Output Shaft: Service and Repair

REMOVAL
1. Remove the vacuum shift motor housing.
2. Remove the outer axle shaft.
3. Remove the inner axle shaft seal from the shift motor housing with a long drift or punch. Be careful not to damage housing.
4. Remove intermediate axle shaft and shift collar.

Fig. 40:

Fig. 41:

5. Remove the intermediate axle shaft bearing (Fig. 40), or bushing (Fig. 41).


INSTALLATION

Fig. 42:

Fig. 43:

1. Position the bearing, or bushing, on installation tool. Seat the bearing (Fig. 42), or bushing (Fig. 43), in the housing bore.
2. Clean the inside perimeter of the axle shaft tube with fine crocus cloth.
3. Apply a light film of oil to the inside lip of the new axle shaft seal.

Fig. 44:

Fig. 45:

4. Install the inner axle seal (Fig. 44) or (Fig. 45).
The inner axle seal position is different on a 216 FBI axle then a 248 FBI axle. Be sure to use the correct installer.
5. Install the shift collar in the axle housing.
6. Lubricate the splined end of the intermediate axle shaft with multipurpose lubricant.
7. Insert the intermediate axle shaft into the differential side gear.

CAUTION: Apply all-purpose lubricant to the axle shaft splines to prevent damage to the seal during axle shaft installation.

8. Insert the axle shaft into the tube. Engage the splined end of the shaft with the shift collar.
9. Install the vacuum shift motor housing.