Differential Replacement (8.6, 9.5, 9.5 LD Inch Axles)

Differential Replacement (8.6, 9.5, 9.5 LD Inch Axles)

^ Tools Required Tools and Equipment
- J 24429 Side Bearing Backlash Spanner

Removal Procedure

Important: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the carrier with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the carrier.

1. Raise the vehicle.

2. Remove the axle shafts. Service and Repair





3. Remove the differential bearing adjuster nut lock (9.5/9.5LD inch axle - right side).





Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

4. Remove the bearing cap bolts.

5. Remove the bearing caps. Mark the bearing caps left and right.





6. For the 8.6 inch axle, install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.

Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

7. For the 8.6 inch axle, rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.

8. For the 9.5/9.5LD inch axle, loosen the differential bearing adjuster nut using the J 24429.

9. Remove the differential assembly.

10. Remove the bearing cups, the shims, and the spacers as necessary.Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

11. Remove the differential side bearings, if necessary. Differential Side Bearings Replacement

12. Remove the ring gear, if necessary. Drive Pinion and Ring Gear Replacement (8.6, 9.5, 9.5LD Inch Axles)

Installation Procedure
1. Install the ring gear, if necessary. Drive Pinion and Ring Gear Replacement (8.6, 9.5, 9.5LD Inch Axles)

2. Install the differential side bearings, if necessary. Differential Side Bearings Replacement

3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Fluid Type Specifications





4. Place the case, with the bearing cups installed, into the axle housing.Support the case in order to keep the case from falling out of the axle housing.





5. Install the bearing caps and the bolts. Do not torque the bearing cap bolts at this time.

6. Adjust the differential side bearing preload.
8.6 Inch Axle Differential Side Bearing Preload Adjustment (8.6 Inch Axle)
9.5, 9.5LD Inch Axle Differential Side Bearing Preload Adjustment (9.5, 9.5LD Inch Axles)

7. Adjust the backlash.
8.6 Inch Axle Backlash Adjustment (8.6 Inch Axle)
9.5, 9.5LD Inch Axle Backlash Adjustment (9.5 Inch Axle)

8. Perform a gear tooth contact pattern check. Gear Tooth Contact Pattern Inspection

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

9. Tighten the bearing cap bolts.
^ For the 8.6 inch axle, tighten the bearing cap bolts to 75 Nm (55 lb ft)
^ For the 9.5/9.5LD inch axle, tighten the bearing cap bolts to 85 Nm (63 lb ft)

10. Install the axle shafts. Service and Repair

11. Fill the axle with the proper lubricant.

12. Lower the vehicle.