Drive Pinion and Ring Gear Replacement 10.5 Inch Axle

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the differential. Refer to Differential Replacement .
3. Remove the pinion gear bearing retainer. Refer to Drive Pinion Housing and/or Seal Replacement .
4. Remove the pinion and the pinion bearings. Refer to Drive Pinion Housing and/or Seal Replacement .



5. Remove the left handed threaded ring gear bolts. Discard the bolts.

Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

6. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.

1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown.

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

2. Install the ring gear to the differential case.

Notice: Refer to Fastener Notice in the Preface section.




3. Install the new left-hand threaded ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 165 N·m (122 lb ft).

4. Install the pinion and the pinion bearings. Refer to Drive Pinion Housing and/or Seal Replacement .
5. Install the pinion gear bearing retainer. Refer to Drive Pinion Housing and/or Seal Replacement .
6. Install the differential. Refer to Differential Replacement .
7. Lower the vehicle.

Drive Pinion and Ring Gear Replacement 8.6 and 9.5 Axles

Tools Required

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the brake calipers (8.6 inch, 9.5 inch axles). Refer to Rear Brake Caliper Replacement in Disc Brakes.
4. Remove the brake rotors (8.6 inch, 9.5 inch axles). Refer to Rear Brake Rotor Replacement in Disc Brakes.
5. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (8.6 inch, 9.5 inch axles).
6. Remove the differential. Refer to Differential Replacement .
7. Remove the pinion yoke and the seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .



8. Install the J 22536 or the J 44421 as shown.

Ensure that the J 22536 or the J 44421 is firmly seated on the pinion.

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

Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing.




10. Remove the collapsible spacer from the pinion. Discard the spacer.
11. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement .
12. Remove the left handed threaded ring gear bolts. Discard the bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.

13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.




1. Install the ring gear to the differential case.
2. Install 2 threaded studs into the ring gear on opposite sides.
3. Place the ring gear on the case. Align the studs with the holes in the case.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the new left-hand threaded ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten

•	For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 N·m (89 lb ft).

•	For the 9.5 inch axle, tighten the ring gear bolts in sequence to 140 N·m (103 lb ft).

5. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement .
6. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment .
7. Install the selective shim onto the pinion.
8. Install the inner pinion bearing to the pinion. Refer to Drive Pinion Bearings Replacement .
9. Install a new collapsible spacer.
10. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
11. Install the pinion to the axle housing.
12. Install the outer pinion bearing onto the pinion.
13. Install a new pinion oil seal and the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
14. Install the differential. Refer to Differential Replacement .
15. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
16. Install the axle shafts. Refer to Rear Axle Shaft Replacement (8.6 inch, 9.5 inch axle).
17. Install the brake rotors (8.6 inch, 9.5 inch axle). Refer to Rear Brake Rotor Replacement in Disc Brakes.
18. Install the brake calipers (8.6 inch, 9.5 inch axle). Refer to Rear Brake Caliper Replacement in Disc Brakes.
19. Install the tire and wheel assemblies (8.6 inch, 9.5 inch axle). Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
20. Fill the axle with lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
21. Lower the vehicle.