Differential Overhaul (8.6, 9.5 Inch Axles)

Differential Overhaul (8.6, 9.5 Inch Axles)

Disassembly Procedure

1. Remove the differential side bearings.






Important: The ring gear bolts have left-hand threads.

2. Remove the ring gear bolts. Discard the bolts.

Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.






3. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.






4. Remove the differential pinion gears and the differential side gears by doing the following:
4.1. Remove the pinion shaft lock bolt
4.2. Remove the pinion shaft.
4.3. Roll the differential pinion gear out of the case with the pinion thrust washers.
4.4. Remove the differential side gears and the side gear thrust washers.

Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure






1. Lubricate all the parts using axle lubricant. Refer to Fluid and Lubricant Recommendations Specifications.
2. Install the thrust washers to the differential side gears.
3. Install the differential side gears and thrust washers into the differential case.

If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to the original locations.

4. Install the differential pinion gears by doing the following:
4.1. Position one pinion gear between the differential side gears.
4.2. Rotate the differential side gears until the pinion gear is directly opposite the opening in the differential case.
4.3. Place the other pinion gear between the differential side gears.

Line up the hole in both the pinion gears.

5. Install the thrust washers.

Rotate the pinion gears toward the opening in order to permit the sliding in of the thrust washers.

6. Install the pinion shaft.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

7. Install a new pinion shaft lock bolt.

Tighten
- For the 8.6 inch axle, tighten the pinion shaft lock bolt to 36 Nm (27 lb ft).
- For the 9.5 inch axle, tighten the pinion shaft lock bolt to 50 Nm (37 lb ft).






Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

8. Install the ring gear to the differential case.






Important: The ring gear bolts have left-hand threads.

9. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

10. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
- For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 Nm (89 lb ft).
- For the 9.5 inch axle, tighten the ring gear bolts in sequence to 140 Nm (103 lb ft).

11. Install the differential side bearings.