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)
Special Tools
* J 22536 - Pinion Remover (8.6, 9.5/9.5LD Inch Axles)
* J 44421 - Pinion Remover (11.5 Inch Axle)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)Differential Replacement (10.5 Inch, 11.5 Inch Axle) Differential Replacement (10.5 Inch, 11.5 Inch Axle).
3. Remove the differential pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement Rear Drive Axle.
Note:
* Ensure that the J 22536 - remover and the J 44421 - remover are firmly seated on the differential pinion gear.
* When removing the differential pinion gear, DO NOT let the differential pinion gear fall out of the axle housing.
4. Using the J 22536 - remover or the J 44421 - remover and a hammer, remove the differential pinion gear from the axle housing.
5. Remove and discard the collapsible spacer from the pinion.
6. Remove the differential pinion bearings and the cups. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle)Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle).
Note:
The differential ring gear bolts on the 8.6 inch and the 9.5/9.5LD inch axles have left-hand threads. The differential ring gear bolts on the 11.5 inch axle have right-hand threads.
7. Remove and discard the differential gear bolts. Replace with NEW only.
Caution:
Refer to Ring Gear Removal Caution Ring Gear Removal Caution.
Note:
It maybe necessary to use a brass drift and a hammer to remove the differential ring gear from the differential case.
8. Remove the differential ring gear from the differential case.
Installation Procedure
Note:
The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
1. Install the differential ring gear to the differential case.
Caution:
Refer to Fastener Caution Fastener Caution.
Note:
* The ring gear bolts on the 8.6 inch and the 9.5/9.5LD inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads.
* Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
* Tighten the differential ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
2. Install the NEW differential ring gear bolts and tighten in sequence to 120 Nm (89 lb ft). for the 8.6 inch axle, 140 Nm (103 lb ft) for the 9.5/9.5LD inch axles and 237 Nm (175 lb ft). for the 11.5 inch axle.
3. Install the pinion bearing cups. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle)Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle).
4. Determine and install the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment (10.5 Inch Axle) Pinion Depth Adjustment (10.5 Inch Axle)Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles).
5. Install the inner pinion bearing to the pinion. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle)Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle).
6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations Maintenance.
8. Install the outer differential pinion bearing, the NEW differential pinion oil seal and the differential yoke into the axle housing. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement Rear Drive Axle.
9. Install the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)Differential Replacement (10.5 Inch, 11.5 Inch Axle) Differential Replacement (10.5 Inch, 11.5 Inch Axle).
10. Fill the axle with lubricant. Use the proper fluid. Refer to Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle)Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle)Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle)Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle).
11. Remove the support and lower the vehicle.