Disassembly of the Rear Axle

- Tools Required:
- J 8107-3 Side Bearing Puller Plug
- J 8614-01 Pinion Flange Holder
- J 24385-01 Differential Housing Spreader
- J 29721 Differential Side Bearing Remover
- J 29721-70 Side Bearing Adapters
- C 4171 Universal Handle
- C 4307 Bearing Cup Remover (Outer)
- D 128 Dial Indicator Set or Equivalent
- D 158 Bearing Cup Remover

REMOVE OR DISCONNECT
1. Place the axle in a suitable support.
2. Bolts and cover.
- Drain the oil.
3. Axle shafts far enough to clear the differential case.
4. Bearing cap bolts.
5. Bearing caps.
A. Corresponding letters are stamped on the caps and axle housing. The caps must be reassembled exactly as removed.





B. Assemble J 24385-01 to the differential housing.
C. Assemble the dial indicator. Preset the gage at least 5 mm (0.200 inch), then rotate the indicator housing to zero the dial.

NOTICE: Do not spread the axle housing more than 0.38 mm (0.015 inch). Overspreading the housing can damage or distort it.

D. Spread the housing while examining the dial indicator. Do not spread the housing more than 0.38 mm (0.015 inch).

CAUTION: Do not allow the case to fall. It can strike legs or feet and may cause serious injury. Also gear teeth may have sharp edges. When handling, use care to avoid cutting hand.





6. Case from the housing using two pry bars.
7. J 24385-01 from the housing.
8. Bearing cups.
- Mark the cups left and right, and place them with the proper bearing caps.





9. Bearings using J 8107-3, J 29721, and J 29721-70.
- Mark the bearings left and right, and place them with their corresponding bearing caps.
10. Shims.
- Mark the shims left or right.
- Check outboard spacers for damage (e.g. bent, or deep grooves caused by worn bearings). If damaged, they should be replaced with new ones at time of assembly.
11. Ring gear bolts and discard.

Important: Place shop towels over the vise jaws and put the case in the vise.

12. Ring gear from the case using a soft-faced hammer.
A. Ring gear from the vise.
B. Put the case back in the vise.

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





13. Roll pin from the case using a hammer and punch.





14. Pinion shaft using a hammer and brass drift.
15. Pinion gears and thrust washers.





- Rotate the side gears until the pinion gears are in the opening of the case.
16. Side gears and thrust washers.
- Mark the gears and washers left and right.
17. Replace the cover using two bolts to keep the pinion from falling.

Inspect





- Drive pinion rotating torque and record.
- For looseness of the pinion assembly by moving it back and forth. (Looseness indicates excessive bearing or pinion wear).





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





19. Pinion flange using J 8614-01.
20. Pinion from the housing using a soft-faced hammer to tap the pinion.
21. Cover and pinion.
22. Pinion preload shims.
- Keep the shims together.
23. Pinion seal.
24. Outer bearing and oil slinger.





25. Bearing cups from the axle housing using D 158 and C 4307.
26. Pinion adjusting shims and baffle (if used).
- Keep the shims together.





27. Pinion inner bearing (3) using J 29721 and J 29721-70.