Rear Axle - Disassemble
Removal Procedure^ Tools Required
- J 8107 - 2 Side Bearing Puller Plug
- J 8614-01 Pinion Flange Holder
- J 24385-01 Differential Housing Spreader
- J 29721 Differential Side Bearing Remover
- J 29721 - 70 Side Bearing Adapters
- J 39330 Bearing Race Remover
- J 39331 Outer Bearing Race Remover
- J 39704 Dial Indicator
- J 39709 Universal Handle
1. Place the axle in a suitable support.
2. Remove the bolts from the housing. 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.
Important: Corresponding letters are stamped on the bearing caps and the axle housing. Reassembly the bearing caps exactly as the bearing caps were removed.
5. Remove the bearing caps.
6. Assemble the J 24385-01 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 J 39704.
8. Preset the gauge to a minimum of 5 mm (0.200 inch). Rotate the indicator housing to zero on the dial.
Notice: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.
9. Spread the housing while examining the J 39704.
10. Remove the case from the housing using 2 pry bars.
11. Remove the J 24385-01 from the housing.
Important: Mark the bearing cups left and right. Place each bearing cup with the corresponding proper bearing cap.
12. Remove the bearing caps.
Important: Mark the bearings left and right. Place each bearing with the corresponding set of bearing cap and cup.
13. Remove the bearings using the J 8107 - 2, the J 29721, and the J 29721-70.
Important: Mark the shims left or right.
14. Remove the shims.
15. Inspect 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
Important: Replace the ring gear bolts with new ones at the time of assembly.
17. Remove the ring gear bolts. Discard the ring gear bolts.
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 a brass drift.
20. Rotate the side gears until the pinion gears are in the opening of the case. Remove the pinion gears and the thrust washers.
Important: Mark the side gears and the thrust washers left and right
21. Remove the side gears and the thrust washers.
22. Replace the cover using 2 bolts in order to keep the pinion from falling.
23. Measure the drive pinion rotating torque. Record the measurement.
24. Inspect 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 the washer using the J 8614-01 in order to hold the pinion.
26. Remove the pinion flange using the J 8614-01.
27. Use a soft-faced hammer in order to tap the pinion in order to remove the pinion from the pinion bore.
28. Remove the cover and the pinion from the vehicle.
Important: Keep the shims together
29. Remove the pinion preload shims.
30. Remove the pinion seal.
31. Remove the outer bearing and the oil slinger.
32. Remove the pinion outer bearing cups from the axle using J 39330.
Important: Keep the shims together.
33. Remove the pinion outer adjusting shims and the baffle, if used.
34. Remove the pinion inner bearing cup using the J 3933 1.
35. Remove the pinion inner bearing using the J 29721 and the J 29721-70.