Differential Overhaul 8.6, 9.5 Inch Axles

1. Remove the differential side bearings. Refer to Differential Side Bearings Replacement .




Important: The ring gear bolts have left-hand threads.

2. Remove the ring gear bolts. Discard the bolts.

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




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



4. Remove the differential pinion gears and the differential side gears by doing the following:

4.1.	Remove the pinion shaft lock bolt

4.2.	Remove the pinion shaft.

4.3.	Roll the differential pinion gear out of the case with the pinion thrust washers.

4.4.	Remove the differential side gears and the side gear thrust washers.

Mark the pinion gears top and bottom and the differential side gears left and right.

1. Lubricate all the parts using axle lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
2. Install the thrust washers to the differential side gears.
3. Install the differential side gears and thrust washers into the differential case.

If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to the original locations.

4. Install the differential pinion gears by doing the following:

4.1.	Position one pinion gear between the differential side gears.

4.2.	Rotate the differential side gears until the pinion gear is directly opposite the opening in the differential case.

4.3.	Place the other pinion gear between the differential side gears.

Line up the hole in both the pinion gears.

5. Install the thrust washers.

Rotate the pinion gears toward the opening in order to permit the sliding in of the thrust washers.

6. Install the pinion shaft.

Notice: Refer to Fastener Notice in the Preface section.

7. Install a new pinion shaft lock bolt.

Tighten

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

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





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

8. Install the ring gear to the differential case.




Important: The ring gear bolts have left-hand threads.

9. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

10. Tighten the new 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).

11. Install the differential side bearings. Refer to Differential Side Bearings Replacement .

Differential Overhaul 10.5 Inch Axle

1. Remove the differential side bearings. Refer to Differential Side Bearings Replacement .




Important: The ring gear bolts have left-hand threads.

2. Remove the ring gear bolts.

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

3. Remove the ring gear from the differential case.

Drive the ring gear off with a brass drift if necessary.

4. Separate the differential case assembly.




Important: If the differential pinion gears, the differential side and the thrust washers are to be reused, mark the components so they can be re-installed in their original location in the differential case.

5. Remove the following from the differential case:

•	The thrust washers

•	The differential pinion gears

•	The differential pinion spider




6. Remove the differential side gears.

1. Lubricate the differential side gears and the differential pinion gears with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.



2. Install the differential side gears into the differential case.

If the original differential side gears are being used, install the gears in the original location.




3. Assemble the differential pinion gears and the thrust washers to the differential spider as shown.

If the original differential pinion gears, the thrust washers and the differential spider are being used, install the components in the original locations.




4. Assemble the differential case halves.

Align the arrow in 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.

5. Install the ring gear to the differential case.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the new ring gear bolts.

Hand start each bolt in ensure the ring gear is properly installed to the differential case.

7. Tighten the ring gear bolts. Tighten the 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).

8. Install the differential side bearings. Refer to Differential Side Bearings Replacement .