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Home › Pontiac › 2004 › Aztek Base, AWD › Repair and Diagnosis › External Pages › Different car › Section 163 (Rear Drive Axle) › Repair Instructions › Differential Replacement › Removal Procedure

Removal Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Oldsmobile Bravada, 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 GMC Envoy, and 2004 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gearset, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the carrier with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the carrier.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the spare tire.
  3. Remove the rear axle tie rod. Refer to Rear Axle Tie Rod Replacement in Rear Suspension.
  4. Remove the axle shafts. Refer to Rear Axle Shaft Replacement  .
  5. Loosen the bearing cap bolts.

    Do not remove the bearing cap bolts at this time.

    6. Fig 1: Installing J 45222 Onto Axle Housing
    GM788484Courtesy of GENERAL MOTORS CORP.
  6. Install the J 45222  onto the axle housing as shown.
    7. Fig 2: J 8001-1, J 8001-2, J 34178, & J 8001-3
    GM788485Courtesy of GENERAL MOTORS CORP.
  7. Install the J 8001-1 (2), the J 8001-2 (3), the J 34178  (4, 6), and the J 8001-3 (5) as shown.
  8. Preload the J 8001-3 (5) approximately 3/4 of a turn clockwise.
  9. Rotate the indicator housing to align the indicator needle of the J 8001-3 (5) and the dial indicator face to ZERO.
  10. Spread the axle housing by turning the clevis screw of the J 34178  while observing the J 8001-3.

    Spread the housing just enough to remove the differential assembly. Do not spread the housing more than 1.02 mm (0.040 in).

    11. Fig 3: View Of Bearing Caps Bolts
    GM788491Courtesy of GENERAL MOTORS CORP.
  11. Remove the bearing caps bolts and the caps. Mark the bearing caps left and right.
    12. CAUTION: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.
    NOTE: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.
    Fig 4: Removing Differential From Axle Housing
    GM788480Courtesy of GENERAL MOTORS CORP.
  12. Remove the differential from the axle housing using a pry bar and a block of wood.
  13. Remove the bearing cups, the shims, and the spacers as necessary.

    Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

  14. Remove the J 8001-1, the J 8001-2, the J 34178  , and the J 8001-3.
  15. Remove the J 45222  .
  16. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement  .
  17. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement  .
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