Differential Replacement (8.6 Inch Axle)
Differential Replacement (8.6 Inch Axle)
Removal Procedure
Note: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the differential side 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 assembly without replacing any other component (i.e. pinion and ring gear set, differential bearings. etc.) then you may reinstall the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (8.6, 9.5 Inch Axles W/O RPO JL4) (Service and Repair)Rear Axle Shaft Replacement (8.6 Inch Axle W/RPO JL4) (Service and Repair)Rear Axle Shaft Replacement (9.5, 9.75Inch Axles ) (Service and Repair).
Warning
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.
3. Remove the differential bearing caps and bolts. Mark the differential bearing caps left and right.
4. 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.
Caution: 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.
5. Rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.
6. Remove the differential assembly.
7. 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.
8. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement (Service and Repair).
9. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch Axle) (Service and Repair)Drive Pinion and Ring Gear Replacement (9.75, 10.5 and 10.75 Inch Axles) (Drive Pinion and Ring Gear Replacement (9.75, 10.5 and 10.75 Inch Axles)).
Installation Procedure
1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch Axle) (Service and Repair)Drive Pinion and Ring Gear Replacement (9.75, 10.5 and 10.75 Inch Axles) (Drive Pinion and Ring Gear Replacement (9.75, 10.5 and 10.75 Inch Axles)).
2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement (Service and Repair).
3. Lubricate the differential side bearings with the proper axle lubricant. Refer to Fluid and Lubricant Recommendations (Service Intervals).
4. Install the differential assembly, with the differential bearing cups installed, into the axle housing.
Support the differential assembly in order to keep the case from falling out of the axle housing.
5. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle) (Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle))Differential Carrier Bearing Preload Adjustment (9.75, 10.5 and 10.75 Inch Axle) (Differential Carrier Bearing Preload Adjustment (9.75, 10.5 and 10.75 Inch Axle)).
6. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment (8.6 Inch Axle) (Backlash Adjustment (8.6 Inch Axle))Backlash Adjustment (9.75, 10.5 and 10.75 Inch Axles) (Backlash Adjustment (9.75, 10.5 and 10.75 Inch Axles)).
7. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection (Gear Tooth Contact Pattern Inspection).
8. Install the differential bearing caps and the bolts, if necessary.
Caution: Refer to Fastener Caution (Fastener Caution).
9. Tighten the differential bearing cap bolts to 75 Nm (55 lb ft).
10. Install the axle shafts. Refer to Rear Axle Shaft Replacement (8.6, 9.5 Inch Axles W/O RPO JL4) (Service and Repair)Rear Axle Shaft Replacement (8.6 Inch Axle W/RPO JL4) (Service and Repair)Rear Axle Shaft Replacement (9.5, 9.75Inch Axles ) (Service and Repair).
11. Fill the axle with the proper axle lubricant. Refer to Rear Axle Lubricant Replacement (8.6, 9.5 Inch Axle) (Rear Axle Lubricant Replacement (8.6, 9.5 Inch Axle))Rear Axle Lubricant Replacement (9.75, 10.5 and 10.75 Inch Axles) (Rear Drive Axle).
12. Lower the vehicle.