Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Lock Tab)

Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Lock Tab)

Special Tools
* J 8092 - Universal Driver Handle - 3/4 in - 10
* J 33842 - Output Pilot Bearing 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, 9.25 inch axle - right side.




3. Install the differential adjuster nut lock, 9.25 inch axle - left side.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the differential adjuster nut lock bolt and tighten to 20 Nm (15 lb ft).
5. Using the correct fluid, lubricate the clutch shaft pilot bearing with axle lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications).




6. Using the J 33842 - installer , install the clutch shaft pilot bearing.




7. Install the clutch shaft to the differential carrier case half.




8. If servicing the 9.25 inch axle, install the vent hose connector and tighten to 28 Nm (21 lb ft).




9. 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).




10. Using the J 45225 - installer (1) and the J 8092 - handle (2), install the new left side axle shaft seal.
11. Install the new left side inner axle shaft retainer ring.




12. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear.
13. Hold 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.
14. 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.
15. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.




16. Install the inner axle shaft housing into a vise.
17. Clamp only on the mounting flange of the inner axle shaft housing.
18. Using the J 36609 - installer (1) and the J 8092 - handle (2), install the bearing.




19. Using the J 45225 - installer (1) and the J 8092 - handle (2), install the new right side inner axle shaft seal.




20. Using a soft faced mallet, install the inner axle shaft (1).

Note:
* Use chassis grease in order to hold the thrust washer in place.
* Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.

21. Install the thrust washer (with tabs) (5).
22. Install the thrust washer (without tabs) (6).
23. Install the new retainer ring (7) onto the inner axle shaft (1).
24. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment (Adjustments).
25. Install the clutch gear shim (9).
26. Install the clutch sleeve (8).
27. Install the clutch fork assembly (11).
28. Install the clutch fork inner spring (10).
29. Install the inner axle housing gasket.

Note: The following service procedure is for the 9.25 inch axle ONLY.

30. Using the correct sealant, apply sealant to the inner shaft housing to differential carrier sealing surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications).




31. Install the inner shaft housing to the differential carrier assembly case.
32. If servicing the 8.25 inch axle, install the inner shaft housing bolts and tighten to 73 Nm (54 lb ft).
33. If servicing the 9.25 inch axle, install the inner shaft housing bolts and tighten to 40 Nm (30 lb ft).
34. Install the drain plug and the washer.
35. Install the fill plug and the washer and tighten to 33 Nm (24 lb ft).




36. Apply sealant to the threads of the front axle actuator. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications).
37. Install the front drive axle actuator and tighten to 20 Nm (15 lb ft).





Note: The following service procedures are for the 9.25 inch axle ONLY.

38. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5).
39. Holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.





Note: The following service procedures are for the 9.25 inch axle ONLY.

40. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
41. Holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
42. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (Service and Repair).