Differential Replacement 8.6, 9.5/9.5 LD Inch Axles

Special Tools

J 24429 Side Bearing Backlash Spanner

Note: Group and mark the shims together as originally removed. If you remove or replace the differential ring and pinion gear set, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other of the components ( pinion and ring gear set, bearings. etc.) then you may reinstall the differential carrier with the original shims in their original locations. ALWAYS perform a gear tooth contact pattern check, even when you remove only the differential carrier.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement.




Note: Step 3 is for the 9.5/9.5LD inch axle.

3. Remove the right side differential bearing adjuster nut lock.

Warning: Refer to Differential Case Removal Warning in the Preface section.





Note: Mark the bearing caps left and right before removing.

4. Remove the bearing cap bolts and caps.




Note: Steps 3 and 4 are for the 8.6 inch axle ONLY.

5. For the 8.6 inch axle, install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.

Caution: Refer to Differential Housing Cover and Gasket Removal Caution in the Preface section.

6. For the 8.6 inch axle, rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.

Note: The following service procedure is for the 9.5/9.5LD inch axle ONLY.

7. Using the J 24429 spanner , loosen the differential bearing adjuster nut.
8. Remove the differential assembly.

Note: Mark the bearing cups, caps and the shims left and right and in the proper order for re-assembly.

9. Remove the bearing cups, the shims, and the spacers as necessary.
10. Remove the differential side bearings. Refer to Differential Side Bearings Replacement.
11. Remove the differential ring gear. Refer to Drive Pinion and Ring Gear Replacement.

1. Install the differential ring gear. Refer to Drive Pinion and Ring Gear Replacement.
2. Install the differential side bearings. Refer to Differential Side Bearings Replacement.
3. Using the proper axle lubricant, lubricate the differential side bearings. Refer to Fluid and Lubricant Recommendations.




Note: Support the case in order to keep the case from falling out of the axle housing.

4. Place the differential case, with the bearing cups installed, into the axle housing.




Note: DO NOT torque the bearing cap bolts at this time.

5. Install the bearing caps and the bolts.
6. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment.
7. Adjust the backlash. Refer to Backlash Adjustment.
8. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection.

Caution: Refer to Fastener Caution in the Preface section.

9. Tighten the bearing cap bolts to 75 N·m (55 lb ft) for the 8.6 inch axle or 85 N·m (63 lb ft) for the 9.5/9.5LD inch axle.
10. Install the axle shafts. Refer to Rear Axle Shaft Replacement.
11. Fill the axle with the proper lubricant. Refer to Rear Axle Lubricant Replacement.
12. Lower the vehicle.

Differential Replacement 10.5 Inch,11.5 Inch Axle

Special Tools

J 24429 Side Bearing Backlash Spanner

1. Raise and support the vehicle the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement.
3. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.



4. Remove the differential bearing adjuster nut retainers.




Note: Mark the bearing caps left and right.

5. Remove the bearing caps and bolts.

Warning: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Caution: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

6. Using the J 24429 spanner , loosen the adjusters.



7. Remove the differential assembly.

Note: Mark the cups left and right. Place the cups with the bearing caps.

8. Remove the bearing cups.
9. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement.
10. Remove the differential ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement.

1. Install the differential ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement.
2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement.
3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations.




Note: Support the differential case in order to keep the differential case from falling out of the axle housing.

4. Place the case, with the bearing cups installed, into the axle housing.




Note: DO NOT torque the bearing cap bolts at this time.

5. Install the bearing caps and the bolts.



6. Using the J 24429 spanner , turn the adjusters evenly on each side until snug against the differential.
7. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment.
8. Adjust the backlash. Refer to Backlash Adjustment.
9. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection.

Caution: Refer to Fastener Caution in the Preface section.

10. Tighten the bearing cap bolts to 185 N·m (136 lb ft) for the and 10.5 inch axle, or 207 N·m (153 lb ft) for the 11.5 inch axle.
11. Install the axle shafts and new gaskets. Refer to Rear Axle Shaft and/or Gasket Replacement.
12. Install the rear axle housing cover and a new gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
13. Fill the axle with lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
14. Remove the support and lower the vehicle.