Drive Axle - Front: Removal & Installation GMC Envoy I

REMOVAL & INSTALLATION

Remove right axle shaft and housing assembly. See RIGHT AXLE SHAFT & HOUSING . Remove clutch shaft from differential carrier. Remove pilot bearing using Pilot Bearing Remover (J-34011). Lubricate NEW pilot bearing with gear oil. Install NEW pilot bearing using Pilot Bearing Installer (J-33842). To complete installation, reverse removal procedure.

Remove differential carrier. See DIFFERENTIAL CARRIER. Using Carrier Bushing Remover/Installer (J-33791), press bushing out of carrier housing. (Scheme 13) To install, reverse tool and press NEW bushing into housing. Repeat procedure for other mounting bushing.

Scheme 13

Removal

1. Unlock steering wheel. Raise and support vehicle. Remove front axle skip plate. Drain front differential. Disconnect axle vent hose. Disconnect steering relay rod from idler arm and pitman arm, and pull steering linkage forward. Mark front of drive shaft to ensure proper installation. Remove bolts and clamps. Wire drive shaft aside.
2. Remove wheels. Remove both outer axles shafts. See «OUTER AXLE SHAFTS»(ref-1408-S31794804462000031300000) . Using a transmission jack, support differential carrier. Remove right axle shaft and housing. See «RIGHT AXLE SHAFT & HOUSING»(ref-1408-S11613115312000031300000) . Remove differential carrier-to-frame bolts and nuts. Tip differential carrier counterclockwise while lifting (to gain clearance from mounting ears) and remove differential carrier.

Installation

To install, reverse removal procedure. Align all marks made during removal. Check fluid level in differential carrier. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS table.

1. Unlock steering column. Raise and support vehicle. Remove wheels. Insert a long drift through caliper and into brake rotor vanes to prevent rotation. Remove axle hub nut and washer from axle shaft CV joint. see scheme 12
2. Remove long drift from brake rotor. Remove ABS wire and brake hose brackets from upper control arm and ball joint. Secure vehicle frame to hoist to prevent movement. Place a stand under lower control arm and support weight of steering knuckle. Partially reinstall axle hub nut. Using a brass drift, separate but do not remove axle shaft from steering knuckle. Disconnect shock absorber from lower mount.
3. Remove cotter pin and nut from upper and lower control arm ball joint stud. Using pry bar, pry between upper or lower control arm and frame. Have an assistance hammer on appropriate steering knuckle during prying. Remove upper and lower ball joint from steering knuckle. Push axle shaft from steering knuckle. Wire steering knuckle aside. Lower stand from lower control arm.
4. Remove front axle skid plate. Using a block of wood or brass drift, placed behind tripot housing, drive outer axle shaft out of front axle. Pull axle shaft straight out of front axle. Support axle shaft so as not to tear dust boot. DO NOT damage front axle outer seals.

1. DO NOT lubricate differential carrier axle seals. To prevent dust boot damage, cover shock mounting lower bracket, lower control arm ball joint stud and all other sharp edges with shop towels. When installing axle shaft into front axle, align splines and center drive axle into front axle. Push shaft until snap ring seats into place.
2. Start steering knuckle onto axle shaft while guiding lower ball joint stud. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1408-S05431005252000031300000) table.

1. Unlock stirring column. Raise and support vehicle. Remove front wheel assembly. Remove and support front brake caliper. Remove brake pads and caliper bracket. Remove rotor. Remove front axle skid plate. Mark position of drive shaft and pinion flange to ensure correct installation. Remove bolts and retainers from pinion flange. Remove drive shaft from pinion flange, and wire aside.
2. Measure amount of torque required to rotate pinion for reassembly. Mark pinion flange, pinion shaft and pinion nut to ensure alignment and bearing preload are maintained on installation. Record number of exposed threads on pinion shaft for reassembly. Using Pinion Flange Remover Set (J-8614-01), hold pinion flange stationary and remove pinion flange nut and washer. Place drain pan under pinion area of differential carrier. Remove pinion flange and oil seal. (Scheme 14)
3. Clean pinion flange in solvent and inspect seal surface of pinion flange for nicks, burrs or damage (such as a groove worn into pinion flange by oil seal). Repair or replace as necessary.

1. Apply sealant to inside sealing surface of pinion flange. Lubricate outside pinion flange surface and sealing lip of oil seal. Install oil seal using seal installer. DO NOT hammer pinion flange onto pinion shaft, pinion components may be damaged. Install pinion flange onto pinion shaft with marks aligned. Install pinion flange by tapping it with a soft-face hammer until a few pinion shaft threads show through flange.
2. Install pinion nut and tighten to position marked on pinion shaft. Tighten nut until pinion end play is just taken up. Rotate pinion while tightening nut to seat bearings. Tighten pinion shaft nut in small increments, until rotating torque if 3-5 INCH lb. greater than recorded totaling torque. If rotating torque is exceeded, pinion will have to be removed and a new collapsible spacer installed.
3. Once specified torque is obtained, rotate pinion several times to ensure bearings have seated. Recheck rotating torque and adjust if necessary. To complete installation, reverse removal procedure. Align all marks made during removal. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1408-S05431005252000031300000) table. Check gear oil level.

Scheme 14

1. Raise and support vehicle. Place drain pan under right axle shaft housing. Remove right outer axle shaft. See «OUTER AXLE SHAFTS»(ref-1408-S31794804462000031300000) . DO NOT damage seal. Remove 5 right axle shaft housing to differential carrier bolts. Remove shift cable housing assembly. Remove 2 right axle shaft housing to frame bracket bolts. Ensure that thrust washers, clutch gear, clutch sleeve and clutch shaft are not damaged, and do not fall out of differential carrier.
2. Remove right axle shaft and housing assembly. Place right axle shaft housing in a vise using mounting flange. Tap out axle shaft using soft mallet. Separate inner axle shaft and clutch gear, if necessary. Remove right axle shaft from housing. Inspect right axle shaft pilot and clutch shaft pilot bearing for wear. Inspect right axle shaft seal, bearing and shift cable housing seal for wear. Replace as necessary. Clean sealing surfaces of right axle shaft housing differential carrier.

1. To install, apply Sealant (GM 1052942 or Loctite 518) on axle housing to differential surface. Ensure thrust washers, clutch shaft, clutch sleeve and clutch gear are in place before installation. Install clutch gear thrust washer to housing as illustrated. (Scheme 16) Use grease to hold washer in place. Install axle shaft and housing assembly to differential carrier. Install axle shaft housing to differential carrier bolt, finger tight, at one o' clock position. Position shaft cable housing on axle housing flange.
2. Pull axle shaft and housing assembly down in order to install remaining bolts. Install and tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1408-S05431005252000031300000). To inspect operation of shift mechanism, install Hub Engagement Tool (J337798) into shift fork. Check for rotation of axle shaft. Install shift cable and indicator assembly. To complete installation, reverse removal procedure. Top off gear oil.

Scheme 15

Scheme 16

Scheme 17

Remove right axle shaft and housing assembly. See RIGHT AXLE SHAFT & HOUSING . Place right axle shaft housing in a vise using mounting flange. Remove right axle shaft seal. Using bearing remover and slide hammer, remove right axle shaft bearing. To install, lubricate bearing using gear oil. Using Bearing Installer (J42211) and Driver Handle (J8092), install right axle shaft bearing. Bearing is installed to proper depth when tool is flush with housing end. Using Seal Installer (J23911), install NEW seal. Drive in seal until seal flange is flush with housing end. To complete installation, reverse removal procedure.

Remove right axle shaft. See RIGHT AXLE SHAFT & HOUSING . Using a punch, drive shift cable housing seal out of axle housing. To install reverse removal procedure. Using Seal Installer (J33799), install seal.

Remove battery and tray. Disconnect vacuum line from actuator. Remove actuator shift cable. Remove vacuum actuator bolts and actuator. To install, reverse removal procedure. When installing hose, ensure it is routed correctly. The front drive axle clutch cable must engage the vacuum actuator retainer spring. Ensure hose is free of kinks and clear of sharp components. Ensure vent is not plugged.

Scheme 18

Scheme 19

Scheme 20

When replacing the hose, ensure that the hose is routed correctly, free of kinks, and clear of sharp components. Ensure the vent is not plugged.

Scheme 21

Scheme 22

1. Remove differential carrier. See «DIFFERENTIAL CARRIER»(ref-1408-S19138900682000031300000) under REMOVAL & INSTALLATION. Remove bolts, shift cable housing and spring. Remove right axle housing, right axle shaft assembly and thrust washers. See «RIGHT AXLE SHAFT & HOUSING»(ref-1408-S11613115312000031300000) under REMOVAL & INSTALLATION.
2. Remove shift fork assembly consisting of sleeve, springs and seals. (Scheme 15) Remove right axle shaft. Remove clutch gear and retaining ring. Remove right axle shaft to housing seal. Using bearing remover and slide hammer, remove right axle shaft bearing. Remove thrust washer, clutch sleeve and shaft.
3. Remove right output shaft bearing using Bearing Remover (J-34011). Remove washer from right side of carrier assembly. Remove left side carrier cover bolts. Remove left side cover and seal assembly. Remove carrier halves assembly bolts. Insert a screwdriver into slots provided. Pry to separate carrier.
4. Remove differential assembly from carrier. (Scheme 15) Remove bolts and lock tabs from side bearing adjuster sleeves. Remove bearing cups and sleeves from carrier. Using Side Bearing Adjusting Socket (J-42213), rotate left adjusting sleeve until cup is pushed out of carrier. Using Side Bearing Adjusting Socket (J-33792), rotate right adjusting sleeve until cup is pushed out of carrier.
5. Remove side bearings from right adjusting sleeve using Bearing Remover (J-21551). Remove side bearings from left adjusting sleeve using Bearing Remover (J-36611). Mark pinion flange, pinion shaft and pinion nut to ensure alignment and bearing preload are maintained on installation. Record number of exposed threads on pinion shaft for reassembly. Using Pinion Yoke Holder (J-8614-01), remove pinion yoke nut and washer. Using Pinion Bearing Cup Remover (J-33837), remove pinion out of carrier from left carrier case half. (Scheme 21) Remove pinion yoke and deflector. Remove pinion, spacer, pinion bearing and shim. Remove pinion spacer.
6. Press bearing from pinion. Remove shim. Using Pinion Bearing Cup Remover (J-33837), remove outer pinion bearing, seal and cup. (Scheme 22) Remove deferential pinion bolt and shaft from differential case. Remove differential pinion gears and thrust washers. Mark side gears and case for reinstallation. Remove side gear and thrust washers. Remove ring gear bolts. Using a brass drift, remove ring gear. DO NOT pry between ring gear and differential case. Using Differential Side Bearing Puller (J-22888-20), remove side bearings. Using Bushing Remover (J-33791), remove case busing.