Drive Pinion Housing and/or Seal Replacement

Drive Pinion Housing and/or Seal Replacement

^ Tools Required
- J 44414 Pinion Seal Installer
- J 22912-01 Bearing Puller
- J 24433 Pinion Cone and Side Bearing Installer
- J 37624 Pinion Bearing Installer
- J 8092 Driver Handle
- J 8608 Rear Pinion Bearing Race Installer
- J 8614-01 Flange/Pulley Holding Tool

Removal Procedure

1. Raise the vehicle. Refer to Vehicle Lifting.

Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly.

2. Drain the axle lubricant.
3. Remove the axle shafts.





4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4).
5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary.





6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components:
^ The pinion bearings
^ The pinion pilot bearing
^ The pinion oil seal
^ The differential case bearings





7. Place an alignment mark between the pinion and the pinion yoke.
8. Remove the pinion gear bearing retainer bolts.
9. Remove the pinion gear bearing retainer and the pinion.
10. Remove the selective shim.
11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly.





12. Install the J 8614-01 as shown.
13. Remove the pinion nut while holding the J 8614-01.
14. Remove the washer.





15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown.
16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3).
17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.
18. Remove the outer pinion bearing.





19. Remove the pinion.





20. Remove the collapsible spacer.





21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press.





22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly.





23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly.

Installation Procedure





1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1).





2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1).





3. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion.
4. Install a new collapsible spacer.
5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid.





6. Install the pinion into the pinion gear bearing retainer.
7. Install the outer pinion bearing onto the pinion.





8. Install a new pinion oil seal using the J 44414.
9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
10. Install the pinion yoke. Align the marks made during removal.

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

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.

12. Install the washer and a new pinion nut.





13. Install the J 8614-01 onto the pinion yoke as shown.

14. Tighten the pinion nut while holding the J 8614-01.
^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

Notice: Refer to Service Precautions.

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






15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal.
^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal.
16. 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.
17. Determine the selective shim thickness for the pinion gear bearing retainer.





18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer.
19. Install the selective shim. Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer.
20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim.
21. Install the pinion gear bearing retainer.
22. Install the pinion gear bearing retainer bolts.
^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.).





23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal.
The rotating torque of the pinion and the ring gear should be between 3.9 - 6.2 Nm (30 - 55 inch lbs.) for new bearings or 2.8 - 5.6 Nm (25 - 50 inch lbs.) for used bearings.
24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary.





25. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal.
26. Install the propeller shaft yoke retaining clamps and the bolts.
^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.).
27. Install the axle shafts.
28. Fill the axle with axle lubricant.
29. Lower the vehicle.