Axle Tube Assembly

^ Tools Required
- J 36609 Bearing Installer
- J 36600 Seal Installer (4WD 15 Series and 4WD 25 Series models)





1. Use the J 36609 in order to install the bearing.
Drive into place with a hammer.
2. For the 4WD 15 Series and 4WD 25 Series models, use the J 36600 in order to install the seal.





3. Install the shaft to the axle tube.
4. Install the washer.
5. For the 4WD 15 Series and 4WD 25 Series models, install the gear with the retaining ring.
Drive the gear into place with a plastic hammer.

Output Shaft Shim Selection

^ Tools Required
- J 34672 Depth Gauge





1. Select the proper size output shaft shim if any of the following parts were replaced:
^ The shaft
^ The axle tube
^ The output shaft
^ The carrier case
^ The ring and pinion gears
^ The differential case
^ The bearings
^ For 4WD 15 Series and 4WD 25 Series models, the carrier connector
2. Push on the inner end of the shaft, and move the shaft outboard as far as it will go. The shaft must be in this position when measuring dimension A.





3. Use the J 34672 in order to measure dimension A.
4. For the 4WD 15 Series and 4WD 25 Series, install the tube flange machined surface to the inner surface of the connector.





5. Measure the dimension B.
Install the carrier machined surface to the outer surface of the output shaft.
6. Subtract the dimension A from the dimension B.
7. The correct shim size will be one size smaller than the figure obtained in the previous step.
Note the following examples:
^ If the figure obtained in step 5 was 3.53 mm, use a 3.30 mm shim.
^ For the 4WD 15 Series and 4WD 25 Series models, if the figure obtained in step 5 was 3.30 mm, use a 2.70 mm shim.
8. For the 4WD 15 Series and 4WD 25 Series models, shims are available in the following sizes:
^ 1.27 mm
^ 1.78 mm
^ 2.29 mm
^ 2.70 mm
^ 3.30 mm
^ 3.81 mm


Alternate Method

^ Tools Required
- J 8001 Dial Indicator

Important: Use this method only if the proper tools for calculating the shim size are unavailable.





1. Install the original shim to the shaft.
Use the chassis grease in order to hold the shim in place.
2. Install the assembled axle tube and the shaft to the carrier.
Do not use sealer at this time.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the bolts.
Tighten the bolts to 40 Nm (30 ft. lbs.).
4. Measure the shaft end play using the following procedure:
4.1. Install the J 8001 or the equivalent on the axle tube end.
The plunger of the indicator must be at a right angle to the axle flange.
4.2. Move the shaft back and forth and read the end play.
The correct end play is 0.03 - 0.51 mm (0.001 - 0.020 inch).
4.3. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.
4.4. Install the bolts.
4.5. Install the axle tube assembly.