GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy MD Steel Tilt (W Model) 🢒 Driveline/Axle 🢒 Transfer Case - NVG 900 🢒 Transfer Case Disassemble

Special Tools

    • J-08614-A
        Pinion Flange Holder and Remover
    • J 23444-A Extreme Press Lubricant - 1/4-Ounce Tube
    • J 29369-2 Bushing and Bearing Remover - 2-3 in
    • J-44873-2 Shoulder Bolts
    • J 44882 Pinion Press Support Bar

    Object Number: 696401 Size: SH
  1. Remove the 3 bolts from the bracket (1).
  2. Remove the bracket (1).

    3. Object Number: 696404 Size: SH
  3. Remove the drain plug (1).

    4. Object Number: 804370 Size: SH
  4. Remove the fill plug (1) and drain the fluid.

    5. Object Number: 1400837 Size: SH
  5. Install J-08614-A  (2) and J-44873-2  (1) to the pinion flange.

    6. Object Number: 1400841 Size: SH
  6. Using a ratchet with a 27 mm socket, remove the pinion nut.

    7. Object Number: 1400842 Size: SH
  7. Insert the forcing screw assembly (1) through the slots in J-08614-A  (2).
  8. Turn the blue collar (1) until it locks into the grooves on the under side of the J-08614-A  (2).

    9. Note: Use high pressure grease J 23444-A on the screw threads.

  9. Tighten the forcing screw to remove the pinion flange.

    10. Object Number: 1400843 Size: SH
  10. Remove the J-08614-A  (3), the J-44873-2  (2), and the forcing screw assembly (1) from the pinion flange.

    11. Object Number: 696418 Size: SH
  11. Remove all bolts (2) from the side cover (1).
  12. Use pry point relief slots to remove the cover.

    13. Object Number: 696428 Size: SH
  13. Remove the carrier assembly (1) from the housing.

    14. Object Number: 1400845 Size: SH

    Note: Perform this step ONLY if the bearing needs to be replaced. DO NOT use old bearing.

  14. Using the J 29369-2 and a slide hammer, remove the stub shaft inner bearing (2) from the carrier bore (1).

    15. Object Number: 696454 Size: SH
  15. Drive the seal (1) out from the inside of the carrier assembly housing.

    16. Object Number: 696421 Size: SH

    Caution: The bearing cup shims must be removed before the seal can be removed. Installing the seal through the bearing cup will damage the new seal. It may be necessary to heat the housing in order to remove the cup.

  16. Remove the bearing cup (1), shims (2) and seal (3) from the side cover (4).

    17. Mark or tag the bearing cup (1) and shims (2) for proper assembly.


    Object Number: 696425 Size: SH
  17. Remove the axle seal (2) from the side cover (1).

    18. Object Number: 696458 Size: SH
  18. Remove the pinion oil seal (1) and slinger washer (2) from the housing.

    19. Object Number: 804373 Size: SH
  19. Tighten the forcing screw in order to push out the pinion gear. The gear will spin when it is being pushed out. When the gear stops spinning, stop pushing. The gear teeth will contact the housing.
  20. Remove the J 44882 .

    21. Object Number: 804374 Size: SH
  21. Install the old pinion nut on the threads of the pinion shaft. Hold the shaft so the gear head faces up, and drive out the pinion shaft, so that it does not contact the housing.

    22. Object Number: 696464 Size: SH
  22. Remove the bearing (1), collapsible spacer (2), and pinion shaft (3) from the housing.