Front Drive Axle

Front Differential Drive Pinion Gear Yoke Replacement

Special Tools

* J 33782 - Pinion Oil Seal Installer

* J 8614-01 - Pinion Flange Holder

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation Service and Repair.

3. Remove the brake calipers. Refer to Front Brake Caliper Replacement (JH6, JH9) Front Brake Caliper Replacement (JH6, JH9)Front Brake Caliper Replacement (JH5) Front Brake Caliper Replacement (JH5).




4. Reference mark the relationship of the propeller shaft to the front axle pinion yoke.

5. Remove the pinion yoke retainer bolts and the yoke retainers from the front axle pinion yoke.

Caution:
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.

6. Disconnect the propeller shaft from the front axle pinion yoke.
Wrap the bearing cups with tape in order to prevent the loss of bearing rollers.




7. Support the propeller shaft and move out of the way as necessary.




8. 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




9. Scribe an alignment line between the pinion shaft and the pinion yoke.




10. Install the J 8614-01 - Pinion Flange Holder onto the pinion yoke as shown.

11. Remove the pinion nut while holding the J 8614-01 - Pinion Flange Holder.




12. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 - Pinion Flange Holder (3) as shown.

13. Remove the pinon yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 - Pinion Flange Holder (3).

Note: Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.

14. Remove the oil seal using a suitable seal removal tool.

Installation Procedure




1. Install the oil seal by doing the following:

1. Position the oil seal in the bore.

2. Install the J 33782 - Pinion Oil Seal Installer over the oil seal.

3. Strike the J 33782 - Pinion Oil Seal Installer 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.

Caution: Refer to Pinion Flange/Yoke Installation Caution Pinion Flange/Yoke Installation Caution.

4. Seat the pinion flange onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the flange.

5. Install the washer.

6. Install a new pinion nut.




7. Install the J 8614-01 - Pinion Flange Holder onto the pinion flange as shown.

Caution: Refer to Fastener Caution Fastener Caution.

Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

8. Tighten the pinion nut while holding the J 8614-01 - Pinion Flange Holder.
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

9. Measure the rotating torque of the pinion. Compare the measurement with the rotating torque recorded earlier.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal.

10. 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.

11. Install the propeller shaft to the pinion yoke.
Align the reference marks made during removal.

12. Install the pinion yoke retainers and the bolts and tighten to 25 Nm (18 lb ft).

13. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level Inspection Front Drive Axle.

14. Install the brake calipers. Refer to Front Brake Caliper Replacement (JH6, JH9) Front Brake Caliper Replacement (JH6, JH9)Front Brake Caliper Replacement (JH5) Front Brake Caliper Replacement (JH5).

15. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation Service and Repair.

16. Lower the vehicle.