Disassembly

1. Raise and support vehicle, then disconnect propeller shaft from companion flange.

Fig. 3 Exploded View Of Models 60, 70 & 80 Drive Axle:

2. Remove differential housing cover, then drain lubricant and remove axle shafts.
3. Remove RWAL brake sensor bolt and pull sensor from differential housing.
4. Clean housing and inner components, then check the following assembly adjustments to aid diagnosis and reassembly. Refer to "Final Assembly & Adjustment" for actual checking procedures.
a. Check ring gear and pinion tooth contact pattern using suitable marking compound. If contact pattern is not centered, check for improper backlash or pinion installation during inspection.
b. Measure ring gear runout using suitable dial indicator. If runout exceeds 0.006 inch, check for improper ring gear mounting or defective ring gear and/or case during inspection.
c. Check ring gear and pinion backlash using suitable dial indicator. If gear set is to be reused, and contact pattern is acceptable, backlash should be adjusted to original value during final assembly to maintain established tooth contact.
d. Check clearance between bearing and bearing cap, prying against case. If a 0.003 inch feeler gauge can be inserted between race and cap, check for spun side bearings.
5. Mark and remove differential bearing caps.

Fig. 4 Case Spreader Installation:

6. Install suitable case spreader and dial indicator on housing as shown preloading indicator approximately 1/2 revolution. Ensure mounting dowels are fully seated in housing and clamps are securing spreader in proper position.
7. Zero dial indicator, then rotate spreader screw to spread housing 0.015 inch. Do not spread housing more than 0.015 inch, as housing may become permanently distorted.
8. Remove dial indicator, then position pry bars under ring gear bolt head and under differential case and remove differential assembly. Remove spreader tool immediately after removing differential to avoid possibility of distorting housing or causing it to take a set.
9. Measure pinion rotating torque (bearing preload) using suitable torque wrench. If preload is not within specifications, or if endplay is present, pinion must be disassembled for inspection.

Fig. 5 Pinion Nut & Yoke Removal:

Fig. 6 Pinion Nut Removal:

10. Using suitable tool, remove and discard pinion nut.
11. Remove companion flange with suitable puller, then pry pinion seal from housing.
12. Remove dust cap from pinion gear, if equipped, then the pinion gear. Strike end of gear with a rawhide hammer to force pinion out of pinion rear bearing and housing. Pinion bearing preload adjusting shims may remain on pinion shaft, stick to bearing remaining in housing or fall out. Tag and retain shims for assembly.
13. Remove front bearing, seal, gasket and slinger from housing, as equipped.
14. On model 30 and 35 axles, remove pinion rear bearing as follows:
a. Install bearing remover set No. J29721, or equivalent, on bearing and gear.
b. Insert bearing remover adapters into remover base from top and position adapters 180° apart.
c. Tighten remover tool forcing screw and remove bearing.
15. On model 44 axles, remove pinion rear bearing as follows:
a. Install bearing removal tool No. J22921-1 or J23674, or equivalents, between bearing and pinion gear.
b. Press bearing to remove.

Fig. 7 Pinion Rear Bearing Removal:

16. On models with 60, 70 and 80 axles, remove pinion rear bearing as shown.
17. On all models, inspect components as outlined in "Cleaning & Inspection," keeping components in order, and replace as needed. Components that are to be reused must be installed in original position to ensure proper operation.