Disassembly

Fig. 1 Ring gear & pinion backlash measurement:

Fig. 2 Typical rotating torque measurement:

Fig. 3 Typical pinion bearing race removal:

Fig. 4 Typical pinion, bearing and depth shim (X) installation:

1. Remove axle housing assembly and mount in a holding fixture.
2. Bend down lock tab on pinion nut, then measure and record total assembly rotating torque, turning pinion shaft nut with a torque wrench.
3. Remove axle housing rear cover, if equipped, and drain lubricant.
4. Pry out drive axle flanges using a lever.
5. Mount a dial indicator on housing with pointer bearing against ring gear tooth and measure and record ring gear and pinion backlash, Fig. 1.
6. Punch matching marks between side bearing caps and case, remove caps along with shims, then remove and discard drive flange seals. Side bearing cap and shim assemblies are used to determine ring gear and pinion backlash and side bearing preload. Retain shim packs with respective side bearing caps and keep assemblies separate to aid assembly.
7. Remove differential assembly from housing.
8. Measure and record pinion rotating torque using a torque wrench, Fig. 2.
9. Hold pinion flange with suitable tool, then remove pinion nut and lock plate.
10. Remove pinion flange and flange seals using a puller.
11. Press drive pinion and rear bearing assembly from housing, taking care not to damage bearing or bearing surfaces, then remove front pinion bearing and spacer from housing.
12. Remove front bearing outer race from housing with a puller, Fig. 3, and place bearing race with bearing.
13. Inspect rear pinion bearing and remove from pinion, as needed, using a puller.
14. Remove rear pinion bearing race from housing using a puller and place race with bearing, then remove pinion depth adjusting shim, Fig. 4, and retain for assembly.
15. Remove speed sensor from housing, if equipped, then clean housing, covers and flanges with solvent and blow dry with compressed air, ensuring all foreign material is removed. Keep all components in order, noting installation position of bearings, races, covers and shims to ensure proper assembly. Any component that is reused should be installed in original position.