Front Axle Assembly: Disassembly

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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. See Figure or Figure . Remove shim (No. 20) and output shaft from right side of carrier assembly. Remove left output flange from carrier assembly by prying on one side with a screwdriver while simultaneously tapping outward on other side with a soft-faced hammer. See Fig 1. Remove deflector from output flange.

Fig 1: Removing Left Output Flange
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 K15/25 or (J-29369-2 ) for K35. 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 K35) and remove differential assembly from carrier. See Figure or Figure . On K35, remove adjuster plug lock and bolt on outer left half of carrier. See Fig 2.
Using Sleeve Adjuster (J-36599 ), rotate sleeve and push side bearings out of bores (do right side only on K35). See Fig 3. On K35 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 (K35)
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. Also use Adapter Plate (J-36598-6 ) for K15/25. 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 K15/25 or (J-36606) for K35, 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 K15/25 or J-36597 for K35), remove side bearings from differential case assembly. See Fig 7. Remove ring gear bolts. Ring gear bolts are 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.
Using a punch and hammer, drive out roll pin from differential pinion gear shaft. On K35, a bolt is used in place of a roll pin. 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. On K35, remove spacer. Using a 6-point socket, remove vent plug. Upper and lower carrier mounting bushings should be replaced using Remover/Installer (J-36616 ).