GM Astro/Safari 1985-1996 Repair Guide

Differential Assembly

Print

REMOVAL & INSTALLATION



See Figure 1

  1. Disconnect the negative battery cable for safety.
  2.  
  3. Unlock the steering.
  4.  
  5. Raise the vehicle and support it with jackstands.
  6.  
  7. Remove the front wheels.
  8.  
  9. Matchmark the positions of the driveshaft and halfshafts to their flanges.
  10.  
  11. Insert a drift through the opening in the top of the brake caliper into the vanes in the brake rotor to keep the axle from turning.
  12.  
  13. Disconnect the front driveshaft from the differential and secure out of the way.
  14.  
  15. Disconnect the vent hose.
  16.  
  17. Remove the halfshaft-to-output shaft bolts.
  18.  
  19. Remove the tube-to-carrier bolts.
  20.  
  21. Unbolt the halfshafts from the front axle (leaving them attached to the hub and knuckle assembly) and support out of the way with wire. Be careful not to damage the joint boots or CV-joints.
  22.  
  23. Remove the axle tube support bracket-to-frame nuts and washers.
  24.  
  25. Remove the upper and lower mounting nuts and bolts.
  26.  
  27. Remove the differential assembly from the vehicle by sliding the entire unit to the right, dropping the tube end and twisting the carrier to clear the mounting brackets, oil pan and steering linkage.
  28.  

To install:
  1. Install the differential and tube assembly.
  2.  
  3. Loosely install the upper, lower and bracket-to-frame mounting bolts and nuts.
  4.  
  5. Tighten the mounting bolts to 65 ft. lbs. (90 Nm), then tighten the frame nuts to 55 ft. lbs. (75 Nm) for 1990-95 vehicles or to 63 ft. lbs. (85 Nm) for 1996 vehicles.
  6.  
  7. Align the marks made earlier and install the halfshafts. Tighten the bolts to 60 ft. lbs. (80 Nm).
  8.  
  9. Connect the vent hose.
  10.  
  11. Align and install the front driveshaft.
  12.  
  13. Install the front wheels.
  14.  
  15. Check and refill the differential fluid, as necessary. Remember that the vehicle must be level or an incorrect level will occur.
  16.  
  17. Remove the jackstands and carefully lower the vehicle.
  18.  


WARNING
Make sure the ignition switch is in the OFF position before connecting the negative battery cable otherwise the engine control computer could be INSTANTLY destroyed when voltage is applied.

  1. Connect the negative battery cable and check for proper operation.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Front differential carrier assembly mounting

 
label.common.footer.alt.autozoneLogo