GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Differential Carrier

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REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Carrier assembly mounting



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Fig. Fig. 2: Exploded view of a common carrier assembly

  1. Unlock the steering column so the linkage is free to move.
  2.  
  3. Remove the battery and battery tray from the vehicle.
  4.  
  5. Disconnect the shift cable from the vacuum actuator. For details, please refer to the procedure located later in this section.
  6.  
  7. Raise and support the front of the vehicle safely using jackstands, then remove the front wheels.
  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. Unplug the wire from the 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 font 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) on 1994 models and 76 ft. lbs. (103 Nm) on 1995-99 models. Tighten 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. 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 repair 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 front wheels, then remove the jackstands and carefully lower the vehicle.
  24.  
  25. Connect the shift cable to the vacuum actuator.
  26.  
  27. Install the battery tray and the battery to the vehicle.
  28.  

 
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