Front Axle Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Remove axle carrier. See FRONT AXLE ASSEMBLY under REMOVAL & INSTALLATION. Remove actuator solenoid and indicator switch from right axle tube. Remove right axle tube and inner axle shaft assembly. See RIGHT AXLE TUBE & INNER AXLE SHAFT under REMOVAL & INSTALLATION.
Remove shift shaft assembly consisting of sleeve, damper spring, shift fork, clip and inner spring. Remove shim (No. 20) See Figure or Figure . and output shaft from right side of carrier assembly. Remove left output shaft with deflector from carrier assembly using Remover (J-2619-1 ). See Fig 1.

Fig 1: Removing Left Output Shaft From Carrier
Courtesy of GENERAL MOTORS CORP.
Pry out left output flange seal with a screwdriver. Remove left and right output shaft bearings using Bearing Remover (J-29369-1 for K2; J-29369-2 for K3). Remove bolts holding carrier halves together. Tap on lugs provided to separate carrier halves.
Pry up on left and right side bearing locks (right side only on K3) and remove differential assembly from carrier. See Figure or Figure . On K3, remove adjuster plug lock and bolt on outer left half of carrier. See Fig 2.
On all models, use Sleeve Adjuster (J-36599 ) to rotate sleeve, and push side bearings out of bores (right side only on K3). See Fig 3. On K3 left side bearing, remove adjuster plug, bearing and "O" ring from left side of carrier by rotating adjuster plug using Adjuster Plug Remover (J-36615 ). See Fig 3.

Fig 2: Removing Bearing Using Adjuster Plug Remover (K3)
Courtesy of GENERAL MOTORS CORP.

Fig 3: Removing Bearing Using Sleeve Adjuster
Courtesy of GENERAL MOTORS CORP.
Using Pinion Flange Remover Set (J-8614-01 ), hold pinion flange stationary and remove pinion nut, flat washer and pinion flange. See Figure. Remove deflector from pinion. Mount left carrier case half in holding fixture from Pinion Service Tool Set (J-36598 ). See Fig 4. On K2, use Adapter Plate (J-36598-6 ). On all models, press pinion from case. Remove pinion with attached shim, inner bearing and spacer as an assembly. Remove collapsible spacer from pinion.

Fig 4: Pressing Pinion From Carrier
Courtesy of GENERAL MOTORS CORP.
Using Pinion Bearing Remover (J-8612-B for K2; J-36606 for K3), press bearing from pinion. See Fig 5. Remove shim(s) from pinion, keeping shims in order.
Using holding fixture and Pinion Service Tool Set (J-36598 ), remove seal and outer bearing from left half of carrier. Using Adapter Plate (J-36598-6 ), remove bearing races using same service tool set. See Fig 6.

Fig 5: Pressing Bearing From Pinion
Courtesy of GENERAL MOTORS CORP.

Fig 6: Removing Outer Bearing, Race, Seal & Inner Race From Carrier
Courtesy of GENERAL MOTORS CORP.
Using Puller (J-22888-D ) and Adapter (J-8107-2 for K2; J-36597 for K3), remove side bearings from differential case assembly. See Fig 7. Remove ring gear bolts (left-hand thread). Using a brass drift, drive ring gear from differential case. DO NOT pry ring gear from differential case, or damage to ring gear and differential case will occur.

Fig 7: Removing Side Bearing From Differential
Courtesy of GENERAL MOTORS CORP.
On K2, use a drift punch and hammer to drive out roll pin from differential pinion gear shaft. On K3, remove bolt from differential pinion gear shaft. On all models, remove pinion gear shaft. Roll pinion gears and thrust washers out of differential case.
Remove side gears and thrust washers, marking side gears and differential case left and right for reassembly reference. Remove spacer (K3). Using a 6-point socket, remove vent plug. Upper and lower carrier mounting bushings should be replaced using Remover/Installer (J-36616 ).