Axle Assembly

Axle

Part 1:

Part 2:

Part 3:

Part 4:

Special Tool(s)

Part 1:

Part 2:

Material

Part 1:

Part 2:

Disassembly
1. Remove the rear axle assembly.





2. Install a Nm (in-lb) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.
3. Remove the differential housing cover and drain the lubricant.





4. 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 4 differential housing cover bolts.
2 Attach the special tools together with 2-3/8 inch x 1-1/2 inch bolts.





5. CAUTION: RH spreader set screw must not be adjusted further down than flush or the spreader rocks and damages the seal and the housing.

Install the special tool by placing the spreader pins in the hole in the housing spreader adapters.





6. Assemble the special tools.
1 Install the special tool.
2 Attach the special tool and position the tip in the housing spreader adapter hole.





7. 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.





8. 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 differential bearing cap bolts.
2 Remove the differential bearing caps.





9. 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 assembly.
2 Pry the differential assembly and the differential bearing shims out of the differential housing.
3 Mark the differential bearing cups and shims for location on installation.
^ Remove the special tool.





10. Remove the 10 ring gear bolts.

11. CAUTION: Do not damage the ring gear bolt hole threads.

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

12. WARNING: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring only if damaged.

If necessary, remove the speed sensor ring.





13. Using the special tools, remove the differential bearing.
^ Repeat for the other side.
14. If necessary, disassemble the differential assembly.





15. Using the special tool, hold the pinion flange to remove and discard the pinion nut.





16. Index-mark the pinion flange to the drive pinion stem.





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





18. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and strike with a hammer to remove the drive pinion oil seal.
19. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger, the outer pinion bearing and the drive pinion collapsible spacer.





20. Using the special tool and a soft-faced hammer, remove the differential pinion gear from the differential housing.





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





22. Using the special tools, remove the axle assembly front lower insulator.





23. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cups from the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.