Rear Axle Shaft Replacement 9.5 HD Axle

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the brake caliper. Refer to Rear Brake Caliper Replacement.
4. Remove the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
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 (1) toward the differential.
10. Remove the C-lock (4) from the button end of the axle shaft (1).

Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult.

11. Remove the axle shaft (1) from the housing (5).

Important: Carefully insert the axle shaft in order to not damage the seal.

1. Install the axle shaft (1) into the rear axle housing (5).
2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
4. On axles with a locking differential, keep the pinion shaft partially withdrawn.



5. 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).
6. Pull the shaft flange outward in order to seat the lock in the differential gear.



7. Align the hole in the pinion shaft with the bolt hole in the differential case.

Notice: Refer to Fastener Notice in the Preface section.

8. Install the new pinion shaft locking bolt.

Tighten
Tighten the pinion shaft locking bolt to 50 N·m (37 lb ft).

9. Install the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
10. Install the brake caliper. Refer to Rear Brake Caliper Replacement.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
12. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
13. Lower the vehicle.

Rear Axle Shaft Replacement 8.6 , 9.5 LD Axle

Tools Required

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Remove the brake caliper. Refer to Rear Brake Caliper Replacement .
4. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement .
5. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
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, in order 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.




Important: 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.



13. If the axle is difficult to remove, use the J 45859  (1) and the J 2619-01  (2) to remove the axle shaft from the housing.

Important: Carefully insert the axle shaft in order to not damage the seal.

1. Install the axle shaft into the rear axle housing.
2. Slide the axle shaft into place allowing the splines to engage the differential side gear.



3. On axles without a locking differential, place the C-lock on the button end of the axle shaft.
4. On axles with a locking differential, keep the pinion shaft partially withdrawn.



5. 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).
6. Pull the shaft flange outward in order to seat the C-lock in the differential gear.



7. Align the hole in the pinion shaft with the bolt hole in the differential case.

Notice: Refer to Fastener Notice in the Preface section.

8. Install the new pinion shaft locking bolt.

Tighten

•	For the 8.6  inch axle, tighten the pinion shaft locking bolt to 36 N·m (27 lb ft).

•	For the 9.5 LD  inch axle, tighten the pinion shaft locking bolt to 50 N·m (37 lb ft).

9. Install the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
10. Install the brake caliper. Refer to Rear Brake Caliper Replacement .
11. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement .
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
13. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Level Inspection .
14. Lower the vehicle.