8.25 F4WD Axle

Differential Carrier Assembly - Disassemble (8.25 F4WD Axle)

Tools Required
^ J 22912-01 Split-Plate Bearing Puller
^ J 2619-01 Slide Hammer
^ J 29369-1 Bushing and Bearing Remover
^ J 33791 Carrier Bushing Remover/installer
^ J 36598 Holding Fixture
^ J 36599-A Side Bearing Nut Wrench
^ J 36616 Axle Mount Bushing Remover/installer
^ J 8614-01 Flange and Pulley Holding Tool

Inspection Procedure
Perform the following before disassembling the axle:
1. Remove the drain plug from the axle.
2. Drain the axle lubricant.
3. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
4. Check the ring gear backlash.
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure





1. Remove the upper differential carrier assembly bushing by performing the following steps:
1.1. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown.
1.2. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.





2. Remove the lower differential carrier assembly bushing by performing the following steps:
2.1. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown.
2.2. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.

3. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift.
4. Remove the inner axle shaft housing to differential carrier assembly bolts.
5. Carefully remove the inner axle shaft and inner axle shaft housing.
6. Remove the inner axle shaft from the inner axle shaft housing.
7. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
8. Install the J 29369-1 behind the inner axle shaft bearing.
9. Install the J 2619-01 to the J 29369-1.
10. Remove the inner axle shaft seal and the inner axle shaft bearing using the J 2619-01.
11. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case.
12. Remove the inner axle shaft using a hammer and a brass drift.
13. Install the J 29369-1 behind the inner axle. shaft bearing.
14. Install the J 2619-01 to the J 29369-1.
15. Remove the inner axle shaft seal and the inner axle shaft bearing using the J 2619-01.
16. Remove the differential carrier assembly from the vise.





17. Remove the vent connector.
18. Remove the differential carrier assembly bolts.
19. Separate the left carrier case halt from the right carrier case half by tapping on the or) the carrier case with a hammer and a brass drift.
20. Remove the differential case assembly.
Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks.





21. Remove the differential bearing adjuster nuts and the bearing cups by doing the following:
21.1. Install the J 36599-A onto the differential bearing adjuster nut.
21.2. Turn the J 36599-A clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore.





22. Install the J 8614-01 as shown.
Remove the pinion nut while holding the J8614-01.
23. Remove the washer.





24. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
25. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J 8614-01 (1).





26. Install the J 36598 into a vise.
27. Install the left differential carrier case half onto the J 36598 and the J 36598-6.
28. While holding the forcing screw of the J36598, turn the handle of the J 36598 counterclockwise in order to remove the pinion with the following components:
^ The pinion gear selectable shim
^ The inner pinion bearing
^ The collapsible spacer

29. Remove the collapsible spacer from the pinion.





30. Remove the inner pinion bearing by installing the J 22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
31. Remove the pinion gear selectable shim.





32. Install the J 36598-5 (3) behind the inner pinion bearing cup.
33. Thread the forcing screw of the J 36598 (1) onto the J 36598-5 (3).
34. While holding the forcing screw of the J36598 (1), turn the handle of the J 36598 (2) counterclockwise and press the inner bearing cup out from the differential carrier case.





35. Install the J 36598-5 (2) behind the outer pinion bearing cup.
36. Install the forcing screw of the J 36598 (1) to the J 36598-5 (2).
37. While holding the forcing screw of the J36598, turn the handle of the J 36598 clockwise in order to remove the following components:
^ The pinion oil seal
^ The pinion outer bearing
^ The pinion outer bearing cup