Axle-Aluminum (Disassembly)

Special Tools:

Disassembly

1. Check the ring gear runout.
1 Remove the differential housing cover.
2 Install the special tool.
3 Check and note the ring gear runout.

2. CAUTION: Extreme care must be taken not to damage aluminum rear axle housing while carrying out these procedures.

Mount the rear axle housing on the Holding Fixture.

1 Attach the special tools to the rear axle housing with four cover bolts.
2 Attach the Housing Spreader Adapters to the Holding Fixture with two 3/8 inch x 1-1/2 inch bolts.

3. Install the Differential Carrier Spreader onto the Housing Spreader Adapters with the spreader pins aligned with the holes in the Housing Spreader Adapters.
4. Assemble the special tools.

1 Install the Dial Indicator.
2 Attach the Clutch Housing Aligning Adapter to the Dial Indicator with the tip positioned in the spreader adapter hole.

5. CAUTION: Overspreading can damage the rear axle housing.

Note: Tighten and loosen the housing spreader adapter screw to normalize the Housing Spreader Adapters prior to the final Dial Indicator reading.

Adjust the dial indicator to zero and tighten the housing spreader screw until the rear axle housing is spread to specification.
- Remove the Dial Indicator.

6. Note: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Remove the differential bearing caps.
1 Remove the bearing cap retaining bolts.
2 Remove the differential bearing caps.

7. CAUTION: Wood blocks must be used to avoid rear axle housing damage.

Remove the differential case.

1 Position wood blocks on top and bottom of the differential.
2 Pry the differential case and the differential bearing shims out of the rear axle housing.
3 Remove the special tool.

8. Remove the 10 ring gear bolts.

9. CAUTION: Care should be taken not to damage the bolt hole threads.

Insert a punch in the bolt holes and drive the ring gear off.

10. Using the special tools, remove the differential bearing.
- Repeat for the other side.

11. Remove the differential pinion shaft lock bolt.

12. Remove the differential pinion shaft.

13. Remove the differential gears.

14. Remove the differential side gears.

15. Install a Nm (inch/pound) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.

16. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.

Note: Make sure to insert the cotter key in the special tool as shown.

Remove the pinion nut.
1 Install the special tool.
2 Install a suitable breaker bar and remove the nut.

17. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation.

18. Using the special tool, remove the pinion flange.

19. Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.
- Remove the rear axle drive pinion shaft oil slinger, the rear axle drive pinion seal and the collapsible spacer.
20. Remove the front pinion bearing.

1 Position the special tool under the pinion bearing.
2 Using a press, remove the pinion bearing.

21. Note: Measure the drive pinion bearing adjustment shim, which is found under the differential pinion bearing, with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing).

Remove the drive pinion bearing adjustment shim.

22. If required, remove damaged rear axle pinion bearing cup from the rear axle housing using the special tools.

23. if required, remove rear axle pinion bearing cup from the rear axle housing using the special tools.