Rear Axle Shaft and/or Gasket Replacement Except Dana 286 Axle

1. Apply the parking brake.
2. Block the wheels.



3. Remove the rear axle shaft housing cover nuts (1).
4. Remove the rear axle shaft housing cover washers (2).




Caution: Do not attempt to loosen the dowels or remove the axle shaft by using a hammer, a chisel or wedge-type tool. To use such tools to loosen the dowels or remove the axle shaft may damage the hub, the axle shaft and/or the oil seals.

5. Remove the rear axle shaft housing locators.

5.1.	Hold a brass drift against the center of the rear axle housing cover.

5.2.	Strike the brass drift with a sharp blow using the 2.3 kg (5 lb) hammer.

Note: Tag the rear axle shafts in order to identify the right and the left rear axle shaft location for reassembly.

6. Remove the rear axle shaft.
7. Remove the rear axle housing cover gaskets.

1. Install the new rear axle shaft housing cover gasket (5).
2. Install the rear axle shaft (4).

2.1.	Dip the splined end of the rear axle shaft into the synthetic lubricant before installing. Refer to Fluid and Lubricant Recommendations.

2.2.	Rotate the rear axle shaft as needed in order to align the rear axle shaft housing cover holes with the studs.

3. Install the rear axle shaft housing cover locators (3).
4. Install the rear axle shaft housing cover washers (2).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the rear axle shaft housing cover nuts (1).

Tighten

•	Tighten the rear axle shaft housing nuts 12 stud rear axle to 77 N·m (57 lb ft).

•	Tighten the rear axle shaft housing nuts 8 stud rear axle to 155 N·m (114 lb ft).





Note: There must be clearance between the rear axle shaft housing cover washers and the rear shaft housing cover. If the rear axle shaft housing cover washers contact the rear axle shaft housing cover, remove the rear axle shaft and inspect and replace the faulty parts.

6. Inspect for clearance between the rear axle shaft housing and the rear axle shaft housing cover washers.
7. Remove the wheel blocks.

Rear Axle Shaft and/or Gasket Replacement Dana 286 Axle

1. Apply the parking brake.
2. Block the wheels.
3. Remove the rear axle shaft bolts.

Note: Tag the rear axle shafts in order to identify the right and the left rear axle shaft location for reassembly.

4. Remove the rear axle shaft.
5. Clean the rear axle shaft and the hub assembly of sealant.

1. Install the new rear axle shaft flange gasket.
2. Install the rear axle shaft into the wheel hub.

2.1.	Dip the splined end of the rear axle shaft into the synthetic lubricant before installing. Refer to Fluid and Lubricant Recommendations.

2.2.	Rotate the rear axle shaft as needed in order to align the rear axle shaft bolt holes with the hub assembly.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the rear axle shaft bolts.

Tighten
Tighten the rear axle shaft bolts to 143 N·m (105 lb ft).

4. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection.
5. Remove the wheel blocks.
6. Release the parking brake.