Differential Replacement (9.75 Inch Axle)

Differential Replacement (9.75 Inch Axle)

^ Tools Required
- J 24385-C Axle Housing Spreader
- J 2-5025 Guide Pins
- J 34178 Spreader Gage Adapter
- J 8001 Dial Indicator Set

Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the axle shafts.
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 2-5025 (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.

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.

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

9. Remove the J 2-5025-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: Refer to Differential Case Removal Caution in Service Precautions.

11. Remove the bearing caps.

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. Remove the differential assembly.
13. Remove the J 24385-C.
14. Remove the ring gear.

Installation Procedure
1. Install the ring gear.
4. Install the J 24385-C onto the axle housing.





5. Install the J 2-5025-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.

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.

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

9. Remove the J 2-5025-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.

12. Install the bearing caps.

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


13. Install the bearing cap bolts.
^ Tighten the bearing cap bolts to 109 Nm (80 ft. lbs.).

Notice: Refer to Service Precautions.

14. Install the axle shafts.
15. Fill the axle with the proper lubricant.
16. Lower the vehicle.