Disassembly of the Rear Axle

Part 1 Of 2:

Part 2 Of 2:

- Tools Required:
- J 8107-3 Differential Side Bearing Puller Plug
- J 22813-01 Axle Bearing Remover
- J 2619-01 Slide Hammer
- J 22888 Differential Side Bearing Remover
- J 8614-01 Pinion Flange Remover
- J 22912-01 Rear Pinion Bearing Cone Remover

REMOVE OR DISCONNECT
- Place the axle in a suitable support.
- Drain the lubricant.

1. The cover bolts and cover.
- Refer to CHECKING THE AXLE BEFORE DISASSEMBLY.





2. Pinion shaft lock bolt.
3. Pinion shaft.
4. "C" clip from the end of the axle shaft.
- Push the axle shaft in towards the center of the differential case.
5. Axle shaft from the axle housing.
6. Oil seal using a seals removal tool behind the seal lip.
- Be careful not to damage the housing.
7. Bearing using J 2619-01 and J 22813-01.
- The tangs of the tool should engage the bearing outer race.
8. Pinion and side gears.
A. Roll the pinion gears out of the case with the pinion thrust washer.
B. Remove the side gears and the side gear thrust washers. Mark the gears and the differential case as left and right.
9. Lock bolt.
10. Lock.
- Loosen the adjusting nut.
11. Bearing cap bolts.
12. Bearing caps.
- Mark the caps and the housing as left and right.

NOTICE: When prying the differential case out of the axle housing, be careful not to damage the cover gasket surface. The differential case must be supported when it is being removed to prevent the case from falling and damaging the case.

13. Differential case.





- Pry the case from the axle housing at the differential "window".
14. Bearing outer races, shims, and adjusting nut.
- Mark the races and the shims as left and right, and place them with the bearing caps.





15. Differential side bearings using J 8107-3 and J 22888-20.
- The jaws of J 22888-20 must pull from beneath the bearing cone and not the cage. Use the slots provided for this purpose.
16. Ring gear bolts.
- Ring gear bolts have left-hand threads.

NOTICE: Do not pry the ring gear from the case. This will damage the ring gear and the differential case.

17. Ring gear from the differential.
- Drive the ring gear off with a brass drift if necessary.

Inspect





- Drive pinion bearing preload with an inch pound torque wrench and record for use when reassembling the pinion.
- Pinion assembly for looseness by moving it back and forth. Looseness indicates excessive bearing wear.





18. Pinion flange nut and washer using J 8614-01 to hold the pinion flange.





19. Pinion flange using J 8614-01.
20. Pinion from the axle housing.
A. Thread the pinion nut halfway onto the pinion.
B. Replace the axle housing cover with two bolts to keep the pinion from falling.





C. Drive the pinion out of the housing with a hammer and soft drift.
- Remove the cover and the pinion.
21. Collapsible spacer from the pinion.
22. Outer seal and outer pinion bearing.
23. Inner bearing and shim from the pinion.





A. Press the bearing off the pinion using J 22912-01.
B. Remove the shim.
24. Bearing cups from the axle housing using a hammer and punch.
- Work the cups out of the housing evenly, moving the punch back and forth between one side of the cup and the other.