Frt Output Shaft Seal

BigCountry571 · November 15, 2001

I took the '96 Tahoe into the dealer to have the left front output shaft seal changed. The called and stated they could not get the shaft to pull out of the differential. It cost me $135 to find this out. The helm manual makes it seem like a easy repair. Has anyone had this problem or can give advice the best way to make this repair. Does the axle shaft have to be removed from the hub or will it swing out of the way enough to get at the output shaft?? Any help will be greatly appreciated.

chevy4x4trucks · November 15, 2001

sorry I can't help you out, but welcome to the forum. I'll bet money that someone will be able to.

95 Silverado · November 16, 2001

the axle shaft has to be unbolted from the axle flange at the differential and the nut removed from the hub,the axle assembly is then removed. then the axle flange is removed from the differential to replace the seal. the axle is retained inside the differential by a wire ring, if it got bent when the axle was installed, it might not release to let the axle come out again. I would think a dealer could deal with this, what did they tell/recommend you to do with it.

BigCountry571 · November 16, 2001

They gave three options:

1) Drive it around awhile and then they could give it another try but another $135 for them to try.

2)Replace the whole differential.

3)They could split the case and start breaking things in order to get it apart. All broken piece would be replaced and it would be re-assembled.

I am going to talk to another dealer today and see what they say. OR I might give the repair a shot my self. Can't see how I can do any worse. It doesn't look that bad to do.

Thanks for input

95 Silverado · November 17, 2001

I rebuilt the front differential in my '95 pick-up about 2 months ago, How many miles are on your Tahoe? On my truck the axle gear had worn into the differential cage, this allowed excessive movement at the axle flange where it bolts to the axle, this caused the seal to leak, it had 155,000 miles on it. I removed the differential, installed a used cage and gear set from a lower mileage truck, and reinstalled it. If your axle shows the same symptoms you may know what to expect. a complete differential costs around 4-500 dollars used, all new parts to repair mine cost about the same. I bought a used diff. out of a wrecked truck that had a broken housing and used the internal parts I needed. If you remove the differential and disassemble it you should be able to remedy this with out breaking anything but it must be reassembled correctly (set gear lash and bearing preload), it depends on what you're comfortable with attempting.

BigCountry571 · November 18, 2001

Our Tahoe has about 74,000 miles on it. I spoke to a tech at another dealer and he made the same comments as the first one....new differential. He stated even if the case is split there is no way to get at the LH output shaft to release the ring. Therefore the whole assembly would need to replaced. I guess I find this very hard to believe this unit is non-serviceable.

Question: Do you have to pop the ball joints to remove the half-shaft (axle) on the left side?? The manaual states you have to in order to provide proper clearance but it sure looks like it would come out without doing that. If the case does need to be split, I will look for the same wear problems you experienced on your '95. Thanks for the heads-up.

If I can get the half-shaft out with messing with the ball joints, I check for the extra movement you spoke of and see if I can get the output shaft out (bigger slide hammer!?). Any other toughts??? Otherwise there is a company called DTS (Drivetrain Specialist) and they have a service center about 2 hours away . I give them a call and see if they can help me out.

Thanks again for you help.

95 Silverado · November 18, 2001

You can remove the axle without disconnecting the suspension, remove the left side tire, take the nut off of the axle end, unbolt the axle from the flange, lift under the left control arm, this keeps the suspension down and gives you a bit more room, it is close, but the axle should come out to give you access to the inner axle. If you decide to remove the front differential you don't have to pull either axle just unbolt them, drop the steering off of the pitman arm and disconnect the front driveshaft and actuator wiring. It will drop right out. Good luck.