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For 1990-2009 cars only

Differential Carrier Assembly Disassemble 8.25 Inch Axle

Tools Required

    • J 22912-B Split-Plate Bearing Puller
    • J 2619-01 Slide Hammer
    • J 29369-1 Bushing and Bearing Remover
    • J 33791 Carrier Bushing Remover/Installer
    • J 34011 Pilot Bearing Remover
    • J 36598 Holding Fixture
    • J 36599-A Side Bearing Nut Wrench
    • J 36616 Axle Mount Bushing Remover/Installer
    • J 45765 Pinion Remover
    • J-45858 Front Axle Bearing Race Remover/Installer - 8.25 Inch Axle
    • J 8614-01 Flange and Pulley Holding Tool

Inspection Procedure

Perform the following before disassembling the axle:

  1. Remove the drain plug from the axle.
  2. Drain the axle lubricant.
  3. Inspect the oil and the case for metal chips.
  4. Determine the source of the metal chips, such as a broken gear or bearing cage.

  5. 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


    Object Number: 893247  Size: SH
  1. Remove the upper differential carrier assembly bushing by performing the following steps:
  2. 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.

    Object Number: 892847  Size: SH
  3. Remove the lower differential carrier assembly bushing by performing the following steps:
  4. 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.

    Object Number: 893264  Size: SH
  5. Remove the front axle actuator, S4WD axle only.
  6. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift, F4WD axle only.
  7. Remove the inner axle shaft, F4WD axle only.
  8. Remove the inner axle shaft housing to differential carrier assembly bolts.
  9. Remove the inner axle shaft housing, F4WD axle only.

  10. Object Number: 893259  Size: SH
  11. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly, S4WD axle only.

  12. Object Number: 695177  Size: SH
  13. Remove the following components from the inner axle shaft housing:
  14. 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).

    Object Number: 834245  Size: SH
  15. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
  16. 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.
    10.3. Install the J 2619-01  (2) to the J 29369-1  (1).
    10.4. Remove the inner axle shaft bearing and the seal using the J 2619-01 .

    Object Number: 1332786  Size: SH
  17. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
  18. 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.
    11.3. Install the J 2619-01  (2) to the J 29369-1 .
    11.4. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01 .
  19. Remove the differential carrier assembly from the vise.
  20. Remove the front drive axle clutch shaft, S4WD axle only.

  21. Object Number: 680254  Size: SH
  22. Use the J 34011 in order to remove the clutch shaft bearing, S4WD axle only.

  23. Object Number: 847064  Size: SH
  24. Remove the vent connector.

  25. Object Number: 1332740  Size: SH
  26. Remove the differential carrier assembly bolts.

  27. Object Number: 1332738  Size: SH
  28. 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.
  29. Remove the differential case assembly.
  30. 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.


    Object Number: 680101  Size: SH
  31. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following, S4WD axle - both sides, F4WD axle - left side:
  32. 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.
  33. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift, S4WD axle - both sides, F4WD axle - left side.

  34. Object Number: 664065  Size: SH
  35. Install the J 8614-01 as shown.
  36. Remove the pinion nut while holding the J 8614-01 .

  37. Remove the washer.

  38. Object Number: 664070  Size: SH
  39. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
  40. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
  41. 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.
  42. Install the J 36598 into a vise.

  43. Object Number: 680106  Size: SH
  44. Install the left differential carrier case half onto the J 36598 and the J 36598-6.
  45. 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:
  46. • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer

    Object Number: 890234  Size: SH
  47. Install the J 36598-5 (3) behind the inner pinion bearing cup.
  48. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3) until fully seated.
  49. 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.

  50. Object Number: 680114  Size: SH
  51. Install the J 36598-5 (2) behind the outer pinion bearing cup.
  52. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2).
  53. While holding the forcing screw of the J 36598 , turn the handle of the J 36598 clockwise in order to remove the following components:
  54. • The pinion oil seal
    • The pinion outer bearing
    • The pinion outer bearing cup

    Object Number: 1486597  Size: SH
  55. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown.
  56. Turn the forcing screw of the J 45765 clockwise to remove the following components from the left side differential carrier case half:
  57. • The drive pinion gear
    • The pinion gear selectable shim
    • The inner pinion bearing
    • The collapsible spacer
  58. Remove the drive pinion seal using a suitable seal remover.
  59. Remove the outer pinion bearing from the differential carrier case half.

  60. Object Number: 1486598  Size: SH
  61. Install the J 45858-4 over the inner pinion bearing cup.

  62. Object Number: 1486602  Size: SH
  63. Install the forcing screw (1) of the J 45858 into the J 45858-4 (2).
  64. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.

  65. Object Number: 1486596  Size: SH
  66. 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.

  67. Object Number: 1486591  Size: SH
  68. Install the J 45858-5 into the pinion bearing bore behind the outer pinion bearing cup.
  69. 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.

  70. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
  71. Remove the collapsible spacer from the drive pinion.

  72. Object Number: 680110  Size: SH
  73. Install the J 22912-B between the pinion bearing and the drive pinion.
  74. Remove the inner pinion bearing using the J 22912-B and a hydraulic press.
  75. Remove the pinion gear selectable shim.