Steps 1 - 30
DISASSEMBLY AND ASSEMBLYFront Axle Assembly
Special Tools And Equipment, Part 1:
Special Tools And Equipment, Part 2:
Special Tools And Equipment, Part 3:
Special Tools And Equipment, Part 4:
Special Tool(s)
Material:
Material
Disassembly
1. Remove the front drive axle assembly. Service and Repair
2. Remove the differential housing cover.
1 Remove the bolts.
2 Remove the differential housing cover.
3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
Install the special tool.
4. Remove the right hand axle shaft.
1 Remove the snap ring.
2 Remove the axle shaft.
5. Remove the axle housing tube.
6. Remove the axle shaft.
1 Remove the snap ring.
2 Remove the axle shaft.
7. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
Install the special tools.
8. Position the special tool on the spreader adapters.
9. Install the special tools.
^ Position the adapter tip in the spreader adapter hole.
10. CAUTION: Overspreading can damage the axle housing.
Spread the axle housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the housing spreader screw to spread the axle housing to the specification.
3 Remove the special tool.
11. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position.
Mark and remove the differential bearing caps.
1 Remove the bolts.
2 Remove the differential bearing caps.
12. CAUTION: Use wood blocks to avoid axle housing damage.
Remove the differential assembly from the axle housing.
1 Position the wood blocks.
2 Position and push down on the two pry bars.
3 Remove the differential assembly.
4 Remove the special tool.
13. Index-mark the axle universal joint flange to the pinion stem.
14. Install the special tool and loosen, but do not remove, the pinion nut.
15. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear.
16. Remove the nut and the flange.
17. Using the special tool and a soft hammer, remove the peon gear.
18. Discard the drive pinion collapsible spacer.
19. CAUTION: Do not damage the carrier housing while removing the pinion seal.
Remove the pinion seal and slinger.
^ Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
20. Remove the outer pinion bearing.
21. Using the special tools, remove the inner pinion bearing cup.
22. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
If necessary, remove the pinion bearing oil baffle.
23. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.
24. Using the special tool and a suitable press, remove the pinion bearing.
25. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing.
Remove and measure the drive pinion bearing adjustment shim.
26. Remove the ten bolts and the ring gear.
^ Use a drift punch to separate the ring gear from the differential case.
27. Using the special tools, remove the differential bearings.
Assembly
1. CAUTION: Do not omit the pinion bearing oil baffle; bearing failure can result.
If removed, position the baffle on the special tool.
2. Using the special tool, install the baffle.
3. NOTE: Always install new pinion bearings when installing new pinion bearing cups.
Lightly oil the new pinion bearing cups and pinion bearings with front axle lubricant.
4. Using the special tool, install the bearing cups.
5. NOTE: You must use the pinion bearings assembled in this procedure step at final assembly.
Assemble and position the special tools and the peon bearings m the carrier housing.
1 Position the screw Adapter.
2 Position the aligning Adapter.
3 Position the pinion bearing.
4 Position the gauge disc Adapter.
5 Position the gauge block Adapter.
6 Position the pinion bearing.
7 Thread on the handle Adapter.
6. NOTE: This step duplicates final pinion bearing preload.
Tighten the special tool to the specification to simulate bearing preload.
7. NOTE: Offset the gauge block Adapter to obtain an accurate reading.
Rotate the gauge block Adapter several half-turns to make sure the pinion bearings seat correctly, and position the gauge block Adapter.
8. Install the special tool.
1 Position the special tool.
2 Install the differential bearing caps.
3 Install the bolts.
9. NOTE: Use only flat, clean drive pinion bearing adjustment shims.
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly of integral axle assemblies. Do not attempt to force the shim between the gauge block Adapter and the gauge tube Adapter. A slight drag indicates correct shim selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ Check the adjustment shim thickness between the gauge block Adapter and the gauge tube Adapter.
^ After determining the correct shim thickness, remove the special tools.
10. NOTE: You must use the same pinion bearings from the previous steps.
Install the pinion bearing.
^ Place the drive pinion bearing adjustment shim on the pinion gear.
^ Using a suitable press and the special tool, press the pinion bearing until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the pinion stem.
12. Install the outer pinion bearing.
13. Install the slinger.
14. NOTE: Coat the lips of the pinion seal with front axle lubricant.
Place the pinion seal on the special tool.
15. Place the special tool and seal in the pinion seal bore and drive the seal into place.
16. Do not allow the drive pinion collapsible spacer to slide on the stem when installing the pinion.
17. Position the drive pinion in the housing.
18. CAUTION: Never install the drive pinion universal joint flange with a hammer or power tools.
NOTE: Disregard the scribe marks if installing a new flange.
Install the drive pinion universal joint flange.
1 Lubricate the drive pinion splines.
2 Align the index marks and position the universal joint flange on the drive pinion.
19. Using the special tool, install the drive pinion universal joint flange.
20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.
21. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut.
Install the special tool, and tighten the pinion nut. Refer to the torque specifications in the Specifications.
^ Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch-pound) torque wrench.
22. CAUTION: Use extreme care not to damage the aluminum differential carrier housing while carrying out the procedure steps.
CAUTION: The special tools are marked LH and RH. Install them accordingly.
Install the special tools.
23. Install the differential case with the Differential Bearings Gauge in the differential carrier housing.
24. NOTE: Repeat this step until you obtain a consistent reading.
Measure the total end play.
1 Position the special tools.
2 Position the indicator tip on the machined surface and adjust it to measure full travel.
3 Push the differential case left and right (as far as possible).
4 Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A, in this procedure.
25. Remove the special tools and the differential case.
26. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.
27. Install the ring gear.
1 Position three bolts to align the holes in the ring gear and the differential case.
2 Using a suitable press, install the ring gear.
28. Install the remaining bolts.
29. Remove three adjacent bolts.
30. CAUTION: Position the three empty bolt holes downward.
Position the differential case with the special tools into the differential carrier housing.