Disassembly And Assembly: Axle: Disassembly

• 1.
  
  Remove the axle assembly. Refer to Axle Assembly .

• 2.
  
  Remove the 10 bolts and the differential housing cover.
  • Drain the fluid.
  • Remove the bolts.
  • Remove the differential housing cover.

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NOTE: The fixture mounting bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.
• 3.
  Install the Transmission Holding Fixture.

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• 4.
  
  Using the Transmission Fluid Pump Remover and Slide Hammer, remove the intermediate shaft.

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• 5.
  
  Remove the 4 bolts and the axle housing tube.

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NOTE: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.
• 6.
  Install the Differential Housing Spreader Plate and Adapter for Differential Housing Spreader.

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• 7.
  
  Position the Differential Carrier Spreader on the spreader adapters.

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• 8.
  
  Install the Dial Indicator Gauge with Holding Fixture and Clutch Holding Gauge.
  • Position the adapter tip in the spreader adapter hole.

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NOTE: Overspreading may damage the axle housing.
• 9.
  Spread the axle housing to the specification.

  • 1.
    
    Adjust the Dial Indicator Gauge to zero.

  • 2.
    
    Tighten the housing spreader screw to spread the axle housing to the specification.

  • 3.
    
    Remove the Dial Indicator Gauge with Holding Fixture.

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NOTE: 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.
• 10.
  Mark and remove the 2 differential bearing caps.

  • 1.
    
    Remove the bolts.

  • 2.
    
    Remove the differential bearing caps.

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NOTE: Use wood blocks to avoid axle housing damage.
• 11.
  Remove the differential assembly from the axle housing.

  • 1.
    
    Position the wood blocks.

  • 2.
    
    Position and push down on the 2 pry bars.

  • 3.
    
    Remove the differential assembly.

  • 4.
    
    Remove the Differential Carrier Spreader.

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• 12.
  
  Index-mark the axle U-joint flange to the pinion stem.

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• 13.
  
  Install the Drive Pinion Flange Holding Fixture and loosen, but do not remove, the pinion nut.

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• 14.
  
  With the pinion nut still engaged by a few threads, use the 2 Jaw Puller to separate the axle U-joint flange from the pinion gear.

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• 15.
  
  Remove the nut and the flange.

• 16.
  
  Using the Drive Pinion Thread Protector and a soft hammer, remove the pinion gear.

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• 17.
  
  Discard the drive pinion collapsible spacer.

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NOTE: Do not damage the carrier housing while removing the pinion seal.
• 18.
  Remove the pinion seal and slinger.
  • Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.

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• 19.
  
  Remove the outer pinion bearing.

• 20.
  
  Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.

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NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
• 21.
  If necessary, remove the pinion bearing oil baffle.

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• 22.
  
  Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.

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• 23.
  
  Using the Bearing Remover and a suitable press, remove the pinion bearing.

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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.
• 24.
  Remove and measure the drive pinion bearing adjustment shim.

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NOTE: Use a drift punch to separate the ring gear from the differential case.
• 25.
  Remove and discard the 10 bolts and remove the ring gear.

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• 26.
  
  Using the 2 Jaw Puller and Step Plate, remove the differential bearings.

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