Disassembly of the Rear Axle

REMOVE OR DISCONNECT
- Tools Required:
- J 2619-01 Slide Hammer
- J 22813-01 Axle Bearing Puller
- J 8107-2 Differential Side Bearing Remover Plug
- J 22888 Side Bearing Remover
- J 8614-01 Pinion Flange Holder and Remover
- J 25320 Rear Pinion Bearing Remover
- Place the axle in a suitable support.

1. Cover bolts and cover.
- Drain the axle lubricant.





2. Pinion shaft lock bolt.
3. Pinion shaft.
- Push the axle shaft in towards the center of the differential case.
4. The "C" lock from the end of the axle shaft.





5. Axle shaft from the axle housing.
6. Oil seal using an oil seal removal tool.
- Be careful not to damage the housing.





7. Bearing using J 2619-01 and J 22813-01.
- Make sure the tangs of the tool engage the bearing outer race.





8. Differential pinion and side gears.
A. Roll the pinion gears out of the case with the pinion thrust washers.
B. Remove the side gears and the side gear thrust washers. Mark the gears and the differential case left and right.
9. Bearing cap bolts.
10. Bearing caps.
- Mark the caps and the housing left and right.

NOTICE: Be careful when prying the differential case out of the axle housing so as 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 being damaged.

11. Differential case.





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





13. Differential side bearings using J 8107-2 and J 22888-20.
- The jaws of J 22888-20 must pull from beneath the bearing cone and not the cage.
14. Ring gear bolts.
- Ring gear bolts have left-handed threads.

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

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

Inspect





- Drive pinion bearing preload and record for use when reassembling the pinion.
- The pinion assembly for looseness by moving it back and forth. Looseness indicates excessive bearing wear.





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





17. Pinion flange using J 8614-01.





18. Pinion from the axle housing.
A. Thread the pinion nut halfway onto the pinion.
B. Install the differential cover with two bolts to keep the pinion from falling.
C. Drive the pinion out of the housing with a hammer and drift.
D. Remove the cover and pinion.





19. Collapsible spacer from the pinion.
20. Outer seal and outer pinion bearing.
21. Inner bearing and shim from the pinion.





A. Press the bearing off the pinion using J 25320.
B. Remove the shim.
22. Bearing cups from the axle housing using a hammer and punch in the slots provided for this purpose.
- Work the cups out of the housing evenly, moving the punch back and forth between one side of the cup and the other.