8.6, 9.5 Inch Axle (without RPO JL4)

Rear Axle Shaft Replacement (8.6 Inch Axle W/O JL4, 9.5 Inch Axle)

Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the tire and wheel assembly.
3. Remove the brake caliper.
4. Remove the rear cover and the gasket.





5. Remove the pinion shaft locking bolt.





6. On axles without a locking differential, remove the pinion shaft.





7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.





8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2).





9. Push the flange of the axle shaft (1) toward the differential.
10. Remove the C-lock (4) from the button end of the axle shaft (1).

Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will mis-align the gears. Mis-aligning the gears will make the assembly difficult.

11. Remove the axle shaft (1) from the housing (5).

Installation Procedure

Important: Carefully insert the axle shaft in order to not damage the seal.





1. Install the axle shaft (1) into the rear axle housing (5).
2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
4. On axles with a locking differential, keep the pinion shaft partially withdrawn.





5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
6. Pull the shaft flange outward in order to seat the lock in the differential gear.





7. Align the hole in the pinion shaft with the bolt hole in the differential case.

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the new pinion shaft locking bolt.
Tighten the pinion shaft locking bolt to 34 Nm (25 lb ft).
9. Install the rear cover and the gasket.
10. Install the brake caliper.
11. Install the tire and wheel assembly.
12. Fill the rear axle. Use the proper fluid.
13. Lower the vehicle.