For 1990-2009 cars

#### Special Tools

• | J 8614-01 Flange Holder and Remover

• | J 33782 Pinion Oil Seal Installer

• | J 38694 Extension Housing Oil Pump/Seal Installer

### Removal Procedure

Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly

1. Raise the and support vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the rear drum brakes. Refer to Brake Drum Replacement.
3. Remove the propeller shaft.

• | For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft Replacement.

• | For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft Replacement.

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

• | The pinion bearings

• | The pinion oil seal

• | The differential case bearings

• | The axle bearings

• | The axle seals

5. Place an alignment mark between the pinion and the pinion yoke.
6. Using the J 8614-01 tool to hold the pinion nut, remove the pinion nut and the washer.

Note: Use a container in order to retrieve the lubricant.

7. Using the J 8614-01 tool (1) to hold the pinion yoke, remove the pinion yoke by turning the J 8614-3 (3) clockwise.

Note: Do not damage the housing.

8. Using a suitable tool, remove the pinion oil seal.

### Installation Procedure

1. Using the J 33782 installer for the 8.0 inch, install the pinion seal.
2. Apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers.
3. Align the reference marks and install the pinion yoke.

Caution: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

4. Using a soft-faced hammer, tap the pinion yoke until the threads on the pinion shaft can be seen.
5. Install the washer and a NEW pinion nut.

Caution: Refer to Fastener Caution in the Preface section.

6. While holding the J 8614-01 tool , tighten the NEW pinion nut in small increments until the end play is just taken up.

Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

Note: Compare this measurement with the rotating torque recorded during removal.

7. Using an inch pound torque wrench, measure the rotating torque of the pinion 0.40-0.57 N·m (3-5 lb in) greater than the rotating torque recorded during removal.
8. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
9. Install the propeller shaft.

• | For vehicles equipped with one piece propeller shafts, refer to One-Piece Propeller Shaft Replacement.

• | For vehicles equipped with two piece propeller shafts, refer to Two-Piece Propeller Shaft Replacement.

10. Install the rear brake rotors. Refer to Brake Drum Replacement.
11. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Replacement.
12. Remove the support and lower the vehicle.