8.6, 9.5 Inch Axle

Differential Overhaul (8.6, 9.5 Inch Axles)

Tools Required
^ J22912-O1 Split Plate Bearing Puller
^ J25299 Side Bearing Installer
^ J8092 Universal Driver Handle 1 3/4 in-10
^ J8107-3 Bearing Puller Pilot
^ J8107-4 Side Bearing Puller Pilot
^ J29710 Differential Side Bearing Installer

Disassembly Procedure
1. Remove the differential side bearings by doing lithe following:





1.1. Install the J22912-O1 (2) onto the differential case.
1.2. Install the J8107-4 (8.6 inch axle) or the J8107-3 (9.5 inch axle) (1) onto the differential case.
1.3. Remove the differential side bearings using the J22912-01 and a hydraulic press.
2. Remove the left handed threaded 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. Roll the differential pinion gear out of the case with the pinion thrust washers.
4.2. 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.





2. Install the thrust washers to the differential side gears. If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to the original locations.
3. Install the differential pinion gears by doing the following:
3.1. Position one pinion gear between the differential side gears.
3.2. Rotate the differential side gears until the pinion gear is directly opposite the opening in the differential case.
3.3. Place the other pinion gear between the differential side gears. Line up the hole in both the pinion gears.
4. Install the thrust washers. Rotate the pinion gears toward the opening in order to permit the sliding in of the thrust washers.
5. Install the pinion shaft.
6. Install a new pinion shaft lock bolt.
Tighten the pinion shaft lock bolt finger tight.

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





7. Install the ring gear to the differential case.
8. Install two threaded studs into the ring gear on opposite sides.
9. Place the ring gear on the case. Align the studs with the holes in the case.

Notice: Refer to Fastener Notice in Service Precautions.

10. Install the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
^ Tighten the ring gear bolts in sequence to 120 Nm (90 ft. lbs.) (8.6 inch axle).
^ Tighten the ring gear bolts in sequence to 140 Nm (103 ft. lbs.) (9.5 inch axle).

11. Install the differential side bearings by doing the following:





11.1. In order to protect the differential case, install the J8107-4 (8.6 inch axle), or the J8107-3 (9.5 inch axle) in the case on the side opposite the bearing installation.
11.2. Install the J25299 (8.6 inch axle) (1), or the J29710 (9.5 inch axle) (1) and the J8092 (2) onto the differential case bearing as shown.
11.3. Drive the bearing onto the case using the J25299 (8.6 inch axle), or the J29710 (9.5 inch axle) and the J8092.