Rear Axle Shaft Replacement 8.6 Inch, 9.5 Inch Axles

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper. Refer to Rear Brake Caliper Bracket Replacement in Disc Brakes.
4. Remove the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
5. Remove the pinion shaft locking bolt.



6. On axles without a locking differential, remove the pinion shaft.



7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.



8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2).



9. Push the flange of the axle shaft (1) toward the differential.
10. Remove the C-lock (4) from the button end of the axle shaft (1).

Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult.

11. Remove the axle shaft (1) from the housing (5).

Important: Carefully insert the axle shaft in order to not damage the seal.

1. Install the axle shaft (1) into the rear axle housing (5).
2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
4. On axles with a locking differential, keep the pinion shaft partially withdrawn.



5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
6. Pull the shaft flange outward in order to seat the lock in the differential gear.



7. Align the hole in the pinion shaft with the bolt hole in the differential case.

Notice: Refer to Fastener Notice in the Preface section.

8. Install the new pinion shaft locking bolt.

Tighten

•	For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 N·m (27 lb ft).

•	For the 9.5 inch axle, tighten the pinion shaft locking bolt to 50 N·m (37 lb ft).

9. Install the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
10. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement in Disc Brakes.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
13. Lower the vehicle.

Rear Axle Shaft Replacement 9.75 Inch Axle

1. Release the park brake.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
4. Remove the rear steering gear assembly. Refer to Steering Gear Actuator and Cover Replacement in Rear Wheel Steering.
5. Remove the steering knuckle assembly. Refer to Steering Knuckle Replacement in Rear Wheel Steering.



6. Remove the lock clip from the axle shaft end. The lock clip is spring loaded and fits securely in the axle shaft slot and may need to be push off the shaft end with a screw driver or related tool. Pushing the axle shaft inwards towards the gears my help in removal of the lock clip.




Important: When removing the axle shaft do not rotate the shaft. Rotating the shaft will cause the gears to move. Misalignment of the gears will make the assembly difficult.

7. Remove the axle shaft.

1. Install the axle shaft.



2. Install the spring loaded lock clip to the axle shaft end.
3. Install the steering knuckle assembly. Refer to Steering Knuckle Replacement in Rear Wheel Steering.
4. Install the rear steering gear assembly. Refer to Steering Gear Actuator and Cover Replacement in Rear Wheel Steering.
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Lower the vehicle.