8.25 S4WD and 9.25 Axles

Differential Carrier Assembly - Disassemble (8.25 S4WD and 9.25 Axles)

Tools Required
^ J22912-01 Split-Plate Bearing Puller
^ J2619-01 Slide Hammer
^ J29369-1 Bushing and Bearing Remover
^ J29369-2 Bushing and Bearing Remover (2-3 inch)
^ J33791 Carrier Bushing Remover/Installer
^ J34011 Pilot Bearing Remover
^ J36598 Holding Fixture
^ J36599-A Side Bearing Nut Wrench
^ J36616 Axle Mount Bushing Remover/Installer
^ J36615 Side Bearing Nut Wrench
^ J8614-01 Flange and Pulley Holding Tool

Inspection Procedure
Perform the following before disassembling the axle:
1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
5. 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 J36616-2 (1), the J33791-1 (2), the thrust bearing (3), the J21474-18 (4), and the forcing screw as shown.
1.2. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J21474-18.





2. Remove the lower differential carrier assembly bushing by performing the following steps:
2.1. Install the J21474-18 (1), the thrust bearing (2), the J33791-1 (3), the J36616-2 (4), and the forcing screw as shown.
2.2. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J21474-18.





3. Remove the front axle actuator.
4. Remove the inner axle shaft housing to differential carrier assembly bolts.





5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly.





6. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
6.1. The clutch fork inner spring (10)
6.2. The clutch fork assembly (11)
6.3. The clutch shaft shim (9)
6.4. The clutch shaft sleeve (8)
6.5. The front drive axle clutch gear (6) by doing the following:
6.5.1. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
6.5.2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
6.6. Remove the thrust washer (5)





7. For the 9.25 inch axle, remove the following components from the inner axle shaft housing (4):
7.1. The clutch fork inner spring (10)
7.2. The clutch fork assembly (11)
7.3. The clutch shaft shim (9)
7.4. The clutch shaft sleeve (8)
7.5. The retainer ring (7)
7.6. The thrust washers (5, 6)





8. Remove the inner axle shaft (2).





9. Install the inner axle shaft housing into a vise.
Clamp only on the mounting flange of the inner axle shaft housing.
10. Install the J29369-1, 8.25 inch axle, or the J29369-2, 9.25 inch axle, behind the inner axle shaft bearing.
11. Install the J2619-01 (2) to the J29369-1 or the J29369-2 (1).
12. Remove the inner axle shaft bearing and the inner axle shaft seal using the J2619-01.
13. Remove the front drive axle clutch shaft





14. Use the J34011 in order to remove the clutch shaft bearing.
15. Place the differential carrier assembly into a vise.
Clamp only on the mounting flange of the differential carrier assembly case,
16. Remove the inner axle shaft using a hammer and a brass drift.
17. Install the J29369-1, 8.25 inch axle, or the J29369-2, 9.25 inch axle, behind the inner axle shaft bearing,
18. Install the J2619-01 to the J29369-1 or the J29369-2.
19. Remove the inner axle shaft seal and the inner axle shaft bearing using the J2619-01.
20. Remove the differential carrier assembly from the vise.





21. Remove the vent connector.
22. Remove the differential carrier assembly bolts.





23. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case with a hammer and a brass drift.
24. Remove the differential case assembly.
Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, 8.25 inch axle - both sides, 9.25 inch axle - right side.





25. Remove the differential bearing adjuster nut lock bolt and the lock from the differential bearing adjuster nut, 9.25 inch axle - left side.





26. Remove the differential bearing adjuster by doing the following, 8.25 inch axle - both sides, 9.25 inch axle - right side:
26.1. Install the J 36599-A onto the differential bearing adjuster nut.
26.2. Turn the J 36599-A clockwise in order to push the bearing cup out of the bore.





27. For the 9.25 inch axle - left side, remove the differential bearing adjuster by doing the following:
27.1. Install the J36615 onto the differential bearing adjuster nut as shown.
27.2. Turn the J 36615 counterclockwise in order to remove the differential bearing adjuster nut and the O-ring.





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





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





32. Install the J 36598 into a vise.
33. Install the left differential carrier case half onto the J36598 and the J 36598-6, 8.25 in axle, or the J 36598, 9.25 inch axle.
34. While holding the forcing screw of the J 36598, 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

35. Remove the collapsible spacer from the pinion.





36. Remove the inner pinion bearing by installing the J22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
37. Remove the pinion gear selectable shim.





38. Install the J 36598-5 (3) behind the inner pinion bearing cup.
39. Thread the forcing screw of the J 36598 (1) onto the J 36598-5 (3) until fully seated.
40. While holding the forcing screw of the J 36598 (1), turn the handle of the J 36598 (2) counterclockwise and press the inner bearing cup out from the differential carrier case.





41. Install the J 36598-5 (2) behind the outer pinion bearing cup.
42. Install the forcing screw of the J 36598 (1) to the J 36598-5 (2).
43. While holding the forcing screw of the J 36598, 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