Need Help, 2003 Yukon Damaged Front Differential

csangster · December 24, 2007

My brother-in-law has a 2003 Yukon XL.

We were changing his tires today.

I put the jack on the cross member underneath the IFS and lifted the entire front end of the truck.

Then the unthinkable happened. The truck slipped off the jack, and the jack hit the centersection of the differential. It did not break the 'pumpkin', it broke the housing on the passenger side of the 'pumpkin'.

I already feel like a complete and total dumb@ss, so please, no recommendations on proper lifting technique of a car, I know what we did wrong, and I will save that for a different forum.

Can anyone help me/us find a replacement part, and also recommend ideas on what will need to be done to fix the housing? I have a pretty good idea of what is necessary, but I am primarily a Ford man and would like any recommendations.

Thank you in advance,

Chris

98 Z71 SLT · December 25, 2007

First, you have to know if you have a selectable 4x4, or if you have an actual All Wheel Drive. The way you tell, is look for an electronic actuator mounted to the axle tube you broke.

Actuator=selectable 4x4.

Then, scavenge the salvage yards for an axle tube. If you can't find one, order a new part from your local GM store.

As far as replacing: using the FRAME and JACKSTANDS, get the front wheels off the ground.

6 bolts holding right front cv shaft to front axle-remove

2 large bolts holding axle tube to support frame-remove

disconnect electronic actuator,lay harness aside

5 bolts (15mm) that hold axle tube to front pumpkin-remove

Now the axle tube can be removed and replaced.

2 things to remember-when you wiggle and remove the tube like this, watch for the actuator spring AND a thrust washer to fall out. DO NOT LOSE THESE. They must be re-used in the front diff. the way they came out.

If you have any doubts, consult a good GM tech to help you out.

csangster · December 28, 2007

First, you have to know if you have a selectable 4x4, or if you have an actual All Wheel Drive. The way you tell, is look for an electronic actuator mounted to the axle tube you broke.

Actuator=selectable 4x4.

Then, scavenge the salvage yards for an axle tube. If you can't find one, order a new part from your local GM store.

As far as replacing: using the FRAME and JACKSTANDS, get the front wheels off the ground.

6 bolts holding right front cv shaft to front axle-remove

2 large bolts holding axle tube to support frame-remove

disconnect electronic actuator,lay harness aside

5 bolts (15mm) that hold axle tube to front pumpkin-remove

Now the axle tube can be removed and replaced.

2 things to remember-when you wiggle and remove the tube like this, watch for the actuator spring AND a thrust washer to fall out. DO NOT LOSE THESE. They must be re-used in the front diff. the way they came out.

If you have any doubts, consult a good GM tech to help you out.

Thank you kindly,

And as you stressed, I will be lifting the vehicle from the frame and placing it on jack stands for sure.

Regards,

Chris

Westlotorn · February 7, 2008

If it makes you feel any better I also found out that the front diff support does not work well for lifting my Tahoe. Fortunately I heard the sound of the jack slipping before it fell and lowered the car. Could have had the same story if the radio was playing.

The car is not flat in this area and if the cement is not smooth the jack will pull out as you lift. The rough floor will catch the jack wheels and keep them from rolling as the jack lifts. I was lifting on exposed aggregate when mine happened.

Good luck.