S10 Pickup, Sonoma 2000-2004

Axle Shaft, Bearing & Seal

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the rear of the vehicle securely on jackstands.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the brake caliper.
  8.  
  9. Remove the brake rotor.
  10.  
  11. Remove the rear cover and the gasket.
  12.  
  13. Remove the pinion shaft locking bolt.
  14.  
  15. On axles without a locking differential, remove the pinion shaft. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
  16.  
  17. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock until the lock aligns with the thrust block.
  18.  
  19. Push the flange of the axle shaft inward towards the differential assembly.
  20.  
  21. Remove the axle shaft lock from the button end of the axle shaft. When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult.
  22.  
  23. Remove the axle shaft from the housing.
  24.  
  25. For axles with drum brakes, remove the axle shaft seal and the bearing from the axle housing using the J 22813-01 (7.6 inch axle)  or the J 23689 (8.6 inch axle) and the J 2619-01.
  26.  
  27. For axles with disc brakes, remove the axle shaft seal and the bearing from the axle housing using one of the following:

    For vehicles with a 7.6 inch axle, use the J 22813-A and the J 2619-01.
     
    For vehicles with a 1st design 8.6 inch axle, use the J 23689-A and the J 2619-01.
     
    For vehicles with a 2nd design 8.6 inch axle, use the J 44685 and the J 2619-01.

    Click image to see an enlarged view

    Fig. Pinion shaft lockbolt and axle C-lock locations, inside the differential



    Click image to see an enlarged view

    Fig. Removing the pinion shaft locking bolt



    Click image to see an enlarged view

    Fig. On axles without a locking differential, remove the pinion shaft



    Click image to see an enlarged view

    Fig. On axles with a locking differential, remove the shaft part way and rotate case until the shaft touches the housing



    Click image to see an enlarged view

    Fig. With a locking differential, use a screwdriver, or similar tool, to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block (2).



    Click image to see an enlarged view

    Fig. Cross-sectional view of the rear axle, bearing and seal assembly

     

  28.  

To install:

  1. Install the axle shaft bearing into the axle tube using of the J 23765 and the J 8092. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.

    Click image to see an enlarged view

    Fig. Install the axle shaft seal using the J 23771

  2.  
  3. Install the axle shaft seal using the J 23771. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube.
  4.  
  5. Carefully insert the axle shaft in order to not damage the seal.
  6.  
  7. Slide the axle shaft into the differential assembly allowing the splines to engage the differential side gear.
  8.  
  9. On axles without a locking differential, place the axle shaft lock on the button end of the axle shaft.
  10.  
  11. On axles with a locking differential, place the axle shaft lock on the axle shaft so that the ends are flush with the thrust block.
  12.  
  13. Pull the shaft flange outward in order to seat the axle shaft lock into the differential side gear.
  14.  
  15. Install the pinion shaft. Align the hole in the pinion shaft with the bolt hole in the differential case.
  16.  
  17. Install the new pinion shaft lock bolt. Tighten the pinion shaft locking bolt to 18 ft. lbs. (25 Nm).
  18.  
  19. Install the rear cover and the gasket.
  20.  
  21. Install the brake rotor.
  22.  
  23. Install the brake caliper.
  24.  
  25. Install the tire and wheel assembly.
  26.  
  27. Fill the rear axle using the proper fluid.
  28.  
  29. Lower the vehicle.
  30.  

 
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