Rear Axle Disassemble 9.5 Inch Axle

Tools Required

1. Remove the rear axle fill plug.



2. Remove the rear axle drain plug.
3. Drain the lubricant into a suitable container.
4. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear.



5. Remove the rear axle housing cover bolts (1).
6. Remove the rear axle housing cover (2) from the axle housing.



7. Remove the pinion shaft locking bolt.



8. On axles without a locking differential, remove the pinion shaft.



9. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.



10. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2).
11. Push the flange of the axle shaft toward the differential.



12. Remove the lock from the button end of the axle shaft.
13. Remove the axle shaft from the housing.



14. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components:

•	The pinion bearings

•	The pinion seal

•	The differential case bearings

15. Draw 2 arrows pointing at each other, one on the pinion stem, the other on the pinion yoke.
16. Record the number of exposed threads on the pinion stem for reference.



17. Install the J 8614-01 as shown.
18. Remove the pinion nut while holding the J 8614-01 .
19. Remove the washer.



20. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
21. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).



22. Remove the axle shaft seal and the bearing from the axle shaft tube using the J 29712 and the J 2619-01 .



23. Remove the differential bearing adjuster nut lock bolt.
24. Remove the differential bearing adjuster nut lock.



25. Remove the bearing caps and bolts. Mark the bearing caps left and right.
26. Loosen the differential bearing adjuster using the J 24429 .
27. Remove the differential case.
28. Remove the bearing cups, the shims, and the spacers as necessary.

Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.




29. Install the J 22536 as shown.

Make sure the J 22536 is firmly seated on the pinion.

30. Drive the pinion out using the J 22536 and a hammer.

Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.

31. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.



32. Remove the collapsible spacer from the pinion. Discard the spacer.
33. Remove the drive pinion bearing cups from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.

Rear Axle Disassemble 8.6 Inch Axle

Tools Required

1. Remove the rear axle fill plug.



2. Remove the rear axle drain plug, if equipped.

Drain the lubricant into a suitable container.




3. Remove the rear axle housing cover bolts (1).

Discard the rear axle housing cover bolts.

4. Remove the rear axle housing cover (2) from the axle housing.

If the vehicle is not equipped with a drain plug, drain the lubricant into a suitable container.




5. Remove the pinion shaft locking bolt.



6. On axles without a locking differential, remove the pinion shaft.



7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.



8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2).
9. Push the flange of the axle shaft toward the differential.



10. Remove the lock from the button end of the axle shaft.
11. Remove the axle shaft from the axle housing.



12. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components:

•	The pinion bearings

•	The pinion seal

•	The differential case bearings

13. Draw two arrows pointing at each other, one on the pinion stem, the other on the pinion yoke.
14. Record the number of exposed threads on the pinion stem for reference.



15. Install the J 8614-01 as shown.
16. Remove the pinion nut while holding the J 8614-01 .
17. Remove the washer.



18. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
19. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).



20. Remove the axle shaft seal and the bearing from the axle shaft tube using the J 44685  (1) and the J 2619-01  (2).



21. Remove the bearing caps and bolts. Mark the bearing caps left and right.

Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.




22. Remove the differential by prying the differential from the axle housing at the differential window.
23. Remove the bearing cups, the shims, and the spacers as necessary.

Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.




24. Install the J 22536 as shown.

Make sure the J 22536 is firmly seated on the pinion.

25. Drive the pinion out using the J 22536 and a hammer.

Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.

26. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.



27. Remove the collapsible spacer from the pinion. Discard the spacer.
28. Remove the drive pinion bearing cups from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.