Astro, Safari 1997-2005

Pinion Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The following procedure requires the use of the Pinion Holding tool J-8614-10, the Pinion Flange Removal tool J-8614-1, J-8614-2, J-8614-3 and the Pinion Seal Installation tool J-23911.

  2.  
  3. Remove driveshaft from the pinion flange. Matchmark the driveshaft prior to removal.
  4.  
  5. Remove driveshaft from the rear axle pinion flange and support the shaft up in body tunnel by wiring it to the exhaust pipe.
    NOTE
    If the U-joint bearings are not retained by a retainer strap, use a piece of tape to hold bearings on their journals.

  6.  
  7. Mark the position of the pinion stem, flange and nut for reference.
  8.  
  9. Use an inch lbs. torque wrench to measure the amount of torque necessary to turn the pinion, then note this measurement as it is the combined pinion bearing, seal, carrier bearing, axle bearing and seal preload.
  10.  
  11. Remove pinion flange nut and washer, using a Pinion Holding tool J-8614-10 and a Pinion Flange Removal tool J-8614-1, J-8614-2, J-8614-3, as applicable.
  12.  
  13. Remove pinion flange.
  14.  
  15. Remove pinion oil seal by driving it out of the differential with a blunt chisel; DO NOT damage the carrier.

    Click image to see an enlarged view

    Fig. Removing the pinion nut using a pinion holding fixture tool



    Click image to see an enlarged view

    Fig. A puller and adapter should be used to withdraw the pinion from the housing



    Click image to see an enlarged view

    Fig. Use the appropriately sized installation tool to drive the new seal into position.

  16.  

To install:

  1. Examine the seal surface of pinion flange for tool marks, nicks or damage, such as a groove worn by the seal. If damaged, replace flange.
  2.  
  3. Examine the carrier bore and remove any burrs that might cause leaks around the O.D. of the seal.
  4.  
  5. Apply GM seal lubricant 1050169 to the outside diameter of the pinion flange and sealing lip of new seal.
  6.  
  7. Install new pinion oil seal using a seal installer tool.
  8.  
  9. Install pinion flange and tighten nut to the same position as marked earlier. Tighten the nut a little at a time and turn the pinion flange several times after each tightening in order to set the rollers.
  10.  
  11. Measure the torque necessary to turn the pinion and compare this to the reading taken during removal. Tighten the nut additionally, as necessary to achieve the same preload as measured earlier.
    NOTE
    If fluid was lost from the differential housing during this procedure, be sure to check and add additional fluid, as necessary.

  12.  
  13. Remove the support then align and secure the driveshaft assembly to the pinion flange.
    NOTE
    The original matchmarks MUST be aligned to assure proper shaft balance and prevent vibration.

  14.  

 
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