8.6 Inch Axle

Rear Axle Shaft Replacement

Removal Procedure
1. Raise the vehicle.
2. Remove the tire and wheel assembly.
3. Remove the brake caliper.
4. Remove the rear axle housing cover and the gasket.





5. Remove the pinion shaft locking bolt.





6. On axles without a locking differential, remove the pinion shaft.





7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.





8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block opening (2).





9. Push the flange of the axle shaft into the axle housing.

10. Remove the rear axle shaft lock from the button end of the axle shaft.






Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make assembly difficult.

11. Remove the axle shaft from the housing.

Installation Procedure






Important: Carefully insert the axle shaft in order to not damage the seal.

1. Install the axle shaft into the rear axle housing.

Rotate the axle shaft as necessary in order to align the axle shaft splines with the differential side gear splines and engage the differential side gear.





2. On axles without a locking differential, place the rear axle shaft lock on the button end of the axle shaft.





3. On axles with a locking differential, install the rear axle shaft lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2) as shown.
4. Pull the shaft flange outward in order to seat the rear axle shaft lock in the differential side gear.
5. Install the pinion shaft into the differential case.
Align the hole in the pinion shaft with the bolt hole in the differential case.






Notice: Refer to Fastener Notice in Service Precautions.

6. Install the new pinion shaft locking bolt.
^ For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 Nm (27 ft. lbs.).
^ For the 9.75 inch axle, tighten the pinion shaft locking bolt to 27 Nm (20 ft. lbs.).

7. Install the rear axle housing cover and the gasket.
8. Install the brake caliper.
9. Install the tire and wheel assembly.
10. Fill the rear axle. Use the proper fluid.
11. Lower the vehicle.