the J 33842.
13. Install the clutch shaft to the differential carrier case half.
14. Install the vent hose connector. Tighten Tighten the vent hose connector to 28 Nm (21 lb ft).
15. Install the new left side axle shaft seal using the J 36600 (1), and J 22833 (2). see scheme 208: Install The New Axle Shaft Seal Using J 45225 & J 8092 -- Front Drive Axle
16. Install the new left side inner axle shaft retainer ring.
17. Install the left side inner axle shaft by doing the following: Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. (Scheme 178): Installing Left Side Inner Axle Shaft
18. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
19. Install the new right side inner axle shaft seal using the J 45225 (1) and the J 8092 (2).
20. Install the following components into the inner shaft housing: Install the inner axle shaft (1). Carefully tap the inner axle shaft into place with a soft-faced mallet. IMPORTANT: Use chassis grease in order to hold the thrust washer in place. Install the thrust washer (with tabs) (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. Install the thrust washer (without tabs) (6). Install the new retainer ring (7) onto the inner axle shaft (1). Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front). Install the clutch gear shim (9). Install the clutch sleeve (8). Install the clutch fork assembly (11). Install the clutch fork inner spring (10). Install the inner axle housing gasket. (Scheme 179): Inner Axle Shaft Housing Components (9.25 Inch)
21. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealer. (Scheme 6)
22. Install the inner shaft housing to the differential carrier assembly case.
23. Install the inner shaft housing bolts. Tighten Tighten the inner shaft housing bolts to 40 N.m (30 lb ft).
24. Install the drain plug and the washer.
25. Install the fill plug and the washer. Tighten Tighten the drain plug and the fill plug to 33 N.m (24 lb ft).
26. Install the front drive axle actuator. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the front axle actuator. (Scheme 6) Tighten Tighten the front drive axle actuator to 20 N.m (15 lb ft).
27. Install the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
28. Install the upper differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered with in the differential carrier assembly bushing bore.
29. Install the differential carrier assembly. Refer to «DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt400-1998-2000/remont/differentials-drive-axles/#drive-axle-front).

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 33791 Carrier Bushing Remover/Installer
3. J 36600 Output Shaft Seal Installer
4. J 36609 Axle Tube Bearing Installer
5. J 36616 Axle Mount Bushing Remover/Installer

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
2. Remove the differential carrier assembly bolts. (Scheme 184): Differential Carrier Assembly Bolts
3. Remove the right differential carrier case half. (Scheme 185): Removing Differential Case Assembly
4. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
5. Apply a bead of sealer to one differential carrier case half sealing surface. Use the correct sealer. (Scheme 6)
6. Install the right differential carrier case half.
7. Install the differential carrier case bolts. Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft).
8. Install the vent hose connector. Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent, onto the threads. Tighten Tighten the vent hose connector to 28 N.m (21 lb ft).
9. Install the new left side axle shaft seal using the J 36600.
10. Install the new left side inner axle shaft retainer ring.
11. Install the left side inner axle shaft by doing the following: Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. (Scheme 187): Installing Left Side Inner Axle Shaft
12. Install the right side inner shaft bearing into the inner shaft housing by performing the following steps: Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
13. Install the new inner shaft seal using the J 36600.
14. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. (Scheme 6)
15. Install the inner shaft housing to the differential carrier assembly case.
16. Install the inner shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
17. Install the inner shaft (2) into the inner shaft housing (1) by doing the following: Install the inner shaft into the inner axle shaft housing until the inner shaft is seated against the differential side gear. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. (Scheme 189): Axle Shaft & Inner Axle Shaft Housing
18. Install the drain plug and the washer.
19. Install the fill plug and the washer. Tighten Tighten the drain plug and the fill plug to 33 N.m (24 lb ft).
20. Install the lower differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
21. Install the upper differential carrier assembly bushing by performing the following steps: Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.

GEAR TOOTH CONTACT PATTERN INSPECTION

The contact pattern check is not a substitute for adjusting the pinion depth and backlash. Use this method in order to verify the correct running position of the ring gear and the drive pinion. Gear sets which are not positioned properly may be noisy and/or have a short life. A pattern check ensures the best contact between the ring gear and the drive pinion for low noise and long life.

Gear Tooth Nomenclature

The side of the ring gear tooth which curves outward, or is convex, is the drive side (4). The concave side is the coast side (3). The end of the tooth nearest the center of the ring gear is the toe end (2). The end of the tooth farthest away from the center is the heel end (1).

Scheme 183

ADJUSTMENTS AFFECTING TOOTH CONTACT

The following 2 adjustments affect the tooth contact pattern

1. Backlash adjustment
2. Pinion depth adjustment

The effects of bearing preloads are not readily apparent on hand-loaded tooth contact pattern tests. However, bearing preloads should be within specifications before proceeding with backlash and pinion depth adjustments.

Pinion Depth Adjustment

Adjust the position of the pinion by increasing or decreasing the distance between the pinion head and the centerline of the ring gear. Decreasing the distance moves the pinion closer to the centerline of the ring gear. Increasing the distance moves the pinion farther away from the centerline of the ring gear.

Backlash Adjustment

Adjust the backlash by means of moving the side bearing adjuster sleeves which move the case and ring gear assembly closer to or farther from the pinion. Also use the adjuster sleeves in order to set the side bearing preload.

1. If the left side adjuster sleeve is moved in, along with an equal outward movement of the right side adjuster, the backlash will increase.
2. If the left side adjuster sleeve is moved out, along with an equal inward movement of the right side adjuster, the backlash will decrease.

Scheme 184

1. Wipe clean the differential case, the ring gear and the differential carrier housing of lubricant. Carefully clean each tooth of the ring gear.
2. Use a medium stiff brush in order to sparingly apply gear marking compound GM P/N 1052351 (Canadian P/N 10953497) or equivalent to all of the ring gear teeth.
3. Using a wrench, turn the drive pinion flange/yoke so that the ring gear rotates at least 3 full revolutions.
4. Turn the drive pinion flange/yoke in the opposite direction so that the ring gear rotates at least 3 full revolutions in the opposite direction.
5. Observe the pattern on the ring gear teeth. Compare the pattern with the following illustrations.

Condition

The backlash and pinion depth is correct.

Correction

None required.

Service Hints

Loose bearing on the drive pinion or in the differential case may cause patterns that vary. If the contact pattern varies, inspect the following preload settings

1. Total assembly
2. Differential case
3. Drive pinion

If these settings are correct, inspect for damage or incorrectly assembled parts.

Scheme 185

The pinion depth is incorrect. The drive pinion is too far away from the ring gear.

Adjust the pinion depth of drive pinion. Refer to PINION DEPTH ADJUSTMENT .

Scheme 186

The pinion depth is incorrect. The drive pinion is too close to the ring gear.

Adjust the pinion depth of drive pinion. Refer to PINION DEPTH ADJUSTMENT .

Scheme 187

The backlash is incorrect. The ring gear is too far away from the drive pinion.

Decrease the backlash. Move the ring gear closer to the drive pinion by adjusting the side bearing adjuster sleeves. Refer to BACKLASH INSPECTION AND ADJUSTMENT .

Scheme 188

The backlash is incorrect. The ring gear is too close to the drive pinion.

Increase the backlash. Move the ring gear away from the drive pinion by adjusting the side bearing adjuster sleeves. Refer to BACKLASH INSPECTION AND ADJUSTMENT .

Scheme 189

Selectable Four Wheel Drive (S4WD) Front Axle Description and Operation

The Selectable Four Wheel Drive (S4WD) Front Axle consist of the following components

1. Differential Carrier Housing
2. Differential Assembly
3. Output Shafts (Left and Right Side)
4. Inner Axle Shaft Housing
5. Inner Axle Shaft (Right Side)
6. Clutch Fork
7. Clutch Fork Sleeve
8. Electric Motor Actuator

The front axle on Selectable Four Wheel Drive model vehicles uses a central disconnect feature in order to engage and disengage the front axle. When the driver engages the 4WD system, the Transfer Case Control Module sends a signal to the electric motor actuator to energize and extend the plunger inside. The extended plunger moves the clutch fork and clutch fork sleeve across the inner axle shaft and the clutch fork shaft and locks the two shafts together. The locking of the two shafts allows the axle to operate in the same manner as a semi-floating rear axle. A propeller shaft connects the transfer case to the front axle. The differential carrier assembly uses a conventional ring and pinion gear set to transmit the driving force of the engine to the wheels. The open differential allows the wheels to turn at different rates of speed while the axle continues to transmit the driving force. This prevents tire scuffing when going around corners and premature wear on internal axle parts. The ring and pinion set and the differential are contained within the carrier. The axle identification number is located on top of the differential carrier assembly or on a label on the bottom of the right half of differential carrier assembly. The drive axles are completely flexible assemblies consisting of inner and outer constant velocity CV joints protected by thermoplastic boots and connected by a wheel drive shaft.

Full-Time Four Wheel Drive (F4WD) Front Axle Description and Operation

The Full-Time Four Wheel Drive (F4WD) Front Axle consist of the following components

1. Differential Carrier Housing
2. Differential Assembly
3. Output Shaft (Left Side)
4. Inner Axle Shaft Housing
5. Inner Axle Shaft (Right Side)

The front axle on Full-Time Four Wheel Drive model vehicles does not have a central disconnect feature in order to engage and disengage the front axle. The left and right axle shafts are connected directly to the differential case assembly. This allows the axle shafts and the propeller shaft to spin continuously. The transfer case controls the amount of torque applied to the front axle. The remaining components are the same as the selectable four wheel drive axle.

SPECIAL TOOLS AND EQUIPMENT

Special Tools Illustration Tool Number/ Description J 2619-01 Slide Hammer J 8001 Dial Indicator Set J 8092 Driver Handle J 8614-01 Pinion Flange Holder J 22761 Differential Side Bearing Installer (8.25 Inch Axle) J 22888-D Side Bearing Remover Kit J 22912-01 Rear Pinion and Axle Bearing Remover J 23907 Slide Hammer J 29369-1 Bushing and Bearing Remover J 29369-2 Bushing and Bearing Remover - 2-3 inch J 29710 Differential Side Bearing Installer J 29763 Static Timing Gage J 33791 Carrier Bushing Remover/Installer J 33842 Pilot Bearing Installer J 34011 Pilot Bearing Remover J 34672 Depth Micrometer J 35512 Inner Pinion Bearing Installer J 36366 Pinion Oil Seal Installer J 36597 Side Bearing Puller Pilot (9.25 Inch Axle) J 36598 Holding Fixture J 36599-A Side Bearing Nut Wrench J 36601 Pinion Shim Selector Kit J 36603 Side Bearing Cup Installer J 36609 Axle Tube Bearing Installer J 36612 Bearing Installer J 36614 Inner Pinion Bearing Installer J 36615 Side Bearing Nut Wrench J 36616 Axle Mount Bushing Remover/Installer J 45225 Axle Seal Installer J 45754 Pinion Bearing Race Remover/Installer - 9.25 Inch Axle J 45765 Pinion Remover - 8.25 inch/9.25 inch Axles J 45858 Pinion Bearing Race Remover/Installer - 8.25 Inch Axle

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

See also:
• JACKING & HOISTING
• STABILIZER BAR
• FRONT BRAKE CALIPER
• RELAY ROD
• DESCRIPTION AND OPERATION
• SYMPTOMS - FRONT DRIVE AXLE
• FRONT AXLE LUBRICANT LEAK DIAGNOSIS
• PINION DEPTH ADJUSTMENT
• GEAR TOOTH CONTACT PATTERN INSPECTION