Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)

Drive Pinion and Ring Gear Replacement (8.6, 9.5LD Inch Axles)

Special Tools

J 22536 - Pinion Remover

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the differential assembly. Refer to Differential Replacement (10.5 Inch Axle) (Differential Replacement (10.5 Inch Axle))Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)).
3. Remove the pinion flange/yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (Service and Repair).





Note: DO NOT let the drive pinion fall out of the rear axle housing.

4. Using the J 22536 - remover and a hammer, remove the drive pinion from the housing.




5. Remove and discard the collapsible spacer from the pinion.
6. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement (10.5 Inch Axle) (Drive Pinion Bearings Replacement (10.5 Inch Axle))Drive Pinion Bearings Replacement (8.6 Inch Axle) (Drive Pinion Bearings Replacement (8.6 Inch Axle)).





Note: The ring gear bolts have left-hand threads.

7. Remove and discard the ring gear bolts. Use NEW ring gear bolts ONLY.





Caution: Refer to Ring Gear Removal Caution (Ring Gear Removal Caution).

8. Using a brass drift, remove the ring gear from the differential.

Installation Procedure

Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.




1. Install the ring gear to the differential case.





Note: The ring gear bolts have left-hand threads. Hand start each ring gear bolt so as not to cross thread the ring gear bolts or the differential carrier.

2.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Use hand tool ONLY when tightening the NEW ring gear bolts.

3. Install the NEW ring gear bolts and tighten to 120 Nm(89 lb ft). in a criss cross pattern to draw and seat the ring gear and the differential carrier.
4. Install the selective shim onto the pinion. Refer to Pinion Depth Adjustment (8.6 Inch Axle) (Pinion Depth Adjustment (8.6 Inch Axle))Pinion Depth Adjustment (9.5LD Inch Axle) (Pinion Depth Adjustment (9.5LD Inch Axle))Pinion Depth Adjustment (10.5 Inch Axle) (Pinion Depth Adjustment (10.5 Inch Axle))
5. Install the inner pinion bearing to the pinion. Refer to Drive Pinion Bearings Replacement (10.5 Inch Axle) (Drive Pinion Bearings Replacement (10.5 Inch Axle))Drive Pinion Bearings Replacement (8.6 Inch Axle) (Drive Pinion Bearings Replacement (8.6 Inch Axle)).
6. Install a NEW collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (Specifications).
8. Install the outer pinion bearing into the axle housing.
9. Install the pinion drive gear into the axle housing.
10. Install the drive pinion flange/yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (Service and Repair).
11. Install the differential assembly. Refer to Differential Replacement (10.5 Inch Axle) (Differential Replacement (10.5 Inch Axle))Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)).
12. Fill the axle with lubricant. Use the proper fluid. Refer to Differential Oil Replacement (10.5 Inch Axle) (Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (Differential Oil Replacement (9.5LD Inch Axle)).
13. Remove the support and lower the vehicle.