Differential Carrier Assembly Final Assembly (8.25 F4WD Axle)
Differential Carrier Assembly Final Assembly (8.25 F4WD Axle)
Special Tools
* J 8092 - Universal Driver Handle - 3/4 in - 10
* J 33791 - Carrier Bushing Remover/Installer
* J 36609 - Axle Tube Bearing Installer
* J 36616 - Axle Mount Bushing Remover/Installer
* J 45225 - Axle Seal Installer
1. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
2. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves.
3. Install the differential carrier assembly into a vise.
4. Inspect the alignment mark between the differential bearing adjuster and the differential carrier assembly case. If the line between the differential bearing adjuster and the differential carrier assembly case is not aligned, re-align the 2 components as necessary.
5. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 9.25 inch axle - right side.
6. Install the differential adjuster nut lock, 9.25 inch axle - left side.
Caution: Refer to Fastener Caution (Fastener Caution).
7. Install the differential adjuster nut lock bolt and tighten to 20 Nm (15 lb ft).
8. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers (Front Drive Axle).
9. Using the J 33842 - installer, install the clutch shaft pilot bearing.
10. Install the clutch shaft to the differential carrier case half.
11. If servicing the 9.25 inch axle, install the vent hose connector and tighten to 28 Nm (21 lb ft).
12. If servicing the 8.25 inch axle, install the vent hose (1) to the vent connector (2) and tighten to 20 Nm (15 lb ft).
13. Using the J 45225 - installer (1) and the J 8092 - handle (2), install the new left side axle shaft seal.
14. Install the new left side inner axle shaft retainer ring.
15. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
16. Holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear.
17. Using a soft-faced mallet, drive the inner shaft into the differential case side gear until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear.
18. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
Note: Clamp only on the mounting flange of the inner axle shaft housing.
19. Install the inner axle shaft housing into a vise.
20. Using the J 36609 - installer (1) and the J 8092 - handle (2), install the bearing with the square shoulder.
21. Using the J 45225 - Axle Seal
Installer (1) and the J 8092 - handle (2), install the new inner shaft seal.
22. Install the differential axle housing gasket.
23. Install the inner shaft housing to the differential carrier assembly case.
Caution: Refer to Fastener Caution (Fastener Caution).
24. Install the inner shaft housing bolts and tighten to 40 Nm (30 lb ft).
25. Install the inner shaft (2) into the inner axle shaft housing (1) until the inner shaft is seated against the differential side gear.
26. While holding the inner shaft (2) against the differential side gear, turn the inner shaft (2) in order to align the splines of the inner shaft (2) with the splines on the differential side gear.
27. Drive the inner shaft (2) into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft (2) is fully seated within the groove in the differential case side gear.
28. Pull back on the inner shaft (2) to ensure that the inner shaft is properly retained in the differential case side gear.
29. Install the drain plug and the washer.
30. Install the fill plug and the washer and tighten to 33 Nm (24 lb ft).
31. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (9.25 inch) (Service and Repair)Differential Carrier Assembly Replacement (8.25 inch) (Service and Repair).