Differential Replacement 8.6 Inch Axle

Important: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the differential side bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential assembly without replacing any other component (i.e. pinion and ring gear set, differential bearings. etc.) then you may reinstall the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement .




Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

3. Remove the differential bearing caps and bolts. Mark the differential bearing caps left and right.



4. Install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.

Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

5. Rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.
6. Remove the differential assembly.
7. Remove the bearing cups, the shims, and the spacers as necessary.

Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

8. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
9. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .

1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
3. Lubricate the differential side bearings with the proper axle lubricant. Refer to Fluid and Lubricant Recommendations .



4. Install the differential assembly, with the differential bearing cups installed, into the axle housing.

Support the differential assembly in order to keep the case from falling out of the axle housing.

5. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment .
6. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment .
7. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .



8. Install the differential bearing caps and the bolts, if necessary.

Notice: Refer to Fastener Notice in the Preface section.

9. Tighten the differential bearing cap bolts.

Tighten
Tighten the differential bearing cap bolts to 75 N·m (55 lb ft).

10. Install the axle shafts. Refer to Rear Axle Shaft Replacement .
11. Fill the axle with the proper axle lubricant. Refer to Rear Axle Lubricant Replacement .
12. Lower the vehicle.

Differential Replacement 9.75, 10.5 and 10.75 Inch Axles

Special Tools

J 24429 Side Bearing Backlash Spanner

Important: If you remove or replace the ring and pinion gear set, perform the differential side bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential assembly without replacing any other component (i.e. pinion and ring gear set, differential bearings. etc.) then you may reinstall the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement or Rear Axle Shaft and/or Gasket Replacement .



3. Remove the differential bearing adjuster nut lock bolts.



4. Remove the differential bearing adjuster nut locks.



5. Remove the differential bearing cap bolts.



6. Remove the differential bearing caps. Mark the differential bearing caps left and right.




Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

7. Loosen the differential bearing adjusters using the J 24429 .
8. Remove the differential assembly and the differential bearing cups.

Mark the differential bearing cups left and right. Place the differential bearing cups with the differential bearing caps.

9. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
10. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .

1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
3. Lubricate the differential side bearings with the proper axle lubricant. Refer to Fluid and Lubricant Recommendations .
4. Install the differential assembly, with the differential bearing cups installed, into the axle housing.

Support the differential assembly in order to keep the case from falling out of the axle housing.




5. Turn the adjusters evenly on each side using the J 24429 until snug against the differential.
6. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment .
7. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment .
8. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .



9. Install the differential bearing caps, if necessary.



10. Install the differential bearing cap bolts, if necessary.

Notice: Refer to Fastener Notice in the Preface section.

11. Tighten the differential bearing cap bolts.

Tighten
Tighten the differential bearing cap bolts to 109 N·m (80 lb ft).




12. Install the differential bearing adjuster retainers.



13. Install the differential bearing adjuster retainer bolts.

Tighten
Tighten the differential bearing adjuster retainer bolts to 13 N·m (10 lb ft).

14. For the 9.75 inch axle, install the axle shafts. Refer to Rear Axle Shaft Replacement .
15. For the 10.5 and 10.75 inch axles, install the axle shafts and new axle shaft gaskets. Refer to Rear Axle Shaft and/or Gasket Replacement .
16. Fill the axle with the proper axle lubricant. Refer to Rear Axle Lubricant Replacement .
17. Lower the vehicle.