Express, Savana, G1500, G2500, G3500, 1998-2005

Pinion Seal

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Removal & Installation



  1. Raise and support the front end on jackstands.
  2.  
  3. Matchmark and disconnect the front driveshaft at the carrier.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    Calipers and wire them up, out of the way
     

  6.  
  7. Position an inch pound torque wrench on the pinion nut. Measure the torque needed to rotate the pinion one full revolution. Record the figure.
  8.  
  9. Matchmark the pinion flange, shaft and nut. Count and record the number of exposed threads on the pinion shaft.

    Nut and washer, while holding the flange
     
    Flange, using a puller
     
    Seal from its bore by carefully prying it. Be careful to avoid scratching the seal bore.
     
    Deflector from the flange

    Click image to see an enlarged view

    Fig. Measuring the pinion rotating torque



    Click image to see an enlarged view

    Fig. View of the scribed marks



    Click image to see an enlarged view

    Fig. Removing the pinion nut



    Click image to see an enlarged view

    Fig. Removing the pinion flange

     

  10.  

To install:

  1. Clean the seal bore thoroughly.
  2.  
  3. Remove any burrs from the deflector staking on the flange.
  4.  
  5. Tap the deflector onto the flange and stake it in three places.
  6.  
  7. Position the new seal in the carrier bore and drive it into place until flush. Coat the seal lips with wheel bearing grease.
  8.  
  9. Coat the outer edge of the flange neck with wheel bearing grease and slide it onto the pinion shaft.
  10.  
  11. Place a new nut and washer onto the pinion shaft and tighten it to the position originally recorded. That is, the alignment marks are aligned, and the recorded number of threads are exposed on the pinion shaft.
    WARNING
    Never hammer the flange onto the pinion!

  12.  
  13. Measure the rotating torque of the pinion. Compare this to the original torque. Tighten the pinion nut, in small increments, until the rotating torque is 3 inch lbs. (0.35 Nm) GREATER than the original torque.
  14.  
  15. Install the driveshaft.
  16.  
  17. Install the calipers and install the wheels.
  18.  

  1. Raise the vehicle on a hoist.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Remove the brake calipers.
  6.  
  7. Remove the differential carrier assembly shield, if equipped.
  8.  
  9. Reference mark the relationship of the propeller shaft to the front axle pinion yoke.
  10.  
  11. Remove the propeller shaft.
  12.  
  13. Tie the propeller shaft to a frame rail or the crossmember.
  14.  
  15. Measure the torque required in order to rotate the pinion. Record the torque value for reassembly.

    Click image to see an enlarged view

    Fig. Measuring the turning torque of the pinion

  16.  
  17. Scribe a line on the pinion stem, the pinion nut and the companion flange. Record the number of exposed threads on the pinion stem.
  18.  
  19. Remove the nut.
  20.  
  21. Position tool J8614-01 on the flange so that the 4 notches on the tool face the flange.
  22.  
  23. Remove the flange. Use the special nut and the forcing screw.
    NOTE
    Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.

  24.  
  25. Remove the oil seal.
  26.  
  27. Inspect the pinion flange for a smooth oil seal surface. Inspect the pinion flange for worn drive splines. Replace the pinion flange if necessary.
  28.  
  29. Remove the dust deflector.
  30.  

To install:


NOTE
Stake the new deflector at 3 new equally spaced positions. You must stake the new deflector in such a way that you do not damage the seal operating surface.

  1. Install and stake the dust deflector on the flange.
  2.  
  3. Position the oil seal in the bore. Then place a driver over the oil seal. Strike the driver with a hammer until the seal flange seats on the axle housing surface. Drive the seal in straight, not at an angle, as this will damage the aluminum housing.
    NOTE
    Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

  4.  
  5. Install the flange onto the pinion using tool J8614-01. Place the washer and a new nut on the pinion threads. Tighten the nut to the original scribed position using the scribe marks and the exposed threads as reference.
  6.  
  7. Measure the rotating torque of the pinion. Compare the measurement with the rotating torque recorded earlier. Tighten the pinion nut by small increments until the torque required in order to rotate the pinion is 3-5 inch lbs. (0.40-0.57 Nm) greater than the original torque.
  8.  
  9. Install the propeller shaft.
  10.  
  11. Install the differential carrier assembly shield, if equipped.
  12.  
  13. Install the brake calipers
  14.  
  15. Install the tire and wheel.
  16.  
  17. Lower the vehicle.
  18.  

 
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