Drive Axle Disassemble
^ Tools Required- J8107-2 Side Bearing Puller Plug
- J8614-01 Pinion Flange Holder
- J24385-01 Differential Housing Spreader
- J29721 Differential Side Bearing Remover
- J29721-70 Side Bearing Adapters
- J39330 Bearing Race Remover
- J39331 Outer Bearing Race Remover
- J39704 Dial Indicator
- J39709 Universal Handle
1. Place the axle in a suitable support.
2. Remove the bolts from the cover and the cover. This will drain the oil.
3. Pull the axle shafts out of the axle housing to the point where the axle shafts are clear of the differential case.
4. Remove the bearing cap bolts.
5. Remove the bearing caps.
IMPORTANT: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled exactly as removed.
6. Assemble the J24385-01 to the differential housing.
NOTICE: You may use the older style gage set if you already have them. The new style gages use the bearings as part of the gage system, while the older style uses a master block that acts as a master bearing.
7. Assemble the J39704.
8. Preset the gage to a minimum of 5 mm (0.200 inch). Rotate the indicator housing to zero on the dial.
9. Spread the housing while examining the J39704.
NOTICE: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.
10. Remove the case from the housing using two pry bars.
11. Remove the J24385-01 from the housing.
12. Remove the bearing caps.
IMPORTANT: Mark the bearing cups left and right and place each bearing cup with the corresponding proper bearing cap.
13. Remove the bearings using the J8107-2 J29721 and J29721-70
IMPORTANT: Mark the bearings left and right and place each bearings with the corresponding set of bearing cap and cup.
14. Remove the shims.
IMPORTANT: Mark the shims left or right.
15. Check the outboard spacers for damage such as bends or deep groves caused by worn bearings. Replace any damaged spacers at the time of assembly.
16. Place towels over the jaws of the vice. Place the differential case in the vice
17. Remove the ring gear bolts. Discard the ring gear bolts.
IMPORTANT: Replace the ring gear bolts with new ones at the time of assembly.
NOTICE: Do not pry the ring gear from the case. This will damage the ring gear and differential case.
18. Remove the lock pin screw.
19. Remove the pinion shaft using a hammer and brass drift.
20. Rotate the side gears until the pinion gears are in the opening of the case. Remove the pinion gears and thrust washers.
21. Remove the side gears and thrust washers.
IMPORTANT: Mark the side gears and thrust washers left and right
22. Replace the cover using two bolts in order to keep the pinion from failing.
23. Measure the drive pinion rotating torque. Record the measurement.
24. Check for looseness of the pinion assembly by moving the assembly back and forth. Looseness indicates excessive bearing or pinion wear.
25. Remove the pinion nut and washer using the J8614-01 in order to hold the pinion.
26. Remove the pinion flange using the J8614-01.
27. Use a soft-faced hammer to tap the pinion in order to remove the pinion from the pinion bore.
28. Remove the cover and the pinion from the vehicle.
29. Remove the pinion preload shims.
IMPORTANT: Keep the shims together
30. Remove the pinion seal.
31. Remove the outer bearing and oil slinger.
32. Remove the pinion outer bearing cups from the axle using J39330.
33. Remove the pinion outer adjusting shims and baffle, if used.
IMPORTANT: Keep the shims together.
34. Remove the pinion inner bearing cup using the J39331.
35. Remove the pinion outer adjusting shims and baffle, if used.
IMPORTANT: Keep the shims together
36. Remove the pinion inner bearing using the J29721 and the J29721-70.