Differential Carrier Assembly Disassemble (9.25 Inch Heavy Duty Axle)

Differential Carrier Assembly Disassemble (9.25 Inch Heavy Duty Axle)

Tools Required
* DT 49906-A - Bearing Cup Remover
* J 2619-A - Slide Hammer
* J 8614-A - Pinion Flange Holder Remover
* J 22912-B - Split Plate Bearing Holder
* J 29369-2 - Bushing and Bearing Remover (2-3 in)
* J 34011 - Pilot Bearing Remover
* J 45859 - Axle Remover

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. Refer to Backlash Inspection and Adjustment (Backlash Inspection and Adjustment).

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




3. Remove the inner axle shaft housing assembly from the differential carrier assembly.




4. Remove the clutch fork inner spring (9), clutch fork assembly (10), clutch shaft shim (8), clutch shaft sleeve (7), retainer ring (6), and the thrust washer (5) from the inner axle shaft housing (4).




5. Remove the inner axle shaft (2) from the inner axle shaft housing (1).





Note: Clamp only on the mounting flange of the inner axle shaft housing.

6. Install the inner axle shaft housing into a vise.
7. Using the J 29369-2 - remover (2-3 in) (1) and the J 2619-A - hammer (2), remove the inner axle shaft bearing and the seal.
8. Remove the inner axle shaft housing from the vise.
9. Remove the front drive axle clutch shaft.




10. Using the J 34011 - remover , remove the clutch shaft bearing.





Note: Clamp only on the mounting flange of the differential carrier assembly case.

11. Place the differential carrier assembly into a vise.
12. Using the J 2619-A - hammer (3) and the J 45859 - remover (2), remove the axle shaft flange (1).




13. Remove the axle shaft seal, including the seal deflector (1) if separated and retained on the axle shaft seal during remove.





Note: Use 3 M6X1X25 to thread into the adjuster lock.

14. Using 3 M6X1X25 bolts (2) and turning them in equally, remove the adjuster lock.




15. Using a 12 point 57 mm socket and rotate the socket counterclock wise in order to remove the differential side bearing adjuster.




16. Remove the differential carrier assembly (1) from the differential case.




17. Using the pinion J 8614-A - remover (1, 2, 3), remove the drive flange nut.
18. Reposition the J 8614-A - remover (1, 2, 3) on the drive pinion flange.
19. Using the J 8614-A - remover (1, 2, 3), loosen the drive flange pinion flange.




20. Remove the J 8614-A - remover (1, 2, 3), and remove the washer (1) and the drive pinon flange (2).




21. Place the differential case on clean flat surface.
22. Using a suitable seal remover, remove the drive pinion flange seal (2) ant the collapsible spacer (1).




23. Remove the drive pinion gear (1) from the drive pinon gear.





Note: The inner drive pinion bearing is NOT serviceable. If the inner drive pinon bearing is found to be excessively worn or damaged, replace the front differential housing.

24. Using the DT 49906-A - remover (1, 2, 3, 4, 5), remove the outer drive pinon bearing cup from the differential housing.




25. Using the J 22912-B - plate and a hydraulic press, remove the drive pinion bearing from the drive pinon gear.




26. Remove the pinion gear selectable shim (1).