Front diff rebuild
- Thread starter JSM
- Start date
Foot Performance
Donating Member
Re: Front diff rebuild
Never done a syty but have done AWD Denali, 1/2 ton pickups 99 and up all the way up to 1 ton front axles.
With all the right tools and a really good holding fixture it is mild
With some hand tools and a poorly mounted vise<<this would take the dificulty level up a notch.
For me getting the bearing pre load is the hardest part. I am 99% sure the front axles have the same adjustments but I will look at my 91 books tommarow at work and let you know for sure if someone doesnt chim in first
Is it doable I think so will it be a pain more than likely but most of us are used to that
Never done a syty but have done AWD Denali, 1/2 ton pickups 99 and up all the way up to 1 ton front axles.
With all the right tools and a really good holding fixture it is mild
With some hand tools and a poorly mounted vise<<this would take the dificulty level up a notch.
For me getting the bearing pre load is the hardest part. I am 99% sure the front axles have the same adjustments but I will look at my 91 books tommarow at work and let you know for sure if someone doesnt chim in first
Is it doable I think so will it be a pain more than likely but most of us are used to that
JSM
Active member
Re: Front diff rebuild
I have a spare core, my current one is doing ok but seems to have some extra slop which isn't a good thing on a couple levels.
So I thought I would look into rebuilding completely my core vs by another used and cross my fingers. Bad part for me now is front diff removal means engine has to come out.
I have a spare core, my current one is doing ok but seems to have some extra slop which isn't a good thing on a couple levels.
So I thought I would look into rebuilding completely my core vs by another used and cross my fingers. Bad part for me now is front diff removal means engine has to come out.
Re: Front diff rebuild
Differential Carrier Assembly - Disassemble A4WD
Tools Required
J 21551 Output Shaft Bearing Remover
J 22912-O1 Pinion Bearing Remover
J 23907 Slide Hammer
J 29369-1 Bushing/Bearing Remover
J 33791 Bushing Remover and Installer Set
J 33792 Side Bearing Adjuster Socket
J 33837 Pinion Bearing Cup Remover and Installer
J 36611 Output Shaft Bearing Remover
J 42213 Side Bearing Adjuster Socket
J 8092 Driver Handle
J 8614-01 Pinion Flange Holder
Inspection Procedure
Perform the following before disassembling the axle:
Remove the drain plug from the axle.
Drain the axle lubricant.
Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
Check the ring gear backlash. Refer to Backlash Inspection and Adjustment .
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.
Disassembly Procedure
Remove the inner axle shaft from the inner axle shaft housing.
Remove the inner axle shaft housing from the differential carrier assembly.
Remove the inner axle shaft seal and the bearing by doing the following:
Install the J 23907 (1) and the J 29369-2 (2) as shown.
Remove the inner axle shaft seal and the bearing by pulling on the J 23907 (1).
Remove the left inner axle shaft.
Remove the inner axle shaft seal cover and the seal.
Remove the inner axle shaft seal by doing the following:
Install the inner axle shaft seal cover in a vise.
Install the J 29369-1 to the backside of the inner axle shaft seal.
Install the J 23907 to the J 29369-1 .
Remove the inner axle shaft seal by pulling on the J 23907 .
Remove the differential carrier assembly bolts.
Separate the left carrier case half from the right carrier case half by inserting a screwdriver into the slots provided and prying the case apart.
Remove the differential case assembly.
Remove the differential bearing adjuster nut lock bolts and the differential bearing adjuster nut locks.
Remove the left differential bearing adjuster and the differential case bearing cup by doing the following:
Install the J 42213 onto the differential bearing adjuster nut.
Turn the J 42213 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
Remove the right differential bearing adjuster and the differential case bearing cup by doing the following:
Install the J 33792 onto the differential bearing adjuster nut.
Turn the J 33792 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
Remove the left inner axle shaft bearing using the J 36611 (2) and the J 8092 (1).
Remove the right inner shaft bearing using the J 21551 (2) and the J 8092 (1).
Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01 .
Remove the washer.
Install the J 8614-2 (2) and the J8614-3 (3) into the J 8614-01 (1) as shown.
Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Remove the dust deflector from the pinion yoke by doing the following:
Tap the deflector off the pinion yoke.
Clean up the stake points on the pinion yoke.
Mount the left side differential carrier case in the J 33837 -1.
Install the J 33837-3.
While holding the J 33837-3 , turn the nut sleeve of the J 33837 -3 counterclockwise to remove the following components:
The drive pinion
The drive pinion selectable shim
The inner pinion bearing
The collapsible spacer
Remove the collapsible spacer from the pinion.
Remove the inner pinion bearing by installing the J 22912-O1 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
Remove the pinion gear selectable shim.
Install the J 33837-6 (2) onto the J 33837-3 between the inner and the outer pinion bearing cup.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 clockwise in order to remove the following components:
The pinion oil seal
The pinion outer bearing
The pinion outer bearing cup
Install the J 33837-6 (2) onto the J 33837-3 on the inside surface of the outer bearing cup.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 counterclockwise in order to press the inner pinion bearing cup out from the differential carrier case.
Install the J 33791 onto the differential carrier assembly bushings.
Remove the bushings using the J 33791 .
Differential Carrier Assembly - Disassemble A4WD
Tools Required
J 21551 Output Shaft Bearing Remover
J 22912-O1 Pinion Bearing Remover
J 23907 Slide Hammer
J 29369-1 Bushing/Bearing Remover
J 33791 Bushing Remover and Installer Set
J 33792 Side Bearing Adjuster Socket
J 33837 Pinion Bearing Cup Remover and Installer
J 36611 Output Shaft Bearing Remover
J 42213 Side Bearing Adjuster Socket
J 8092 Driver Handle
J 8614-01 Pinion Flange Holder
Inspection Procedure
Perform the following before disassembling the axle:
Remove the drain plug from the axle.
Drain the axle lubricant.
Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
Check the ring gear backlash. Refer to Backlash Inspection and Adjustment .
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.
Disassembly Procedure
Remove the inner axle shaft from the inner axle shaft housing.
Remove the inner axle shaft housing from the differential carrier assembly.
Remove the inner axle shaft seal and the bearing by doing the following:
Install the J 23907 (1) and the J 29369-2 (2) as shown.
Remove the inner axle shaft seal and the bearing by pulling on the J 23907 (1).
Remove the left inner axle shaft.
Remove the inner axle shaft seal cover and the seal.
Remove the inner axle shaft seal by doing the following:
Install the inner axle shaft seal cover in a vise.
Install the J 29369-1 to the backside of the inner axle shaft seal.
Install the J 23907 to the J 29369-1 .
Remove the inner axle shaft seal by pulling on the J 23907 .
Remove the differential carrier assembly bolts.
Separate the left carrier case half from the right carrier case half by inserting a screwdriver into the slots provided and prying the case apart.
Remove the differential case assembly.
Remove the differential bearing adjuster nut lock bolts and the differential bearing adjuster nut locks.
Remove the left differential bearing adjuster and the differential case bearing cup by doing the following:
Install the J 42213 onto the differential bearing adjuster nut.
Turn the J 42213 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
Remove the right differential bearing adjuster and the differential case bearing cup by doing the following:
Install the J 33792 onto the differential bearing adjuster nut.
Turn the J 33792 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
Remove the left inner axle shaft bearing using the J 36611 (2) and the J 8092 (1).
Remove the right inner shaft bearing using the J 21551 (2) and the J 8092 (1).
Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01 .
Remove the washer.
Install the J 8614-2 (2) and the J8614-3 (3) into the J 8614-01 (1) as shown.
Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Remove the dust deflector from the pinion yoke by doing the following:
Tap the deflector off the pinion yoke.
Clean up the stake points on the pinion yoke.
Mount the left side differential carrier case in the J 33837 -1.
Install the J 33837-3.
While holding the J 33837-3 , turn the nut sleeve of the J 33837 -3 counterclockwise to remove the following components:
The drive pinion
The drive pinion selectable shim
The inner pinion bearing
The collapsible spacer
Remove the collapsible spacer from the pinion.
Remove the inner pinion bearing by installing the J 22912-O1 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
Remove the pinion gear selectable shim.
Install the J 33837-6 (2) onto the J 33837-3 between the inner and the outer pinion bearing cup.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 clockwise in order to remove the following components:
The pinion oil seal
The pinion outer bearing
The pinion outer bearing cup
Install the J 33837-6 (2) onto the J 33837-3 on the inside surface of the outer bearing cup.
While holding the J 33837-3, turn the nut sleeve of the J 33837-1 counterclockwise in order to press the inner pinion bearing cup out from the differential carrier case.
Install the J 33791 onto the differential carrier assembly bushings.
Remove the bushings using the J 33791 .
Re: Front diff rebuild
Differential Carrier Assembly - Final Assembly
Tools Required
J 42738 Front Output Shaft Seal Installer
J 33842 Pilot Bearing Installer
J 33791 Carrier Case Bushing Installer
J 42211 Inner Axle Shaft Housing Bearing Installer
J 33799 Shaft Cable Housing Seal Installer
Install the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the differential adjuster nut lock tab bolts. Tighten
Tighten the differential adjuster nut lock tab bolt to 8 N·m (71 lb in).
Remove the differential carrier assembly bolts.
Remove the right differential carrier case half.
Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
Apply a bead of sealer (GM P/N 1052942 or the equivalent) to one differential carrier case half sealing surface.
Install the right differential carrier case half.
Install the differential carrier case bolts. Tighten
Tighten the differential carrier case bolts to 50 N·m (37 lb ft).
Lubricate the clutch shaft pilot bearing with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
Install the clutch shaft pilot bearing using the J 33842 .
Install the clutch shaft thrust washer into the differential carrier assembly.
Install the clutch shaft to the differential carrier assembly.
Install the inner shaft seal cover.
Install the inner shaft seal cover bolts. Tighten
Tighten the inner axle shaft seal cover bolts to 25 N·m (18 lb ft).
Install the new left side axle shaft seal using the J 42738 .
Install the inner axle shaft retaining ring (A4WD only).
Install the left inner axle shaft (A4WD only). Carefully tap the inner axle shaft into place with a soft mallet.
Install the differential carrier bushings using the J 33791 .
Install the right side inner axle shaft housing bearing and the seal using the following procedure:
Install the bearing with the square shoulder in using the J 42211 .
Install the new axle shaft seal using the J 42738 .
Install the clutch cable housing seal using the J 33799 (S4WD only).
Install the new inner axle shaft retaining ring (A4WD only).
Install the inner axle shaft into the inner axle shaft housing.
Install the thrust washer into the inner axle shaft housing. Use chassis grease in order to hold the thrust washer in place (S4WD only). Ensure the tabs on the thrust washer align with the slot in the inner axle shaft housing.
Install the new retaining ring into the clutch gear (S4WD only).
Install the clutch gear onto the inner axle shaft (S4WD only). Drive the clutch gear into place with a plastic hammer.
Install the following components into the inner axle shaft housing (S4WD only):
The thrust washer (9)
The clutch fork inner spring (16)
The clutch fork (17)
The clutch fork sleeve (11)
Apply sealant (GM P/N 1052492 or equivalent) to the inner axle housing to differential carrier sealing surface.
Install the inner axle shaft housing to the differential carrier assembly.
Install the 2 upper inner axle shaft housing bolts (S4WD only). Tighten the bolts finger tight.
Install the 5 inner axle shaft housing bolts (A4WD only). Tighten
Tighten the inner axle shaft housing bolts to 48 N·m (36 lb ft) (A4WD only).
The clutch cable retainer spring to the clutch fork (S4WD only).
Install the clutch cable housing (S4WD only).
Install the clutch cable housing bolts (S4WD only). Tighten
Tighten the inner axle shaft housing and the clutch cable housing bolts to 48 N·m (36 lb ft).
Install the drain plug and the washer.
Install the fill plug and the washer. Tighten
Tighten the drain plug and the fill plug to 33 N·m (24 lb ft).
Install the four-wheel drive indicator switch (S4WD only). Tighten
Tighten the four-wheel drive indicator switch to 5 N·m (44 lb ft).
Differential Carrier Assembly - Final Assembly
Tools Required
J 42738 Front Output Shaft Seal Installer
J 33842 Pilot Bearing Installer
J 33791 Carrier Case Bushing Installer
J 42211 Inner Axle Shaft Housing Bearing Installer
J 33799 Shaft Cable Housing Seal Installer
Install the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the differential adjuster nut lock tab bolts. Tighten
Tighten the differential adjuster nut lock tab bolt to 8 N·m (71 lb in).
Remove the differential carrier assembly bolts.
Remove the right differential carrier case half.
Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
Apply a bead of sealer (GM P/N 1052942 or the equivalent) to one differential carrier case half sealing surface.
Install the right differential carrier case half.
Install the differential carrier case bolts. Tighten
Tighten the differential carrier case bolts to 50 N·m (37 lb ft).
Lubricate the clutch shaft pilot bearing with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
Install the clutch shaft pilot bearing using the J 33842 .
Install the clutch shaft thrust washer into the differential carrier assembly.
Install the clutch shaft to the differential carrier assembly.
Install the inner shaft seal cover.
Install the inner shaft seal cover bolts. Tighten
Tighten the inner axle shaft seal cover bolts to 25 N·m (18 lb ft).
Install the new left side axle shaft seal using the J 42738 .
Install the inner axle shaft retaining ring (A4WD only).
Install the left inner axle shaft (A4WD only). Carefully tap the inner axle shaft into place with a soft mallet.
Install the differential carrier bushings using the J 33791 .
Install the right side inner axle shaft housing bearing and the seal using the following procedure:
Install the bearing with the square shoulder in using the J 42211 .
Install the new axle shaft seal using the J 42738 .
Install the clutch cable housing seal using the J 33799 (S4WD only).
Install the new inner axle shaft retaining ring (A4WD only).
Install the inner axle shaft into the inner axle shaft housing.
Install the thrust washer into the inner axle shaft housing. Use chassis grease in order to hold the thrust washer in place (S4WD only). Ensure the tabs on the thrust washer align with the slot in the inner axle shaft housing.
Install the new retaining ring into the clutch gear (S4WD only).
Install the clutch gear onto the inner axle shaft (S4WD only). Drive the clutch gear into place with a plastic hammer.
Install the following components into the inner axle shaft housing (S4WD only):
The thrust washer (9)
The clutch fork inner spring (16)
The clutch fork (17)
The clutch fork sleeve (11)
Apply sealant (GM P/N 1052492 or equivalent) to the inner axle housing to differential carrier sealing surface.
Install the inner axle shaft housing to the differential carrier assembly.
Install the 2 upper inner axle shaft housing bolts (S4WD only). Tighten the bolts finger tight.
Install the 5 inner axle shaft housing bolts (A4WD only). Tighten
Tighten the inner axle shaft housing bolts to 48 N·m (36 lb ft) (A4WD only).
The clutch cable retainer spring to the clutch fork (S4WD only).
Install the clutch cable housing (S4WD only).
Install the clutch cable housing bolts (S4WD only). Tighten
Tighten the inner axle shaft housing and the clutch cable housing bolts to 48 N·m (36 lb ft).
Install the drain plug and the washer.
Install the fill plug and the washer. Tighten
Tighten the drain plug and the fill plug to 33 N·m (24 lb ft).
Install the four-wheel drive indicator switch (S4WD only). Tighten
Tighten the four-wheel drive indicator switch to 5 N·m (44 lb ft).
Foot Performance
Donating Member
Re: Front diff rebuild
That is a very bad part. But I did look at my manual and it does look like the have spin adjusters for the side bearings (which is what I wanted to check)
side bearing adjuster to me that will be the one tool I would have to have most everything else is just bearing install or removal and usuall just finding a pipe or something with the right I.D./O.D.
Good thing is you can probably make the adjust tool and/or any other tool you may need.
I am sure back lash is checked at the pinion flange just remeber that what ever number you get back lash is half of that I usually shoot for .010-.014 whis gives you .005-.007 actual back lash.
Other than that it is pritty basic the adjuster most people are not used to so it can take some time to get bearing preload and back lash just where you want it.
That is a very bad part. But I did look at my manual and it does look like the have spin adjusters for the side bearings (which is what I wanted to check)
side bearing adjuster to me that will be the one tool I would have to have most everything else is just bearing install or removal and usuall just finding a pipe or something with the right I.D./O.D.
Good thing is you can probably make the adjust tool and/or any other tool you may need.
I am sure back lash is checked at the pinion flange just remeber that what ever number you get back lash is half of that I usually shoot for .010-.014 whis gives you .005-.007 actual back lash.
Other than that it is pritty basic the adjuster most people are not used to so it can take some time to get bearing preload and back lash just where you want it.
bigmileage
Member
Re: Front diff rebuild
It's not as hard as people say, i've removed and installed more s-series front diffs for gears swaps than I care to remember. Do lots of reading and get the proper tool to adjust side bearing preload (GM required tool, any dealer should have it). Trying to adjust side bearing preload with a punch will damage or brake the teeth, i've learned the hard way. If you take the two halfs apart (no load), you can usually adjust them with a screwdriver without damage.
New gears should be set 0.05 to .10, used gears should be set slightly looser.
It's not as hard as people say, i've removed and installed more s-series front diffs for gears swaps than I care to remember. Do lots of reading and get the proper tool to adjust side bearing preload (GM required tool, any dealer should have it). Trying to adjust side bearing preload with a punch will damage or brake the teeth, i've learned the hard way. If you take the two halfs apart (no load), you can usually adjust them with a screwdriver without damage.
New gears should be set 0.05 to .10, used gears should be set slightly looser.
Foot Performance
Donating Member
Re: Front diff rebuild
That was my thoughts if you need a rough idea of what a tool looks like to kinda build off of let me know I can probably take a picture and send it to you:tup:
That was my thoughts if you need a rough idea of what a tool looks like to kinda build off of let me know I can probably take a picture and send it to you:tup:
Re: Front diff rebuild
There are a bunch of pictures that go with those instructions, if you want me to try to send them to you email me poconojoe@verizon,net
There are a bunch of pictures that go with those instructions, if you want me to try to send them to you email me poconojoe@verizon,net