Astro, Safari 1997-2005

Pinion Seal

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Removal & Installation



  1. Disconnect the negative battery cable for safety.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Matchmark and remove the front driveshaft from the vehicle.
  6.  
  7. Mark the nut, washer and flange so during installation the same amount of torque can be provided for the correct amount of bearing pre-load.
  8.  
  9. Using an inch lbs. torque wrench (beam type with a needle gauge is usually easiest for this), measure the current pinion pre-load (the amount of force necessary to rotate the pinion).
  10.  
  11. Remove the pinion flange nut and washer using a companion flange holder J8614-01 or equivalent to keep the assembly from spinning.
  12.  
  13. Place a container under the flange to catch any fluid which may leak, then remove the flange.
  14.  
  15. Remove the oil seal by driving it out of the carrier with a blunt chisel.
    WARNING
    Be careful when removing the seal not to damage the sealing surface of the bore.



    Click image to see an enlarged view

    Fig. Before removing the flange nut, measure pre-load (rotational force) using an inch lbs. torque wrench



    Click image to see an enlarged view

    Fig. A flange holding tool will be necessary to loosen or tighten the pinion nut



    Click image to see an enlarged view

    Fig. Use a suitable driver or seal installer to seat the replacement seal

  16.  

To install:

  1. Clean all seal surfaces and remove burrs.
  2.  
  3. Install the new seal using a suitable driver or an oil seal installer such as J-33782.
  4.  
  5. Lubricate the seal lip and outside of the pinion flange with differential fluid or, if available, GM seal lubricant no. 1050169.
  6.  
  7. Install the pinion flange, washer and nut, aligning all of the marks made earlier. The pinion flange must be installed with the SAME spline relationship marked during removal.
  8.  
  9. Tighten the nut to previously marked position, then check the pre-load.
  10.  
  11. If necessary, tighten the nut additionally to match the pre-load recorded earlier. Remember that the flange holding tool should be removed each time before re-checking the pre-load.
  12.  
  13. Align and install the front driveshaft.
  14.  
  15. Check and add fluid to the front differential, as necessary. Remember that the vehicle must be level or you will not obtain the proper reading.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  

 
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