8.25 S4WD and 9.25 Axles

Differential Carrier Assembly - Disassemble (8.25 S4WD and 9.25 Axles)

^ Tools Required
- J 22912-01 Pinion Bearing Remover
- J 2619-01 Slide Hammer
- J 29369-1 Bushing and Bearing Remover
- J 29369-2 Bushing and Bearing Remover
- J 34011 Pilot Bearing Remover
- J 36598 Holding Fixture and Pinion Service Tool
- J 36599 Side Bearing Nut Wrench
- J 36616 Axle Mount Bushing Remover/Installer
- J 36615 Side Bearing Nut Wrench, 9.25 inch axle
- J 8614-01 Pinion Flange Holder

Inspection Procedure
Perform the following before disassembling the axle:
1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips.
Determine the source of the metal chips, such as a broken gear or bearing cage.
5. Check the ring gear backlash.
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure





1. Remove the front axle actuator.
2. Remove the inner axle shaft housing to differential carrier assembly bolts.





3. Remove the inner axle housing with the inner axle shaft.





4. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
4.1. The clutch fork inner spring (10)
4.2. The clutch fork shaft assembly components (14, 13, 1 2, 11)
4.3. The clutch shaft shim (9)
4.4. The clutch shaft sleeve (8)
4.5. The front drive axle clutch gear (6) by doing the following:
4.5.1. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
4.5.2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
4.6. Remove the thrust washer (5).
4.7. Disassemble the following components from the clutch fork shaft (14):
4.7.1. The clutch fork shaft retainer ring (11)
4.7.2. The clutch fork (12)
4.7.3. The clutch fork outer spring (13)





5. For the 9.25 inch axle, remove the following components from the inner axle shaft housing (4):
5.1. The clutch fork inner spring (10)
5.2. The clutch fork assembly components (14, 13, 12, 11)
5.3. The clutch shaft shim (9)
5.4. The clutch shaft sleeve (8)
5.5. The retainer ring (7)
5.6. The thrust washers (5, 6)
5.7. Disassemble the following components from the clutch fork shaft (14):
5.7.1. The clutch fork shaft retainer ring (11)
5.7.2. The clutch fork (12)
5.7.3. The clutch fork outer spring (13)





6. Remove the inner axle shaft (2).





7. Install the inner axle shaft housing into a vise.
Clamp only on the mounting flange of the inner axle shaft housing.
8. Install the J29369-1, 8.25 inch axle, or the J29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
9. Install the J2619-01 (2) to the J29369-1 or the J 29369-2 (1).
10. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J2619-01.
11. Remove the front drive axle clutch shaft.





12. Use the J 34011 in order to remove the clutch shaft bearing.
13. Place the differential carrier assembly into a vise.
Clamp only on the mounting flange of the differential carrier assembly case.
14. Remove the inner axle shaft using a hammer and a brass drift.
15. Install the J29369-1, 8.25 inch axle, or the J29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
16. Install the J2619-01 to the J29369-1 or the J 29369-2.
17. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J2619-01.
18. Remove the vent plug.
19. Remove the differential carrier assembly bolts.





20. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case lugs with a plastic hammer.
21. Remove the differential case assembly.
Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, 8.25 inch axle - both sides, 9.25 inch axle - right side.





22. Remove the differential bearing adjuster nut lock bolt and the lock from the differential bearing adjuster nut, 9.25 inch axle - left side.





23. Remove the differential bearing adjuster by doing the following, 8.25 inch axle - both sides, 9.25 inch axle - right side:
23.1. Install the J 36599 onto the differential bearing adjuster nut.
23.2. Turn the J 36599 clockwise in order to push the bearing cup out of the bore.





24. For the 9.25 inch axle - left side, remove the differential bearing adjuster by doing the following:
24.1. Install the J 36615 onto the differential bearing adjuster nut as shown.
24.2. Turn the J 36615 counterclockwise in order to remove the differential bearing adjuster nut and the O-ring.





25. Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01.
26. Remove the washer.





27. Install the J 8614-2 (2) and the J 86103 (3) into the J 8614-01 (1) as shown.
28. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J8614-01 (1).
29. Remove the dust deflector from the pinion yoke by doing the following:
29.1. Tap the deflector off the pinion yoke.
29.2. Clean up the stake points on the pinion yoke.





30. Mount the left carrier case in the J 36598 and the J 36598-6 or the J 36598.
31. While holding the nut of the J 36598, turn the bolt of the J 36598 clockwise in order to remove the pinion with the following components:
^ The pinion gear selectable shim
^ The inner pinion bearing
^ The collapsible spacer
32. Remove the collapsible spacer from the pinion.





33. Remove the inner pinion bearing by installing the J22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
34. Remove the pinion gear selectable shim.





35. Install the J 36598-5 (2) onto the J 36598 (1) behind the outer bearing cup.
36. While holding the handle of the J 36598, turn the bolt of the J 36598 counterclockwise in order to remove the following components:
^ The pinion oil seal
^ The pinion outer bearing
^ The pinion outer bearing cup





37. Install the J 36598-5 (2) onto the J 36598 (1).
38. Place the J 36598-5 on the inside surface of the inner bearing cup.
39. While holding the nut on the J 36598, turn the bolt of the J 36598 clockwise and press the inner bearing cup out from the carrier case.





40. Install the J 36616 onto the differential carrier assembly bushings.
41. Remove the bushings using the J 36616.