Differential Replacement (8.6, 9.5 Inch Axle)

Differential Replacement (8.6, 9.5 Inch Axle)

Tools Required

- J 24429 Slide Bearing Backlash Spanner

Removal Procedure

Important: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gearset, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the carrier with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the carrier.

1. Raise the vehicle.
2. Remove the tires and wheel assemblies.
3. Remove the brake drums. Refer to Brake Drum Replacement Service and Repair.
4. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement Service and Repair.
5. Remove the axle shafts. Refer to Rear Axle Shaft Replacement Service and Repair.






6. Remove the differential bearing adjuster nut lock (9.5 inch axle - right side).






7. Remove the bearing caps and bolts. Mark the bearing caps left and right.

Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.






8. Remove the differential by prying the differential from the axle housing at the differential window (8.6 inch axle).
9. Loosen the differential bearing adjuster nut using the J 24429 (9.5 inch axle).
10. Remove the differential (9.5 inch axle).
11. Remove the bearing cups, the shims, and the spacers as necessary.

Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

12. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement Service and Repair.
13. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement Service and Repair.

Installation Procedure

1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement Service and Repair.
2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement Service and Repair.
3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations Specifications.






4. Place the case, with the bearing cups installed, into the axle housing.

Support the case in order to keep the case from falling out of the axle housing.






5. Install the bearing caps and the bolts.

Do not torque the bearing cap bolts at this time.

6. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment Service and Repair.
7. Adjust the backlash. Refer to Backlash Adjustment .
8. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection Service and Repair.
9. Install the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 85 Nm (63 lb ft).

10. Install the differential bearing adjuster nut lock.
11. Install the differential bearing adjuster nut lock bolt.

Tighten
Tighten the differential bearing adjuster lock nut bolt to 26 Nm (19 lb ft).

12. Install the axle shafts. Refer to Rear Axle Shaft Replacement Service and Repair.
13. Install the rear axle housing cover and a new gasket. Refer to Rear Axle Housing Cover and Gasket Replacement Service and Repair.
14. Install the brake drums. Refer to Brake Drum Replacement in Drum Brakes.
15. Install the tire and wheel assemblies.
16. Fill the axle with lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations Specifications.
17. Lower the vehicle.