GM Blazer/Jimmy/Typhoon/Bravada 1983-1993 Repair Guide

Differential Carrier

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REMOVAL & INSTALLATION



Vehicles Through 1988

See Figures 1, 2, 3, 4 and 5

  1. Remove the axle tube and output shaft assembly. For details, please refer to the procedures earlier in this section.
  2.  
  3. Remove the stabilizer-to-frame bolts.
  4.  
  5. Using a scribing tool, mark the location of the steering idler arm-to-frame, then remove the steering arm-to-frame bolts.
  6.  
  7. Push the steering linkage towards the front of the truck.
  8.  
  9. Disconnect the axle vent hose from the carrier fitting.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: The differential carrier and axle tube assembly is visible at the center of this picture



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Fig. Fig. 2: Disconnecting the cable from the vacuum actuator and shift cable housing

  1. Align the left-side drive axle to the carrier flange. Remove the left-side drive axle shaft-to-carrier bolts, then separate the drive axle from the carrier.
  2.  

To keep the axle from turning, insert a drift through the top opening of the brake caliper, then through the corresponding vane of the brake rotor.

  1. Matchmark and remove the front driveshaft.
  2.  
  3. Remove the differential carrier-to-frame bolts and nuts, as applicable; use an 18mm combination wrench to hold the upper nut from turning, by holding it through the frame.
  4.  
  5. To remove the differential carrier, tip it counterclockwise while lifting it up to gain clearance from the mounting ears.
  6.  

To install:
  1. Position the carrier assembly into the vehicle.
  2.  
  3. Install the carrier-to-frame retaining bolts and nuts. Tighten the bolts to 65 ft. lbs. (90 Nm) and the nuts to 55 ft. lbs. (75 Nm).
  4.  
  5. Align and install the front driveshaft.
  6.  
  7. Align and attach the left drive axle to the carrier and secure using the retaining bolts.
  8.  
  9. Connect the vent hose.
  10.  
  11. Reposition the steering linkage, then align and install the idler arm. Install the stabilizer-to-frame bolts. For steering linkage details, please refer to Suspension & Steering of this guide.
  12.  
  13. Install the axle tube and output shaft assembly to the vehicle.
  14.  
  15. Check and/or add axle lubricant, as necessary.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: Shift vacuum hose routing



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Fig. Fig. 4: Carrier assembly installation



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Fig. Fig. 5: Exploded view of a common carrier assembly (Typhoon and Bravada similar, but without shift mechanisms)

1989-93 Vehicles
EXCEPT 1991-92 BRAVADA AND TYPHOON
  1. Unlock the steering column so the linkage is free to move.
  2.  
  3. Disconnect the shift cable from the vacuum actuator. For details, please refer to the procedure located later in this section.
  4.  
  5. Raise and support the front of the vehicle safely using jackstands, then remove the front wheels.
  6.  
  7. Remove the engine drive belt shield.
  8.  
  9. If equipped, remove the skid plate.
  10.  
  11. Remove the drain plug and flat washer, then drain the fluid from the carrier.
  12.  
  13. Remove the right lower shock retainer, then push the shock upward and wire it out of the way for access to the output shaft bolts.
  14.  
  15. Disengage the wire from the 4wd indicator switch.
  16.  
  17. Disconnect the shift cable housing and/or shift cable from the carrier housing, as necessary. Refer to the shift cable procedure later in this section for details.
  18.  
  19. Disconnect the vent hose.
  20.  
  21. Remove the steering relay rod from the idler arm and Pitman arm, then pull the linkage forward for access.
  22.  
  23. Align the drive axles to their flanges. Hold the drive axles from turning by inserting a brass drift through the calipers into the rotor vanes, then remove the drive axle to output shaft retaining bolts.
  24.  
  25. Remove the nuts and washers holding the axle tube to the frame.
  26.  
  27. Matchmark and remove the front driveshaft.
  28.  
  29. Support both lower control arms using jackstands at the edge of the stabilizer shaft. Lower the vehicle until the front weight is resting on the stands.
  30.  
  31. Remove the bolts and nuts retaining the carrier assembly to the vehicle. Use an 18mm wrench inserted through the frame to keep the upper nut from turning.
  32.  
  33. Roll the carrier assembly counterclockwise while lifting upward to gain the necessary clearance from the mounting ears and remove the carrier from the vehicle.
  34.  

To install:
  1. Install the carrier assembly to the vehicle and secure using the retaining nuts and bolts. Tighten the bolts to 65 ft. lbs. (90 Nm) and the nuts to 55 ft. lbs. (75 Nm).
  2.  
  3. Install the nuts and washers holding the axle tube to the frame, then tighten to 36 ft. lbs. (48 Nm).
  4.  
  5. Matchmark and install the front driveshaft assembly.
  6.  
  7. Align and install the drive axles to the carrier/output shaft flanges.
  8.  
  9. Connect the vent hose.
  10.  
  11. Connect the idler and Pitman arms to the steering relay rod. For more information, please refer to Suspension & Steering of this guide.
  12.  
  13. Connect the shift cable housing and/or cable, as applicable.
  14.  
  15. Engage the indicator switch wiring.
  16.  
  17. Remove the safety wire, then reposition and secure the shock.
  18.  
  19. If not done already, install the drain plug and flat washer, then check the fluid level and add as necessary. Remember that the vehicle must be level when checking or adding fluid.
  20.  
  21. If equipped, install the skid plate.
  22.  
  23. Install the engine drive belt shield.
  24.  
  25. Install the front wheels, then remove the jackstands and carefully lower the vehicle.
  26.  
  27. Connect the shift cable to the vacuum actuator.
  28.  

1991-92 BRAVADA AND TYPHOON
  1. Disconnect the negative battery cable, then unlock the steering column so the linkage is free to move.
  2.  
  3. Raise and support the front of the vehicle safely using jackstands.
  4.  
  5. Remove the front wheels from the vehicle.
  6.  

Hold the drive axles from turning by inserting a brass drift through the calipers into the rotor vanes.

  1. Matchmark and remove the front driveshaft assembly from the vehicle.
  2.  
  3. Disconnect the front differential vent hose.
  4.  
  5. Matchmark the drive axle flanges to the output shaft/carrier flanges. Remove the drive axle retaining bolts. For details, please refer to the procedures located earlier in this section.
  6.  
  7. Remove the axle tube-to-carrier retaining bolts.
  8.  
  9. Separate the drive axles from the output shaft/carrier flanges and support out of the way.
  10.  
  11. Remove the axle tube support bracket-to-frame nuts and washers.
  12.  
  13. Remove the carrier upper and lower mounting bolts (with nuts).
  14.  
  15. Remove the carrier and tube assembly. Slide the entire assembly to the right, then drop the tube end and twist the carrier to clear the mounting brackets, oil pan and steering linkage.
  16.  

To install:
  1. Install the carrier and tube assembly to the vehicle.
  2.  
  3. Loosely install the carrier upper and lower bolts and nuts.
  4.  
  5. Install the axle tube support brackets nuts and washers. Tighten the upper and lower carrier bolts to 66 ft. lbs. (90 Nm), then tighten the axle tube support bracket nuts to 75 ft. lbs. (55 Nm).
  6.  

 
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