Rear Axle Housing Replacement (Under 3500 GVW with Drums)

Rear Axle Housing Replacement (Under 3500 GVW with Drums)

Removal Procedure

1. Remove the rear axle. Refer to Rear Axle Replacement (10.5 Inch Axle) Rear Axle Replacement (10.5 Inch Axle)Rear Axle Replacement (8.6, 9.5LD Inch Axles) Rear Axle Replacement (8.6, 9.5LD Inch Axles).

2. Remove the rear axle cover housing and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle) Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle).

3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement Service and Repair.

4. Remove the axle shafts. Refer to Rear Axle Shaft Replacement Service and Repair.




5. Remove the rear brake assembly bolts (2).

6. Remove the rear brake assemblies (1).

7. Remove the rear axle shaft oil seals and bearings (3). Refer to Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement.

8. Remove the drive pinion shaft yoke and oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement Service and Repair.

9. Remove the differential assembly. Refer to Differential Replacement (10.5 Inch Axle) Differential Replacement (10.5 Inch Axle)Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) Differential Replacement (8.6, 9.5/9.5 LD Inch Axles).

10. Remove the drive pinion and the inner pinion bearing. Refer to Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles).

11. Remove the pinion bearing cups. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6 Inch Axle)Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle).

12. Remove the rear wheel speed sensor ring. Refer to Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement.

Installation Procedure

1. Install the pinion bearing cups. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6 Inch Axle)Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle).

2. Install the drive pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement Service and Repair.

3. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (9.5LD Inch Axle) Pinion Depth Adjustment (9.5LD Inch Axle)Pinion Depth Adjustment (10.5 Inch Axle) Pinion Depth Adjustment (10.5 Inch Axle)Pinion Depth Adjustment (8.6 Inch Axle) Pinion Depth Adjustment (8.6 Inch Axle).

4. Install the inner pinion bearing onto the drive pinion. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6 Inch Axle)Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle).

5. Install the drive pinion. Refer to Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles).

6. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement Service and Repair.

7. Install the differential assembly. Refer to Differential Replacement (10.5 Inch Axle) Differential Replacement (10.5 Inch Axle)Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) Differential Replacement (8.6, 9.5/9.5 LD Inch Axles).

8. 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 (9.5LD Inch Axle) Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)Differential Carrier Bearing Preload Adjustment (10.5 Inch Axle) Differential Carrier Bearing Preload Adjustment (10.5 Inch Axle).

9. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment (10.5 Inch Axle) Backlash Adjustment (10.5 Inch Axle)Backlash Adjustment (9.5 LD Axle) Backlash Adjustment (9.5 LD Axle)Backlash Adjustment (8.6 Inch Axle) Backlash Adjustment (8.6 Inch Axle).

10. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection Gear Tooth Contact Pattern Inspection.




11. Install the rear axle shaft oil seals and bearings (3). Refer to Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement.

12. Install the rear brake assemblies (1).

Caution: Refer to Fastener Caution Fastener Caution.

13. Install the rear brake assembly bolts (2) and tighten to 135 Nm (100 lb ft).

14. Install the axle shafts. Refer to Rear Axle Shaft Replacement Service and Repair.

15. Install the rear axle cover housing and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles)Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle) Rear Axle Housing Cover and Gasket Replacement (10.5 Inch Axle).

16. Install the rear axle. Refer to Rear Axle Replacement (10.5 Inch Axle) Rear Axle Replacement (10.5 Inch Axle)Rear Axle Replacement (8.6, 9.5LD Inch Axles) Rear Axle Replacement (8.6, 9.5LD Inch Axles).

17. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement Service and Repair.

18. Install the rear wheel speed sensor ring. Refer to Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement.