Part 1
Front Axle AssemblyPart 1 Of 5:
Part 2 Of 5:
Part 3 Of 5:
Part 4 Of 5:
Part 5 Of 5:
Special Tool(s)
Material
CAUTION: Any operation in which the pinion nut and washer were disturbed changes the differential pinion bearing preload. Carefully reset the preload during assembly.
1. Place the vehicle in NEUTRAL and position on a hoist.
2. Remove the front axle assembly from the vehicle.
Part 1 Of 2:
Part 2 Of 2:
3. Remove the parts in the order indicated in the above illustration and table.
4. To assemble, reverse the disassembly procedure.
5. Fill the axle to the specified fluid level with the fluid listed in Specifications.
Item 1: Pinion Nut and Washer Disassembly Note
1. Measure and record the pinion bearing torque preload.
^ Using a Nm (inch-pound) torque wrench, rotate the pinion. Measure the torque required to maintain pinion rotation.
2. Index-mark the pinion flange and the pinion stem.
3. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
Item 2: Pinion Flange Disassembly Note
1. Using the special tool, remove the pinion flange.
2. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange if damaged.
Item 4: Pinion Oil Seal Disassembly Note
1. Using the special tool, remove the pinion seal.
Item 8: Axle Shaft Oil Seal Disassembly Note
1. Using the special tool, remove the axle seal.
Item 9: Axle Shaft Bearing Disassembly Note
1. Using the special tool, remove the axle shaft bearing.
Item 14: Differential Case Disassembly Note
1. Install the special tool.
2. Install the axle assembly into the bench fixture.
3. Install the special tools.
4. CAUTION: Overspreading can damage the differential housing.
Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the differential carrier spreader screw.
3 Remove the dial indicator.
5. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly from the housing.
1 Position the wood blocks.
2 Push downward on the pry bars.
3 Remove the differential assembly.
4 Remove the special tool.
Item 16: Inner Pinion Bearing Disassembly Note
1. Press the differential inner pinion bearing off the pinion.
1 Install special tool under the pinion bearing.
2 Using a shop press, remove the bearing from the pinion.
Item 17: Pinion Position Shim Disassembly Note
1. Measure and record the thickness of the pinion position shim for reference during assembly.
Item 18: Inner Pinion Bearing Cup Disassembly Note
1. To prevent it from cocking in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the cup with a brass drift.
Item 20: Outer Pinion Bearing Cup Disassembly Note
1. To prevent it from cocking in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the cup with a brass drift.
Item 24: Differential Bearing Disassembly Note
1. Assemble the special tools.
2. Position the special tool on the differential bearing.
3. Using the special tool, remove the bearing.
Item 32 and 33: Axle Isolator Bushing Disassembly Note
1. Place the special tool on the isolator and index-mark the housing in line with the arrow on the special tool.
2. Using a feeler gauge, measure the gap between the isolator flange and the axle housing.
3. Tap the special tool on, between the axle housing and the isolator flange.
4. Assemble the remaining special tools and remove and discard the isolator.
Item 32 and 33: Axle Isolator Bushing Assembly Note
1. Position the new isolator in the housing bore and install the special tools. Align the arrow on the special tool with the index mark on the housing.
2. Tighten the drawbolt to install the isolator.
^ Draw the isolator into the housing to the gap measured when the isolator was removed.
Item 25: Differential Bearing Shim Assembly Note
1. Install the special tool.
2. Install the differential case in the differential housing.
3. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play.
1 Install the special tool.
2 Force the differential case as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.
3 Force the differential case as far as possible in the opposite direction.
4 Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this procedure.
4. Remove the special tool, then remove the differential case.
1 Remove the special tool.
2 Remove the differential case.
5. CAUTION: Do not reuse the original bolts.
Using a suitable press, install the differential ring gear.
1 Position the differential ring gear and the differential case. Start two or three new bolts to align the holes in the ring gear and the differential case.
2 Using a suitable press, install the differential ring gear.
6. Install the remaining new bolts. Tighten all of the bolts to specification.
7. Install the special tool, and position the assembly in the differential housing.
1 Install the special tool.
2 Position the assembly in the differential housing.
8. Position the special tool.
9. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied set the special tool to zero.
10. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D in this procedure.
11. Remove the special tool.
12. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
13. Complete the worksheet, and select the appropriate thickness differential shims. New differential shims are available in 0.0762 mm (0.003 inch), 0.127 mm (0.005 inch), 0.254 mm (0.010 inch), and 0.762 mm (0.030 inch) thickness.
Differential Bearing Shim Selection Procedure Worksheet
Item 24: Differential Bearings Assembly Note
1. Install the differential shims and the differential bearing.
1 Position the differential shims and the differential bearing.
2 Using a suitable press, install the differential bearing.
^ Repeat this step for opposite side of the differential case.
^ Most axles will have the larger amount of shims on the ring gear side and the smaller amount on the case side.