Rear Axle Assembly
Rear Axle AssemblyPart 1 Of 4:
Part 2 Of 4:
Part 3 Of 4:
Part 4 Of 4:
Special Tool(s)
Material
1. Position the vehicle on a hoist.
2. Remove the rear axle assembly.
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 with the specified quantity of the specified lubricant.
Item 1: Pinion Nut Disassembly Note
1. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions
2. CAUTION: After removing the nut, discard it. Use a new nut for installation.
Use the special tool to hold the rear axle pinion flange while removing the nut.
3. Index-mark the rear axle pinion flange to the drive pinion stem.
Item 2: Rear Axle Pinion Flange Disassembly Note
1. Using the special tool, remove the rear axle pinion flange.
Item 4: Rear Pinion Oil Seal Disassembly Note
1. Use a screwdriver to force up the metal flange of the rear pinion oil seal. Install gripping pliers and strike with a hammer to remove the rear pinion oil seal.
Item 15: Differential Case Disassembly Note
1. CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
Using the special tools, mount the differential housing to a work bench.
1 Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
2 Attach the special tools together with two 3/8 inch x 1-1/2 inch bolts.
2. Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters.
3. Assemble the special tools.
1 Install the special tool.
2 Attach the special tool and position the tip in the Housing Spreader Adapter hole.
4. CAUTION: Overspreading can damage the differential housing.
NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing Spreader Adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the screw until the differential housing is spread to the specification.
3 Remove the special tool.
5. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
Remove the differential bearing caps.
1 Remove the bolts.
2 Remove the differential bearing caps.
6. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly.
1 Position wood blocks at the top and bottom of the differential case.
2 Pry the differential assembly and the differential bearing shims out of the differential housing.
3 Mark the bearing cups and shims for location on installation.
^ Remove the special tool.
Item 18: Differential Bearing Disassembly Note
1. Using the special tools, remove the differential bearing.
^ Repeat for the other side.
Item 21: Differential Pinion Gear Disassembly Note
1. Using the special tool and a hammer, remove the differential pinion gear from the differential case.
Item 22: Inner Pinion Bearing Disassembly Note
1. Using the special tool and a press, remove the pinion bearing.
1 Position the special tool under the pinion bearing.
2 Using a press, remove the pinion bearing.
Item 30: Axle Isolator Bushing Disassembly Note
1. Using the special tools, remove the rear axle isolator bushing.
Item 31 and 32: Inner and Outer Pinion Bearing Cup Disassembly Note
1. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cup from the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.
Item 32 and 31: Outer and Inner Pinion Bearing Cup Assembly Note
1. Coat the new differential drive pinion bearing cup(s) with lubricant.
2. Using the special tool, install the differential drive pinion bearing cup(s).
1 Position the bearing cup(s) on the special tool.
2 Position the special tool and the bearing cup(s) in the differential housing.
3 Tighten the special tool to fully seat the bearing cup(s) in the bore(s).
Item 30: Axle Isolator Bushing Assembly Note
1. Using the special tools, install the rear axle isolator bushing.
Item 23: Drive Pinion Bearing Adjustment Shim Assembly Note
1. NOTE: Apply a light film of lubricant on the front and rear pinion bearings.
Install the pinion bearings and special tools as shown.
2. NOTE: This step duplicates pinion bearing preload.
Thread the special tool onto the Screw and tighten to the specification shown.
3. CAUTION: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as shown.
4. Install the special tool.
1 Position the special tool on the differential housing differential bearing seat.
2 Install the differential bearing caps.
3 Install the bolts.
5. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection.
^ Notice the plus (+), minus (-), or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
6. Remove all of the special tools.
7. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
Position the drive pinion bearing adjustment shim and the pinion bearing on the drive pinion gear stem.
Item 22: Inner Pinion Bearing Assembly Note
1. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the drive pinion gear stem.
Item 18: Differential Bearing and Item 15: Differential Case Assembly Note
1. CAUTION: The master bearings are marked LH and RH. Install them as shown.
Install the special tools on the differential case.
2. CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
Place the differential case with the special tools in the differential housing.
3. Position the special tool on the outside mounting hole.
4. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play.
1 Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2 Move the differential case to the left and the right (as far as possible).
3 Record the reading on the differential bearing shim selection procedure line A.
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
Differential Bearing Shim Selection Chart
5. Remove the Dial Indicator and the differential case from the differential housing.
6. Install the differential ring gear.
1 Place the differential ring gear on the differential case.
2 Hand start three bolts to align the holes in the differential ring gear and the differential case.
3 Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4 Press the differential ring gear into place.
7. Install the remaining bolts.
8. Place the differential case with the special tools into the differential housing.
9. NOTE: The bolts retaining the differential ring gear to the differential case may interfere while carrying out this procedure. If so, remove three to five bolts to provide clearance.
Measure the end play.
1 Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2 Rock the differential ring gear to allow full mesh with the drive pinion gear.
3 With the gears in full mesh, set the special tool to zero.
4 Move the differential case as far as possible to the left and note the reading.
5 Record the reading on the differential bearing shim selection procedure line B.
^ Remove the special tool.
10. Remove the differential case from the differential housing.
11. Remove the bolts. Apply stud and bearing mount to the bolt threads, and reinstall the bolts.
12. NOTE: Measure the stand height of both differential bearings prior to installation.
NOTE: Mark the differential bearings left and right before measuring them.
Install the special tool.
1 Place the special tool base in a softjawed vise with the bearing mounting surface above the vise jaws.
2 Position the differential bearing on the special tool base.
3 Attach the bolt, spring, washers and spacer.
4 Tighten the bolt.
13. Measure the differential bearing stand height.
1 Invert the special tool and clamp the bolt head in a vise.
2 Position a depth micrometer flat on the differential bearing.
14. Measure both differential bearings stand height. Record the measurement on the differential bearing shim selection procedure line D.
15. Press the left and right differential bearing on the differential case.
1 Position the appropriate differential bearing (LH or RH).
2 Repeat the procedure for the opposing side.
16. Install the special tools.
17. CAUTION: Overspreading may damage the differential housing.
NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing Spreader Adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the screw until spreading the differential housing to the specification.
3 Remove the special tools.
18. NOTE: Select the correct size differential bearing shims by completing the differential bearing shim selection chart.
NOTE: Apply a light coating of grease to the differential bearing shim to help hold in place.
Place the differential bearing shims in the differential housing.
19. Install the differential case.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential case in place between the differential bearing shims.
20. NOTE: Tighten the bolts prior to releasing the carrier spreader.
Install the differential bearing caps in their original locations and positions and tighten the bolts.
21. Remove the special tool.
22. Install the special tool at the 12 o'clock position.
23. Using the special tools, measure the differential ring gear backlash at four equally spaced points.
1 Attach the special tool.
2 Position the special tool tip centrally on a drive tooth.
3 Zero the indicator.
4 Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.254 mm (0.010 inch) to 0.305 mm (0.012 inch) and must not vary more than 0.101 mm (0.004 inch) between points measured. A backlash variation of more than 0.101 mm (0.004 inch) between points checked indicates gear/case runout.
^ If backlash is within specifications, install the differential assembly.
^ To correct for a high or low backlash, proceed as follows.
Part 1 Of 2:
Part 2 Of 2:
24. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. When the backlash is within specifications, install the differential assembly.
Part 1 Of 2:
Part 2 Of 2:
Differential Shim Size Chart - 4067
Item 16: Differential Bearing Shim Assembly Note
1. Establish differential bearing preload.
^ To establish bearing preload, use the special tool to increase both the left and right shim sizes by the specification shown.
^ Use the special tool to make sure the differential bearing shims are fully seated.
Item 7: Drive Pinion Collapsible Spacer Assembly Note
1. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.
2. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.
Item 4: Rear Pinion Oil Seal Assembly Note
1. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the seal becomes misaligned during installation, remove it and install a new one.
NOTE: Coat the rear axle drive pinion seal lips with grease.
Using the special tool, install the new rear axle drive pinion seal.
Item 2: Rear Axle Pinion Flange Assembly Note
1. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange.
1 Lubricate the rear axle pinion flange splines.
2 Position the rear axle pinion flange.
2. Using the special tool, install the rear axle pinion flange.
Item 1: Pinion Nut Assembly Note
1. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
Use the special tool to hold the pinion flange while tightening the nut.
^ Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
2. Tighten the nut to set the preload.