Differential Overhaul (8.6, 9.5LD Inch Axles)

Differential Overhaul (8.6, 9.5LD Inch Axles)

Disassembly Procedure

1. Remove the differential ring gear. Refer to Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles)Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)

2. Remove the differential side bearings. Refer to Differential Bearing Replacement Differential Bearing Replacement.





3. Remove and discard the differential pinion gear shaft lock bolt (2). Replace with NEW only.

4. Remove the differential pinion gear shaft (1).

Note:
Mark the top and bottom differential pinion gears and thrust washers, if reusing.

5. Roll the differential pinion gears (7) and the thrust washers (6) out of the differential case 2).

Note:
Mark the left and right side differential side gears and the thrust washers, if reusing.

6. Remove the differential side gears (5) and the thrust washers (4).

Assembly Procedure

1. Lubricate the pinion and side gears using the proper axle lubricant. Refer to Fluid and Lubricant Recommendations Maintenance.

2. Install the differential side gear thrust washers (4) to the differential side gears (5).





Note:
If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.

3. Install the differential side gears (5) and thrust washers (4) into the differential case (2).

4. Position one pinion gear (7) between the differential side gears (5).

5. Position the second pinion gear (7) between the differential side gears (5).

6. Rotate the differential side gears (5) until the pinion gears (7) are directly opposite the opening in the differential case (2).

7. Rotate the pinion gears (7) toward the differential opening.

8. Install the thrust washers (6) on the pinion gears (5).

9. Rotate the pinion gears until they are aligned with the holes in the differential case (2) for the pinion shaft (1).

10. Install the pinion shaft (1).

Caution:
Refer to Fastener Caution Fastener Caution.

11. Install the NEW differential pinion gear shaft locking bolt and tighten to.

* For the 8.6 inch axle, tighten the pinion bolt to 36 Nm (27 lb ft).

* For the 9.5 inch axle, tighten the pinion bolt to 50 Nm (37 lb ft).

12. Install the differential ring gear to the differential case. Refer to Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles)Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle).

13. Install the differential side bearings. Refer to Differential Bearing Replacement Differential Bearing Replacement.