Tools Required

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the differential. Refer to Differential Replacement .
3. Remove the drive pinion from the axle. Refer to Drive Pinion and Ring Gear Replacement .



4. For the 8.0 inch axle, press off the pinion bearing using the J 22912-B .



5. For the 8.6 inch axle, install the J 45871  (1) around the pinion bearing and the J 22912-B  (2) in the inverted position around the J 45871 .
6. Press the bearing off of the pinion using the J 45871 and the J 22912-B .
7. Remove the shim.



8. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.



9. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.

1. Install the outer pinion bearing cup using the J 7817 , 8.0 inch axle, or the J 8611-01 , 8.6 inch axle (1), and the J 8092  (2).



2. Install the inner pinion bearing cup using the J 8608  (2) and the J 8092  (1).
3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment .



4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J 24433 .

Press the bearing on until the cone seats on the pinion shim.

6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
8. Install the pinion into the axle housing.
9. Install the outer pinion bearing onto the pinion.



10. Install a new pinion oil seal using theJ 33782 , 8.0 inch axle, or the J 38694 , 8.6 inch axle.
11. Apply sealant to the splines of the pinion yoke.



12. Install the pinion yoke.

Align the marks made during removal.

13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
14. Install the washer and a new pinion nut.



15. Install the J 8614-01 onto the pinion yoke as shown.

Notice: Refer to Fastener Notice in the Preface section.

Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

16. Tighten the pinion nut while holding the J 8614-01 .

Tighten
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.




17. Measure the rotating torque of the pinion using an inch-pound torque wrench.

Specification
The rotating torque of the pinion should be 1.0-2.3 N·m (10-20 lb in) for used bearings, or 1.7-3.4 N·m (15-30 lb in) for new bearings.

18. If the rotating torque measurement is below 1.0 N·m (10 lb in) for used bearings, or 1.7 N·m (15 lb in) for new bearings, continue to tighten the pinion nut.

Tighten
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.3 N·m (10-20 lb in) for used bearings, or 1.7-3.4 N·m (15-30 lb in) for new bearings.

19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.

20. Install the differential. Refer to Differential Replacement .
21. Fill the axle with axle lubricant lubricant. Use the proper fluid. Refer to Front Axle Lubricant Replacement .
22. Lower the vehicle.