Drive Axle - Front: Removal & Installation GMC Pickup C2500

REMOVAL & INSTALLATION

Remove front axle assembly. See FRONT AXLE ASSEMBLY under REMOVAL & INSTALLATION. Using Carrier Bushing Remover/Installer (J-36616 ), 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

1. Disconnect battery negative cable. Raise and support vehicle. Remove wheels. Remove 6 right stub shaft-to-axle flange bolts. Remove 6 left axle shaft-to-output shaft flange bolts. Wire left axle shaft and right stub shaft aside.
2. Disconnect drive shaft at pinion yoke. Wrap tape around all "U" joint caps to secure in position. Wire drive shaft aside. Disconnect harness connectors for indicator light switch and actuator solenoid at right axle tube. Disconnect vent hose at axle. Remove bolts securing right axle tube to frame rail.
3. Remove lower mounting bolt from axle assembly. Disconnect right side inner tie rod from steering linkage rod. Remove engine oil filter (if necessary). Support axle assembly using appropriate transmission jack. Remove upper axle assembly mounting bolt. Lower transmission jack and remove axle assembly from vehicle.
4. To install axle assembly, reverse removal procedure. Tighten all nuts and bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-46662-S08361197132001011500000) table.

Scheme 14

1. Raise and support vehicle. Remove skid plate (if equipped). Remove wheel. Remove stabilizer bar from lower control arm. If both ends of stabilizer bar are being removed, DO NOT mix left and right stabilizer bar components. (Scheme 14) CAUTION: DO NOT use wedge type remover tool on tie rod end. Damage to tie rod end will result.
2. Disconnect left outer tie rod end from steering knuckle using Steering Linkage Puller (J-24319-01 or J-6627-A ). Wire tie rod end aside. Insert a long drift through caliper and into disc rotor vanes to prevent rotation. Remove axle hub nut and washer from drive axle shaft CV joint. Loosen 6 drive axle shaft flange bolts retaining tripod joint housing to axle carrier output shaft drive flange.
3. Remove brake line bracket from upper control arm. Remove shock absorber from lower control arm mounting bracket. Install floor stand or jack under lower control arm near ball joint to maintain spring tension and lower control arm position.
4. Remove upper control arm ball joint-to-steering knuckle nut. Separate upper control arm ball joint stud from knuckle. Using shop towel, cover lower shock mount ears on lower control arm to prevent CV joint boot damage when removing axle shaft. Install Puller (J-28733 ) to left rotor to push CV joint splined shaft through hub splines.
5. Remove 6 drive axle shaft flange bolts retaining tripod joint housing to axle carrier output shaft drive flange. DO NOT allow drive axle shaft to hang free. Pull slightly outward on top of steering knuckle to enable drive axle shaft removal. DO NOT stretch brake hose. Remove drive axle shaft.

Installation

1. Before installing drive axle shaft, inspect inner wheel bearing seal on rear of knuckle. Replace if required using Seal Installer (J-36605 ). Lube seal lip.
2. To install drive axle shaft, reverse removal procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-46662-S08361197132001011500000) table.

Scheme 15

1. Raise vehicle on hoist. Remove pinion flange retaining bolts. Mark position of drive shaft yoke ear to pinion flange to ensure correct installation. Remove drive shaft from pinion flange and support shaft out of way.
2. Scribe mark pinion, pinion nut and pinion flange to ensure proper alignment and bearing preload during installation. Count and record number of exposed threads on pinion. Using pinion flange holder of Pinion Flange Remover Set (J-8614-01 ), hold pinion flange stationary. Using large socket and wrench, remove pinion flange nut and washer.
3. Place drain pan under pinion area of differential carrier. Insert pinion flange remover through pinion flange holder and rotate 90°. Tighten bolt to remove pinion flange. (Scheme 15) Pry pinion seal from housing. DO NOT damage differential carrier or seal running surface on pinion when removing pinion oil seal.
4. 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. CAUTION: DO NOT use "hard-faced" hammer to drive/install flange onto pinion shaft; ring gear, pinion and flange will be damaged.

1. Lubricate pinion flange seal running surface. Lubricate lip of oil seal. Install oil seal using Seal Installer (J-39366 ). Ensure seal is driven in straight or aluminum housing will be severely damaged.
2. Install new dust deflector onto pinion flange and stake in 3 places. Install pinion flange onto pinion shaft aligning marks made before removal. If required, use only "soft" faced (rubber) hammer to tap flange onto pinion.
3. Install pinion nut and tighten to no more than position marked on pinion shaft and flange. Note number of threads exposed. Tighten pinion nut no more than 1/16" beyond alignment marks. If this marked position is exceeded by more than 1/16", remove pinion and install NEW collapsible sleeve. Install drive shaft and tighten bolts to 15 ft. lbs. (20 N.m). Check gear oil level.

Removal

1. Disconnect battery negative cable. Raise and support vehicle. Remove skid plate (if equipped). Remove wheel. Remove stabilizer bar from both lower control arms. DO NOT mix left and right stabilizer bar components.
2. Disconnect right outer tie rod end from steering knuckle using Steering Linkage Puller (J-24319-01 or J-6627-A ). Wire right outer tie rod linkage aside.
3. Remove stub axle shaft flange bolts from inner axle shaft flange. Turn right wheel outward to loosen stub axle shaft from inner axle shaft flange. Push stub axle shaft toward front of vehicle, and wire shaft aside.
4. Disconnect harness connectors for indicator light switch and actuator solenoid at right axle tube. Place drain pan under drive axle. Remove drain plug to drain lubricant. Remove bolts retaining axle tube to right frame.
5. Remove bolts attaching axle tube to axle carrier. Remove axle tube by pulling away from axle carrier to clear shift shaft. While pulling axle tube away, note shifter fork spring location to keep from losing it off end of shifter shaft when removing axle tube. Ensure that open end of tube is pointed upward.

Scheme 16

Scheme 17

1. If internal carrier components have been changed, see reassembly steps 4) through 9) of «RIGHT AXLE TUBE ASSEMBLY»(ref-46662-S34518130942001011500000) under OVERHAUL. If internal carrier components have NOT been changed, clean mating surfaces thoroughly to remove any oil residue. Ensure shift shaft spring is in position.
2. Apply sealant (GM 1052942 or Loctite 518 ) to carrier sealing surfaces. Install axle tube to carrier housing. Install 6 axle tube retaining bolts and tighten to 30 ft. lbs. (40 N.m). Connect stub shaft to inner shaft flange and install 6 bolts. Using a criss-cross pattern, tighten bolts evenly to 59 ft. lbs. (80 N.m).
3. Raise axle tube and install frame-to-tube mounting bolts. On K15/25, tighten nuts to 75 ft. lbs. (102 N.m). On K35, tighten nuts to 110 ft. lbs. (149 N.m). Install tie rod end to steering knuckle. Tighten tie rod nut to 35 ft. lbs (48 N.m).
4. Install stabilizer bar and hardware. Tighten stabilizer bracket-to-frame bolts to 24 ft. lbs. (33 N.m). Tighten all remaining stabilizer hardware to 13 ft. lbs. (18 N.m).
5. Reconnect harness connectors for indicator light switch and actuator solenoid at right axle tube. Install differential carrier drain plug, and tighten it to 24 ft. lbs. (33 N.m). Remove differential carrier filler plug and fill drive axle to hole level with SAE 80W-90 GL5 gear lubricant. Tighten fill plug to 24 ft. lbs. (33 N.m). To complete installation, reverse removal procedure. Recheck gear oil when vehicle is on level ground.

Remove right axle tube and inner axle shaft assembly. See RIGHT AXLE TUBE & INNER AXLE SHAFT. Remove shim (No. 20). (Scheme 16)or (Scheme 17). Remove pilot bearing using Pilot Bearing Remover (J-34011 ). Lubricate new pilot bearing with wheel bearing grease. Install pilot bearing using Pilot Bearing Installer (J-33842 ). Install shim (No. 20). To complete installation, reverse removal procedure.