- Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components
as necessary.
- Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 9.25 inch axle - right side.
- Install the differential adjuster nut lock, 9.25 inch axle - left side.
Caution: Refer to Fastener Caution in the Preface section.
- Install the differential adjuster nut lock bolt and tighten to
20 N·m (15 lb ft).
- Lubricate the clutch shaft pilot bearing with axle lubricant. Use the correct fluid. Refer to
Adhesives, Fluids, Lubricants, and Sealers.
- Install the clutch shaft pilot bearing using the
J 33842 .
- Install the clutch shaft to the differential carrier case half.
- If servicing the 9.25 inch axle, install the vent hose connector and tighten to
28 N·m (21 lb ft).
- If servicing the 8.25 inch axle, install the vent hose (1) to the vent connector (2) and tighten to
20 N·m (15 lb ft).
- Install the new left side axle shaft seal using the
J 45225 (1) and the
J 8092 (2).
- Install the new left side inner axle shaft retainer ring.
- Install the left side inner axle shaft by doing the following:
| 12.1. | Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. |
| 12.2. | While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. |
| 12.3. | Drive the inner shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. |
- Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear
- Install the right side inner shaft bearing into the inner shaft housing by performing the following steps:
| 14.1. | Install the inner axle shaft housing into a vise. |
| 14.2. | Clamp only on the mounting flange of the inner axle shaft housing. |
| 14.3. | Using the
J 36609 (1) and the
J 8092 (2), install the bearing. |
- Using the
J 45225 (1) and the
J 8092 (2), install the new right side inner axle shaft seal.
- Install the following components into the inner shaft housing:
| 16.1. | Install the inner axle shaft (1). |
Carefully tap the inner axle shaft into place with a soft-faced mallet.
| | Note: Use chassis grease in order to hold the thrust washer in place.
|
| 16.2. | Install the thrust washer (with tabs) (5). |
Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.
| 16.3. | Install the thrust washer (without tabs) (6). |
| 16.4. | Install the new retainer ring (7) onto the inner axle shaft (1). |
| 16.6. | Install the clutch gear shim (9). |
| 16.7. | Install the clutch sleeve (8). |
| 16.8. | Install the clutch fork assembly (11). |
| 16.9. | Install the clutch fork inner spring (10). |
| 16.10. | Install the inner axle housing gasket. |
Note: The following service procedure is for the 9.25 inch axle ONLY.
- Apply sealant to the inner shaft housing to differential carrier sealing surface. Use the correct sealant. Refer to
Adhesives, Fluids, Lubricants, and Sealers.
- Install the inner shaft housing to the differential carrier assembly case.
- If servicing the 8.25 inch axle, install the inner shaft housing bolts and tighten to
73 N·m (54 lb ft).
- If servicing the 9.25 inch axle, install the inner shaft housing bolts and tighten to
40 N·m (30 lb ft).
- Install the drain plug with the washer and tighten to
33 N·m (24 lb ft).
- Install the fill plug with the washer and tighten to
33 N·m (24 lb ft).
Caution: Refer to Component Fastener Tightening Caution in the Preface section.
- Install the front drive axle actuator.
Apply sealant to the threads of the front axle actuator. Use the correct sealant. Refer to
Adhesives, Fluids, Lubricants, and Sealers.
Tighten
Tighten the front drive axle actuator to 20 N·m (15 lb ft).
Note: The following service procedures are for the 9.25 inch axle ONLY.
- Install the lower differential carrier assembly bushing by performing the following steps:
| 24.1. | Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. |
| 24.2. | While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore. |
Note: The following service procedures are for the 9.25 inch axle ONLY.
- Install the upper differential carrier assembly bushing by performing the following steps:
| 25.1. | Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. |
| 25.2. | While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore. |
- Install the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement.
