Drive Pinion Flange/Yoke and/or Oil Seal Replacement 8.6, 9.5 Inch Axles

Special Tools

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 and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
3. Remove the rear brake calipers. Refer to Rear Brake Caliper Replacement.
4. Remove the rear propeller shaft.

•	For the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement.

•	For the 2 piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement.




5. Using 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




6. Scribe an alignment line between the pinion shaft and the pinion yoke.



7. Using the J 8614-01 holding tool , remove and discard the pinion nut.
8. Remove the washer.




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

9. Using the J 8614-01 holding tool  (1), (2) and (3), remove the pinion yoke.
10. Using a suitable tool, remove and discard the pinion oil seal.

1. Using the J 38694 installer , install the NEW pinion seal
2. Apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers.

Caution: Refer to Pinion Flange/Yoke Installation Caution in the Preface section.




3. Align the reference marks and install the pinion yoke.

Note: Proceed to step 5 if the new pinion nut cannot be installed.

4. Install the washer and the NEW pinion nut.
5. Perform the following steps in order to seat the pinion yoke onto the pinion.

5.1.	Remove the pinion nut washer.

5.2.	Install the old pinion nut.

5.3.	Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed.

5.4.	Remove the old pinon nut.

5.5.	Install the pinion nut washer

5.6.	Install the new pinion nut.

Caution: Refer to Fastener Caution in the Preface section.





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

6. Using the J 8614-01 holding tool , tighten the pinion nut until the pinion end play is just taken up.
7. Rotate the pinion while tightening the nut to seat the bearings.




Note: Tighten the pinion nut in small increments until the proper torque is reached.

8. Using a inch pound torque wrench, measure and the rotating torque of the pinion. The rotating torque is 0.40-0.57 N·m (3-5 lb in) is greater than the rotating torque recorded during removal and compare that to the measurement taken during the removal.
9. 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.



10. Align the reference marks and install the propeller shaft (3) to the pinion yoke (4).
11. Install the propeller shaft.

•	For the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement.

•	For the 2 piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement.

12. Install the rear brake calipers. Refer to Rear Brake Caliper Replacement.
13. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
14. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection.
15. Remove the support and lower the vehicle.

Drive Pinion Flange/Yoke and/or Oil Seal Replacement 9.75, 10.5 and 10.75 Inch Axles

Special Tools

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 vehicle. Refer to Lifting and Jacking the Vehicle.
2. Disconnect the propeller shaft from the rear axle pinion yoke. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement.



3. Place an alignment mark between the pinion and the pinion yoke.



4. Install the J 8614-01 as shown.
5. Remove the pinion nut while holding the J 8614-01 .



6. Remove the washer.



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

Use a container in order to retrieve the lubricant.

9. Remove the pinion oil seal using a suitable seal removal tool.

1. Install the new seal using the J 45710 .



2. Install the pinion yoke.

Caution: Refer to Pinion Flange/Yoke Installation Caution in the Preface section.

3. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.



4. Install the washer.




Note: Do not reuse the pinion nut.

5. Install the new pinion nut.



6. Install the J 8614-01 onto the pinion yoke as shown.

Caution: Refer to Fastener Caution in the Preface section.

7. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut to 339 N·m (250 lb ft).
8. Install the propeller shaft to the rear axle pinion yoke. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement.
9. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection.
10. Lower the vehicle.