Front Drive Axle: Removal & Installation Chevrolet Silverado 1500

Installation Procedure

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 correct fluid. Refer to «Capacities - Approximate Fluid»(ref-238237-S04944626252006072400000) in Maintenance and Lubrication and «Sealers, Adhesives, and Lubricants»(ref-238218-S28683498372006072400000) .
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»(ref-238218-S16994149072006072400000) .
5. Lower the vehicle.

Scheme 30

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the front differential carrier shield bolts.
3. Remove the front differential carrier shield.

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.

Removal Procedure

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the front differential carrier shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
3. Disconnect the electrical connector from the actuator.
4. Remove the electric motor actuator (3) by turning the actuator counterclockwise.

1. Apply sealant to the threads of the electric motor actuator. Use the correct sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-238218-S28683498372006072400000) .
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»(ref-238218-S16994149072006072400000) .
5. Lower the vehicle.

Scheme 31

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the front differential carrier shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
3. Remove the vent hose (1) from the wiring bundle (2), S4WD axles only.
4. Remove the vent hose from the retainer clips, all axles.
5. Remove the vent hose from the differential carrier assembly.
6. Remove the vent hose from the vehicle.

Scheme 32

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. Connect the vent hose to the differential carrier assembly.
3. Install the vent hose (1) to the wiring bundle (2), S4WD axles only.
4. Install the vent hose to the retainer clips, all axles.
5. Install the front differential carrier shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
6. Lower the vehicle.

Scheme 33

1. Raise the vehicle. Refer «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Disconnect the vent hose from the vent hose connector.
3. Remove the vent hose connector from the differential carrier assembly.

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.
2. Tighten the vent hose connector. Tighten: Tighten the vent hose connector to 28 N.m (21 lb ft).
3. Connect the vent hose to the vent hose connector.
4. Lower the vehicle.

Scheme 34

Scheme 35

Scheme 36

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Scheme 39

Scheme 40

Scheme 41

Scheme 42

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Drain the differential carrier assembly. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
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 Shaft Link Replacement»(ref-238259-S42906438922006072400000) in Front Suspension.
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. For 25/35 series vehicles, perform the following steps in order to provide additional clearance so the inner axle housing can be removed from the vehicle: Remove the front axle mounting bracket to frame nuts. Slide the front axle mounting bracket towards the engine. It may be necessary to pull down on the inner axle housing and/or push up on the mounting bracket in order to gain clearance.
9. Remove the inner axle shaft housing bolts from the differential carrier case.
10. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.
11. 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 (11) The clutch shaft shim (9) The clutch sleeve (8) 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). The thrust washer (5)
12. 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 (11) The clutch shaft shim (9) The clutch sleeve (8) The retainer ring (7) The thrust washers (5, 6)
13. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
14. Remove the inner axle seal and the bearing from the axle housing. Refer to «Inner Axle Seal and/or Bearing Replacement - Front Drive Axle»(ref-238218-S12476220862006072400000) .

Scheme 43

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»(ref-238218-S12476220862006072400000) .
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. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
4. For the 8.25 inch axle, install the following components into the inner axle shaft housing: IMPORTANT: Use chassis grease in order to hold the thrust washer in place. The thrust washer (5) 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»(ref-238218-S28831073312006072400000) . The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (11) The clutch fork inner spring (10)
5. For the 9.25 inch axle, install the following components into the inner axle shaft housing: IMPORTANT: Use chassis grease in order to hold the thrust washer in place. The thrust washer (5) 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»(ref-238218-S28831073312006072400000) . The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (11) The clutch fork inner spring (10)
6. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-238218-S28683498372006072400000) .
7. Install the inner axle shaft housing assembly to the differential carrier assembly.
8. Install the inner axle shaft housing bolts. Tighten: Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
9. For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing: Slide the front axle mounting bracket towards the frame. Install the front axle mounting bracket studs into the inner shaft housing mounting flange. It may be necessary to push up on the front axle mounting bracket and/or pull down on the inner axle housing in order to gain enough clearance to install the mounting bracket studs into the inner shaft housing. Install the front axle mounting bracket to frame nuts. Tighten: Tighten the inner axle shaft housing mounting bracket to frame nuts to 90 N.m (67 lb ft).
10. 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).
11. Connect the wheel drive shaft inboard flange to the inner axle shaft.
12. 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).
13. Install the stabilizer shaft link assembly. Refer to «Stabilizer Shaft Link Replacement»(ref-238259-S42906438922006072400000) in Front Suspension.
14. Connect the wire harness to the inner axle shaft housing.
15. Connect the electrical connector to the front axle actuator.
16. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
17. Lower the vehicle.

Scheme 44

Scheme 45

Scheme 46

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Drain the differential carrier assembly. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
3. Remove the stabilizer shaft link assembly. Refer to «Stabilizer Shaft Link Replacement»(ref-238259-S42906438922006072400000) in Front Suspension.
4. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
5. Disconnect the wheel drive shaft from the inner axle shaft.
6. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift.
7. Remove the inner axle shaft housing nuts from the bracket.
8. Remove the inner axle shaft housing bolts from the differential carrier assembly.
9. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
10. Remove the inner axle shaft from the inner axle shaft housing.
11. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing. Refer to «Inner Axle Seal and/or Bearing Replacement - Front Drive Axle»(ref-238218-S12476220862006072400000) .

1. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing. Refer to «Inner Axle Seal and/or Bearing Replacement - Front Drive Axle»(ref-238218-S12476220862006072400000) .
2. Install the inner axle shaft into the inner axle shaft housing. Do not install the inner axle shaft completely into the inner axle shaft housing at this time.
3. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-238218-S28683498372006072400000) .
4. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.
5. Install the inner axle shaft housing bolts. Tighten: Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
6. Install the inner axle shaft housing nuts to the bracket. Tighten: Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft).
7. Install the inner axle shaft into the differential case side gear by doing the following: Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear. 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.
8. Install the wheel drive shaft inboard flange to the inner axle shaft.
9. Install the wheel drive shaft inboard flange to inner axle shaft bolts. Tighten: Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).
10. Install the stabilizer shaft link assembly. Refer to «Stabilizer Shaft Link Replacement»(ref-238259-S42906438922006072400000) in Front Suspension.
11. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
12. Lower the vehicle.

Scheme 47

1. Remove the inner axle shaft and housing assembly. Refer to «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) .
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.

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 (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) .

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. See «Special Tools»(ref-238218-S10438743342006072400000) .
2. J 33842 Pilot Bearing Installer. See «Special Tools»(ref-238218-S10438743342006072400000) .

Scheme 48

1. Remove the inner axle shaft and housing assembly. Refer to «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) .
2. Remove the clutch shaft from the differential carrier assembly.
3. Remove the clutch shaft pilot bearing using the J 34011 . See «Special Tools»(ref-238218-S10438743342006072400000) .

Scheme 49

1. Lubricate the bearing with axle lubricant. Use the proper fluid. Refer to «Fluid and Lubricant Recommendations»(ref-238237-S14219643232006072400000) in Maintenance and Lubrication.
2. Install the clutch shaft pilot bearing using the J 33842 . See «Special Tools»(ref-238218-S10438743342006072400000) .
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 (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) .

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10. See «Special Tools»(ref-238218-S10438743342006072400000) .
2. J 2619-01 Slide Hammer
3. J 29369-1 Bushing and Bearing Remover. See «Special Tools»(ref-238218-S10438743342006072400000) .
4. J 29369-2 Bushing and Bearing Remover (2-3 inch). See «Special Tools»(ref-238218-S10438743342006072400000) .
5. J 36609 Axle Tube Bearing Installer. See «Special Tools»(ref-238218-S10438743342006072400000) .
6. J 45225 Axle Seal Installer. See «Special Tools»(ref-238218-S10438743342006072400000) .

Scheme 50

Scheme 51

Scheme 52

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Drain the differential carrier assembly. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
3. Remove the right side seal and/or bearing by performing 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 (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) . 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 (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) . 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. See «Special Tools»(ref-238218-S10438743342006072400000) . Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). See «Special Tools»(ref-238218-S10438743342006072400000) . 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.
5. If replacing both the left side seal and bearing, perform the following steps: Remove the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(ref-238218-S32738054852006072400000) . 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 (1), 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 . See «Special Tools»(ref-238218-S10438743342006072400000) . Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 .

Scheme 53

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Scheme 56

Scheme 57

Scheme 58

1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). See «Special Tools»(ref-238218-S10438743342006072400000) .
2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). See «Special Tools»(ref-238218-S10438743342006072400000) .
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 shaft housing. Refer to «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) .
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 (8.25 S4WD and 9.25 Axles)»(ref-238218-S04839976342006072400000) or «Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle)»(ref-238218-S40645349622006072400000) .
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). See «Special Tools»(ref-238218-S10438743342006072400000) .
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). See «Special Tools»(ref-238218-S10438743342006072400000) .
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»(ref-238218-S32738054852006072400000) .
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. See «Special Tools»(ref-238218-S10438743342006072400000) . Tap only on the center portion of the J 45225 in order to drive the seal in evenly. See «Special Tools»(ref-238218-S10438743342006072400000) .
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. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
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 N.m (58 lb ft).
14. Fill the differential carrier assembly. Use the correct fluid. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
15. Lower the vehicle.

Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front

Tools Required

1. J 8614-01 Flange and Pulley Holding Tool. See «Special Tools»(ref-238218-S10438743342006072400000) .
2. J 36366 Pinion Oil Seal Installer

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-238261-S35716783552006072400000) in Tires and Wheels.
3. Remove the brake calipers. Refer to «Brake Caliper Replacement - Front (1500 Series)»(ref-238255-S08172228292006072400000) or «Brake Caliper Replacement - Front (25/3500 Series)»(ref-238255-S26845726472006072400000) in Disc Brakes.
4. Remove the differential carrier assembly shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
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).
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. See «Special Tools»(ref-238218-S10438743342006072400000) .
12. Remove the pinion nut while holding the J 8614-01 . See «Special Tools»(ref-238218-S10438743342006072400000) .
13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. See «Special Tools»(ref-238218-S10438743342006072400000) .
14. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). See «Special Tools»(ref-238218-S10438743342006072400000) .
15. Remove the oil seal using a suitable seal removal tool.

Scheme 64

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. See «Special Tools»(ref-238218-S10438743342006072400000) .
7. Tighten the pinion nut while holding the J 8614-01 . See «Special Tools»(ref-238218-S10438743342006072400000) . 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»(ref-238218-S22009538722006072400000) .
13. Install the differential carrier assembly shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
14. Install the brake calipers. Refer to «Brake Caliper Replacement - Front (1500 Series)»(ref-238255-S08172228292006072400000) or «Brake Caliper Replacement - Front (25/3500 Series)»(ref-238255-S26845726472006072400000) in Disc Brakes.
15. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-238261-S35716783552006072400000) in Tires and Wheels.
16. Lower the vehicle.

Differential Carrier Assembly Bushing Replacement

Tools Required

1. J 33791 Carrier Bushing Remover/Installer. See «Special Tools»(ref-238218-S10438743342006072400000) .
2. J 36616 Axle Mount Bushing Remover/Installer. See «Special Tools»(ref-238218-S10438743342006072400000) .

Scheme 65

Scheme 66

1. Remove the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(ref-238218-S32738054852006072400000) .
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 67

Scheme 68

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»(ref-238218-S32738054852006072400000) .

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Turn the steering wheel all the way to the left.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
3. Place jack or utility stands at the rear end of the vehicle.
4. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
5. Remove the front differential carrier assembly shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
6. Drain the differential carrier assembly. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
7. Disconnect the front propeller shaft from the differential carrier assembly. Refer to «Propeller Shaft Replacement - Front»(ref-238283-S22320670012006072400000) in Propeller Shaft.
8. Remove the relay rod. Refer to «Relay Rod Replacement»(ref-238288-S15472892242006072400000) in Steering Linkage.
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.

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 Replacement»(ref-238288-S15472892242006072400000) in Steering Linkage.
13. Install the front propeller shaft to the differential carrier assembly. Refer to «Propeller Shaft Replacement - Front»(ref-238283-S22320670012006072400000) in Propeller Shaft.
14. Fill the differential carrier assembly. Use the correct fluid. Refer to «Lubricant Replacement - Front Drive Axle»(ref-238218-S30436697792006072400000) .
15. Install the front differential carrier assembly shield, if equipped. Refer to «Shield Replacement»(ref-238218-S16994149072006072400000) .
16. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
17. Remove the utility stands.
18. Lower the vehicle.

Scheme 73

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(ref-238218-S32738054852006072400000) .
3. Remove the nuts and the washers from the bracket.
4. Remove the bolt from the bracket.
5. Remove the bracket from the vehicle.

1. Install the bracket to the vehicle.
2. Install the bolt to the frame and the bracket. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
3. Install the washers and the nuts to the bracket. Tighten: Tighten the nuts to 90 N.m (70 lb ft).
4. Install the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(ref-238218-S32738054852006072400000) .
5. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(ref-238218-S32738054852006072400000) .
3. Remove the air conditioning compressor - (4.8 L, 5.3 L and 6.0 L engines). Refer to «Compressor Replacement (L18)»(ref-238212-S24832539212006072400000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-238212-S02372827462006072400000) or «Compressor Replacement (LLY)»(ref-238212-S10871610492006072400000) in HVAC Systems with A/C-Manual.
4. Remove the nuts and the washers from the bracket.
5. Remove the bracket from the vehicle.

1. Install the bracket to the vehicle.
2. Install the washers and the nuts to the bracket. Tighten: Tighten the bracket to frame nuts to 90 N.m (67 lb ft).
3. Install the air conditioning compressor -4.8 L, 5.3 L and 6.0 L engines. Refer to «Compressor Replacement (L18)»(ref-238212-S24832539212006072400000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-238212-S02372827462006072400000) or «Compressor Replacement (LLY)»(ref-238212-S10871610492006072400000) in HVAC Systems with A/C-Manual.
4. Install the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(ref-238218-S32738054852006072400000) .
5. Lower the vehicle.

Pinion Bearing Cup Installation (9.25 Inch Axle w/J 45754)

Tools Required

J 45754 Pinion Bearing Race Remover/Installer - 9.25 in Axle. See Special Tools

Scheme 74

Scheme 75

Scheme 76

Scheme 77

1. Before assembly, lubricate the following parts with axle lubricant. Use the correct fluid. Refer to «Sealers, Adhesives, and Lubricants»(ref-238218-S28683498372006072400000) . 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.
3. Install the J 45754-1 over the outer pinion bearing cup.
4. Install the forcing screw (1), the J 45754-2 (2) into the inner pinion bearing cup bore.
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. See «Special Tools»(ref-238218-S10438743342006072400000) .
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 . See «Special Tools»(ref-238218-S10438743342006072400000) .
9. Install the inner pinion bearing cup onto the J 45754-2 (2) and the forcing screw (1).
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.
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. See «Special Tools»(ref-238218-S10438743342006072400000) .
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 . See «Special Tools»(ref-238218-S10438743342006072400000) .
16. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to «Pinion Depth Adjustment»(ref-238218-S32984709762006072400000) .