Differential Replacement Dana 286 Axle

Tools Required

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
3. Loosen the bearing cap bolts.

Do not remove the bearing cap bolts at this time.




4. Install the J 24385-C onto the axle housing as shown.



5. Install the J 25025  (2), the J 8001-1 and the J 8001-2  (1), the J 34178  (3), and the J 8001-3 and the J 8001-4  (4) onto the axle housing as shown.
6. Preload the dial of the J 8001-3 by pushing the J 8001-3 against the edge of the J 24385-C until the needle of the J 8001-3 has moved approximately 3/4 of a turn clockwise.
7. Rotate the indicator housing to align the indicator needle of the J 8001-3 and the dial indicator face to ZERO.

Notice: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.

8. Spread the axle housing by turning the clevis screw of the J 24385-C clockwise while observing the J 8001 .

Spread the housing just enough to remove the differential assembly.

9. Remove the J 25025-B , the J 8001-1 , the J 8001-2 , the J 34178 , the J 8001-3 and the J 8001-4 from the axle housing.
10. Remove the bearing cap bolts.

Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Important: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.

11. Remove the bearing caps.
12. Remove the differential assembly.
13. Remove the J 24385-C .
14. Remove the ring gear. Refer to Drive Pinion and Ring Gear Replacement .
15. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .

1. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
2. Install the ring gear. Refer to Drive Pinion and Ring Gear Replacement .
3. Determine the differential side bearing shim pack size and side bearing preload for the differential assembly. Refer to Differential Carrier Bearing Preload Adjustment .
4. Install the J 24385-C onto the axle housing.



5. Install the J 25025-B  (4), the J 8001-1 and the J 8001-2  (5, 1), the J 34178  (2), and the J 8001-3 and the J 8001-4  (3) onto the axle housing as shown.
6. Preload the dial of the J 8001-3 by pushing the J 8001-3 against the edge of the J 24385-C until the needle of the J 8001-3 has moved approximately 3/4 of a turn clockwise.
7. Rotate the indicator housing to align the indicator needle of the J 8001-3 and the dial indicator face to ZERO.

Notice: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing may result in component damage.

8. Spread the axle housing by turning the clevis screw of the J 24385-C clockwise while observing the J 8001 .

Spread the housing just enough to install the differential assembly.

9. Remove the J 25025-B , the J 8001-1 , the J 8001-2 , the J 34178 , the J 8001-3 and the J 8001-4 from the axle housing.
10. Install the differential assembly.
11. Remove the J 24385-C .

Important: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.

12. Install the bearing caps.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

13. Install the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 108 N·m (80 lb ft).

14. Install the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
15. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement .
16. Lower the vehicle.