How do you remove the differential pinion shaft on an 83 suburban rearend?

Answer 1

If you have never set up a differentials gear lash and pinion depth don't even try, seek professional assistance or pay someone.

In a nutshell, jack up and support the axle, pull the diff. cover and drain the oil, remove the wheels and brake assemblies to access the axle mounting flange bolts on 1/2 ton models, remove the axles. Some 1/2 ton axes (I can't remember which) you will have to pull the spider and remove the inner axle clips to pull the axles, so if your axles don't come out easy, don't force them. On 3/4 ton models with full floating axles remove the hub caps and remove the 8 axle flange bolts, pull the axles. With the gears exposed you will see 4 large bolt heads that hold the ring gear and spider assembly, these are the carrier bolts. On the left and right you will see a spanner nut that the axles go through, this is how you adjust your ring in and out of your pinion. Again, if you look in hear and have not done anything with a rear end, get help. Count the number of teeth on the ring gear and the pinion gear. Divide the number of teeth on the ring gear by the pinion, if the number comes out even you will need to mark the teeth location to ea. other so they go back together the same, they are a non-hunting assembly and the teeth have matched themselves together. If there is a decimal they are a hunting gear set and can go back together any way. To be safe, mark them anyway if you are unsure. Have something below to set the gear assembly on that will not damage it, i.e. a piece of clean plywood, and remove the carrier bolts and carrier caps, do not use excessive force to pull the gear-set if it is hung up, try rotating the pinion and look for something else holding the set. Your pinion should be clearly visible. Drop the drive shaft and remove the U-joint. Use a yoke holder and remove the yoke nut, use a yoke puller and remove the yoke, reinstall the yoke nut about 7/8 back onto the pinion so you are not striking the threads and use a rubber dead blow to tap the pinion loose, once loose remove the yoke nut and dis-guard (unless yoke nut uses a cotter key to keep placement, never reuse a yoke nut), pull pinion out through the rear, the rear tappered roller bearing will still be on and you will have to use a press and a bearing splitter to remove. There will also be a crush sleeve that will have to be removed and replaced. You can remove the pinion seal and front bearing for inspection.

If you are removing the pinion because you think it is worn, the ring gear is also worn. You can't replace a pinion without replacing the ring gear, they are matched. If you do you will be rebuilding this set again. Get a book, usually MOTOR manuals are really detailed or go to the dealer and ask about in shop manuals. In my area our local library has the MOTOR manuals for check out. Good luck, I will not try to explain how to set up gears, this takes practice and is better left to a Pro. The books however do show you how to disassemble, clean, inspect, reassemble and adjust properly and have detailed pics. of what a properly set up gear pattern looks like.