Drive Pinion and Ring Gear Replacement 8.6 Inch, 9.5 Inch Axles

Tools Required

J 22536 Pinion Driver

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the brake drums. Refer to Brake Drum Replacement in Drum Brakes.
4. Remove the axle shafts. Refer to Rear Axle Shaft Replacement .
5. Remove the differential. Refer to Differential Replacement .
6. Remove the drive pinion flange/yoke and the seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .



7. Install the J 22536 as shown.

Ensure that the J 22536 is firmly seated on the pinion.

8. Drive the pinion out using the J 22536 and a hammer.

Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.




9. Remove the collapsible spacer from the pinion. Discard the spacer.
10. Remove the pinion bearings and the bearing cups. Refer to Drive Pinion Bearings Replacement .
11. Remove the left handed threaded ring gear bolts. Discard the bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.

12. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

1. Install the ring gear to the differential case.




Important: The ring gear bolts have left-hand threads.

2. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

Notice: Refer to Fastener Notice in the Preface section.

3. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten

•	For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 N·m (89 lb ft).

•	For the 9.5 inch axle, tighten the ring gear bolts in sequence to 140 N·m (103 lb ft).

4. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement .
5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment .
6. Install the selective shim onto the pinion.
7. Install the inner pinion bearing to the pinion. Refer to Drive Pinion Bearings Replacement .
8. Install a new collapsible spacer.
9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
10. Install the pinion to the axle housing.
11. Install the outer pinion bearing. Refer to Drive Pinion Bearings Replacement .
12. Install a new pinion oil seal and the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
13. Install the differential. Refer to Differential Replacement .
14. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
15. Install the axle shafts. Refer to Rear Axle Shaft Replacement .
16. Install the brake drums. Refer to Brake Drum Replacement in Drum Brakes.
17. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
18. Fill the axle with lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
19. Lower the vehicle.

Drive Pinion and Ring Gear Replacement 11 Inch Axle

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
3. Remove the differential case assembly. Refer to Differential Replacement .
4. Remove the drive pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
5. Remove the thrust washer and the outer pinion bearing.
6. Remove the drive pinion from the axle using a soft-faced hammer.

Important: The location of the pinion preload shims may vary. The pinion preload shims may also be located on the backface of the outer pinion bearing or in the oil sump.

7. Remove the pinion preload shims from the drive pinion and set aside.
8. Remove the inner pinion bearing and the pinion position shim. Refer to Drive Pinion Bearings Replacement .
9. Remove the ring gear bolts.

Discard the ring gear bolts.

Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

10. Remove the ring gear from the differential case assembly. Drive the gear off with a brass drift if necessary.

1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. Refer to Pinion Depth Adjustment .
2. Install the differential case assembly. Refer to Differential Replacement .
3. Install the axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement .
4. Fill the axle with lubricant. Use the proper fluid. Refer to Lubricant Change .
5. Lower the vehicle.

Drive Pinion and Ring Gear Replacement 10.5 Inch Axle

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the differential. Refer to Differential Replacement .
3. Remove the pinion gear bearing retainer. Refer to Drive Pinion Housing and/or Seal Replacement .
4. Remove the pinion and the pinion bearings. Refer to Drive Pinion Housing and/or Seal Replacement .



5. Remove the left handed threaded ring gear bolts. Discard the bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.

6. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.

1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown.

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

2. Install the ring gear to the differential case.

Important: The ring gear bolts have left-hand threads.




3. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

Notice: Refer to Fastener Notice in the Preface section.

4. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 165 N·m (122 lb ft).

5. Install the pinion and the pinion bearings. Refer to Drive Pinion Housing and/or Seal Replacement .
6. Install the pinion gear bearing retainer. Refer to Drive Pinion Housing and/or Seal Replacement .
7. Install the differential assembly. Refer to Differential Replacement .
8. Lower the vehicle.