Differential Carrier Assembly Disassemble 8.25 Inch Axle
Tools Required
• | J 33791 Carrier Bushing
Remover/Installer |
• | J 36616 Axle Mount
Bushing Remover/Installer |
• | J-45858 Front Axle
Bearing Race Remover/Installer - 8.25 Inch Axle |
Inspection Procedure
Perform the following before disassembling the axle:
- Remove the drain plug from the axle.
- Drain the axle lubricant.
- Inspect the oil and the case for metal chips.
Determine the source of the metal chips, such as a broken gear or bearing cage.
- Check the ring gear backlash. Refer to
Backlash Inspection and Adjustment
.
This information can be used in order to determine the cause of the axle problem.
The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.
Disassembly Procedure
- Remove the upper differential carrier assembly bushing by performing the following
steps:
1.1. | Install the J 36616-2 (1), the J 33791-1 (2),
the thrust bearing (3), the J 21474-18 (4), and the forcing screw
as shown. |
1.2. | Remove the upper differential carrier assembly bushing by holding the
forcing screw and tightening the J 21474-18. |
- Remove the lower differential carrier assembly bushing by performing the following
steps:
2.1. | Install the J 21474-18 (1), the thrust bearing (2),
the J 33791-1 (3), the J 36616-2 (4), and the forcing
screw as shown. |
2.2. | Remove the lower differential carrier assembly bushing by holding the
forcing screw and tightening the J 21474-18. |
- Remove the front axle actuator, S4WD axle
only.
- Disconnect the right side inner axle shaft from the differential side
gear using a hammer and a brass drift, F4WD axle only.
- Remove the inner axle shaft, F4WD axle only.
- Remove the inner axle shaft housing to differential carrier assembly bolts.
- Remove the inner axle shaft housing, F4WD axle only.
- Carefully remove the inner axle shaft housing
with the inner axle shaft and clutch fork components from the differential carrier
assembly, S4WD axle only.
- Remove the following components from the
inner axle shaft housing:
9.1. | The clutch fork inner spring (10) |
9.2. | The clutch fork assembly (11, 12, 13, 14) |
9.3. | The clutch shaft shim (9) |
9.4. | The clutch shaft sleeve (8) |
9.5. | The front drive axle clutch gear (6) by doing the following: |
9.5.1. | Clamp the inner axle shaft housing (4) in a vise. |
Clamp only on the mounting flange.
9.5.2. | Strike the inside surface of the shaft (1) flange with a hammer
and a brass drift in order to dislodge the front drive axle clutch gear (6)
from the inner axle shaft (1). |
9.6. | Remove the thrust washer (5). |
- Remove the inner axle shaft bearing and
the inner axle shaft seal by performing the following steps:
10.1. | Install the inner axle shaft housing into a vise. |
Clamp only on the mounting flange of the inner axle shaft housing.
10.2. | Install the J 29369-1
(1)
behind the inner axle shaft bearing. |
10.4. | Remove the inner axle shaft bearing and the seal using the J 2619-01
. |
- Remove the inner axle shaft bearing and
the inner axle shaft seal by performing the following steps:
11.1. | Place the differential carrier assembly into a vise. |
Clamp only on the mounting flange of the differential carrier assembly case.
11.2. | Install the J 29369-1
(1)
behind the inner axle shaft bearing. |
11.4. | Remove the inner axle shaft bearing and the inner axle shaft seal using
the J 2619-01
. |
- Remove the differential carrier assembly from the vise.
- Remove the front drive axle clutch shaft, S4WD axle only.
- Use
the J 34011
in order to remove
the clutch shaft bearing, S4WD axle only.
- Remove the vent connector.
- Remove the differential carrier assembly
bolts.
- Separate the left carrier case half from the right carrier case half by tapping
on the on the carrier case with a hammer and a brass drift.
- Remove the differential case assembly.
Disconnect the differential bearing adjuster nut locks from the differential
bearing adjuster nut by prying up on the locks, S4WD axle - both sides, F4WD
axle - left side.
- Remove
the differential bearing adjuster nuts and the differential bearing cups by doing
the following, S4WD axle - both sides, F4WD axle - left side:
19.1. | Install the J 36599-A
onto
the differential bearing adjuster nut. |
19.2. | Turn the J 36599-A
clockwise
in order to push the differential bearing adjuster nut and the bearing cup out of
the bore. |
- Remove the differential bearing adjuster nut sleeves using a hammer and
brass drift, S4WD axle - both sides, F4WD axle - left side.
- Install the J 8614-01
as shown.
Remove the pinion nut while holding the J 8614-01
.
- Remove the washer.
- Install the J 8614-2 (2)
and the J 8614-3 (3) into the J 8614-01
(1) as shown.
- Remove the pinion yoke by turning the J 8614-3 (3) clockwise
while holding the J 8614-01
(1).
- The steps below explain how to remove the drive pinion and pinion bearing
cups using the J 36598
or the J 45765
and the J-45858
. Follow the appropriate steps depending on what
tool is available.
- Install the J 36598
into
a vise.
- Install the left differential carrier case
half onto the J 36598
and the
J 36598-6.
- While holding the forcing screw of the J 36598
, turn the handle of the J 36598
counterclockwise in order to remove the pinion with the following
components:
• | The pinion gear selectable shim |
• | The inner pinion bearing |
- Install the J 36598-5 (3) behind the inner pinion bearing cup.
- Thread the forcing screw of the J 36598
(1) onto the J 36598-5 (3) until fully seated.
- While holding the forcing screw of the J 36598
(1), turn the handle of the J 36598
(2) counterclockwise and press the inner bearing cup out from
the differential carrier case.
- Install the J 36598-5 (2) behind the outer pinion bearing cup.
- Install the forcing screw of the J 36598
(1) to the J 36598-5 (2).
- While holding the forcing screw of the J 36598
, turn the handle of the J 36598
clockwise in order to remove the following components:
• | The pinion outer bearing |
• | The pinion outer bearing cup |
- Install the J 45765
to the left side differential carrier case half over the drive pinion
as shown.
- Turn the forcing screw of the J 45765
clockwise to remove the following components from the left side differential
carrier case half:
• | The pinion gear selectable shim |
• | The inner pinion bearing |
- Remove the drive pinion seal using a suitable seal remover.
- Remove the outer pinion bearing from the differential carrier case half.
- Install the J 45858-4 over the inner
pinion bearing cup.
- Install the forcing screw (1) of
the J 45858 into the J 45858-4 (2).
- Drive out the inner pinion bearing cup by pounding on the forcing screw
with a hammer.
- Install the J 45858-3 (3),
the thrust bearing and the washer (2), and the forcing screw (1) over
the outer pinion bearing cup bore.
- Install the J 45858-5 into the pinion
bearing bore behind the outer pinion bearing cup.
Slowly turn the forcing screw clockwise until the J 45858-5 is evenly
seated behind the outer pinion bearing cup bore and the J 45858-3 is evenly
seated over the outer pinion bearing cup bore.
- Remove the outer pinion bearing cup by turning the forcing screw clockwise.
- Remove the collapsible spacer from the drive pinion.
- Install the J 22912-B
between the pinion bearing and the drive pinion.
- Remove the inner pinion bearing using the J 22912-B
and a hydraulic press.
- Remove the pinion gear selectable shim.