Front Drive Axle

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

^ Tools Required
- J 33782 Pinion Seal Installer
- J 8614-01 Pinion Flange Holder

Removal Procedure





1. Raise the vehicle.
2. Remove the tire and wheel assemblies.
3. Remove the brake calipers.
4. Reference mark the relationship of the propeller shaft to the front axle pinion flange.
5. Remove the pinion flange bolts from the front axle pinion flange.

Notice: 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 flange.
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 and the pinion flange.





10. Install the J 8614-01 onto the pinion as shown.
11. Remove the pinion nut while holding the J 8614-01.





12. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
13. Remove the pinon flange by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).

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

14. Remove the oil seal using a flat-bladed tool.
15. Remove the dust deflector from the pinion flange by doing the following:
^ Tap the deflector off the pinion flange.
^ Clean up the stake points on the pinion flange.

Installation Procedure

Important: Stake the new deflector at 3 new equally spaced positions. You must stake the new deflector in such a way that you do not damage the seal operating surface.





1. Install the new deflector and stake the dust deflector onto the pinion flange.

Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing.

2. Install the oil seal by doing the following:
2.1. Position the oil seal in the bore.
2.2. Install the J 33782 over the oil seal.
2.3. Strike the J 33782 with a hammer until the seal flange seats on the axle housing surface.
3. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the drive pinion yoke.
4. Install the pinion flange. Align the reference marks made during removal.

Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

5. 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.
6. Install the washer and a new pinion nut.





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

Notice: Refer to Fastener Notice in Service Precautions.

Important: 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 8614-0 1.
^ 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 inch lbs.) 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 flange. Align the reference marks made during removal.
12. Install the pinion flange bolts.
^ Tighten the pinion flange bolts to 45 Nm (33 ft. lbs.).
13. Inspect the axle lubricant level, and add, if necessary.
14. Install the brake calipers.
15. Install the tire and wheel assemblies.
16. Lower the vehicle.