Axle Shaft: Service and Repair
Rear Axle Shaft Replacement
Special Tools
* J 2619-01 - Slide Hammer W/ 1/2 x 13 Adapter
* J 45859 - Axle Shaft Remover/Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Service and Repair.
3. Remove the brake caliper mounting bracket. Refer to Rear Brake Caliper Bracket Replacement (1500 Series) Rear Brake Caliper Bracket Replacement (1500 Series)Rear Brake Caliper Bracket Replacement (2500 Series) Rear Brake Caliper Bracket Replacement (2500 Series).
4. Remove the rear wheel speed sensor.
* For the Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement.
* For the non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement.
* For the non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement.
5. Remove the rear axle housing cover and the 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).
6. Remove the pinion shaft locking bolt.
7. On axles without a locking differential, remove the pinion shaft.
8. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
9. On axles with a locking differential, use a screwdriver, or a similar tool, to enter the differential case and rotate the C-lock (1) until the C-lock aligns with the thrust block (2).
10. Push the flange of the axle shaft (1) toward the differential.
11. Remove the C-lock from the button end of the axle shaft.
Note: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the installing of the axle shaft difficult.
12. Remove the axle shaft from the housing.
Note: Perform the following step if the axle shaft is hard to remove.
13. Using the J 2619-01 - slide hammer (1) and the J 45859 - remover/installer (2) to remove the axle shaft from the housing.
Installation Procedure
1. Install the axle shaft into the rear axle housing, allowing the splines to engage the differential side gear.
2. On axles without a locking differential, place the C-lock on the button end of the axle shaft.
3. On axles with a locking differential, keep the pinion shaft partially withdrawn.
4. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
5. Pull the shaft flange outward in order to seat the C-lock in the differential gear.
6. Align the hole in the pinion shaft with the bolt hole in the differential case.
Caution: Refer to Fastener Caution Fastener Caution.
7. Install the new pinion shaft locking bolt.
* For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 Nm (27 lb ft).
* For the 9.5 LD inch axle, tighten the pinion shaft locking bolt to 50 Nm (37 lb ft).
Note: End play is the in and out movement of the rear axle shaft. Radial play is the up and own movement in the rear axle shaft.
8. Check the rear axle shaft end play and the radial play. The rear axle shaft end play should be 0.012 inch per side and the radial play should be 0.002-0.003 inch. If the rear axle shaft is NOT within the specifications, replace any excessively worn parts.
9. Install the rear axle housing cover and the 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).
10. Install the brake caliper mounting bracket. Refer to Rear Brake Caliper Bracket Replacement (1500 Series) Rear Brake Caliper Bracket Replacement (1500 Series)Rear Brake Caliper Bracket Replacement (2500 Series) Rear Brake Caliper Bracket Replacement (2500 Series).
11. Install the rear wheel speed sensor.
* For the Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement.
* For the non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement.
* For the non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement.
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Service and Repair.
13. Fill the rear axle with the proper axle lubricant. Refer to Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle)Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle).
14. Lower the vehicle.