Axle Assembly - Part 1
Axle Assembly
Special Tool(s)
Material
Disassembly
1. Remove the axle assembly.
2. Remove the differential housing cover.
^ Drain the fluid.
^ Remove the 10 differential housing cover bolts.
^ Remove the differential housing cover.
3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
Install the special tool.
4. Using a suitable axle shaft remover, remove the RH and LH axle shafts.
5. Remove the 4 axle tube bolts and the axle tube.
6. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
Install the special tools.
7. Install the special tools, measure and record the differential ring gear backlash between teeth in 4 opposing places.
1 Mount the special tool.
2 Position the special tool.
3 Zero the indicator.
4 Turn the differential ring gear without turning the pinion gear. Record the measurement.
^ If the backlash between teeth exceeds the specification of 0.203 - 0.381 mm (0.008 - 0.015 inch), continue with disassembly.
^ If the backlash variation between points checked exceeds the specification of 0.101 mm (0.004 inch), do a differential case runout check.
8. Position the special tool on the spreader adapters.
9. Install the special tools.
^ Position the adapter tip in the spreader adapter hole.
10. CAUTION: Overspreading can damage the axle housing.
Spread the axle housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the housing spreader screw to spread the axle housing to the specification.
3 Remove the special tool.
11. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions.
Mark and remove the differential bearing caps.
1 Remove the 4 differential bearing cap bolts.
2 Remove the differential bearing caps.
12. CAUTION: Use wood blocks to avoid axle housing damage.
Remove the differential assembly from the axle housing.
1 Position the wood blocks.
2 Position and push down on the two pry bars.
3 Remove the differential assembly.
4 Remove the special tool.
13. Remove the 10 differential ring gear bolts and the differential ring gear.
^ Use a drift punch to separate the differential ring gear from the differential case.
14. Using the special tools, remove the 2 differential bearings.
15. If necessary, disassemble the differential assembly.
16. Index mark the pinion flange to the drive pinion ~ear.
17. Install the special tool and loosen, but do not remove, the pinion nut.
^ Remove the special tool.
18. With the pinion nut still engaged by a few threads, use the special tool to separate the pinion flange from the drive pinion gear.
19. Remove the pinion nut and the pinion flange.
20. CAUTION: Do not damage the axle housing while removing the drive pinion seal.
Remove the drive pinion seal and drive pinion oil slinger.
^ Pry up on the drive pinion seal flange. Install gripping pliers, and strike with a hammer to remove the drive pinion seal.
21. Remove the outer drive pinion bearing.
22. Using the special tool and a soft hammer, remove the drive pinion gear.
23. Remove and discard the drive pinion collapsible spacer.
24. Using the special tools, remove the inner drive pinion bearing cup.
25. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
If necessary, remove the pinion bearing oil baffle.
26. Remove the outer drive pinion bearing cup by tapping alternately on each side to prevent the drive pinion bearing cup from becoming misaligned.
27. Using the special tool and a suitable press, remove the inner drive pinion bearing.
28. NOTE: A drive pinion bearing adjustment shim sits under the drive pinion bearing. Use a micrometer to measure the drive pinion bearing adjustment shim thickness. Record the measurement for comparison to the drive pinion bearing adjustment shim gauge reading taken prior to installing the drive pinion bearing.
Remove and measure the drive pinion bearing adjustment shim.