Rear Axle Shaft Replacement 8.6, 9.5 Inch Axles W/O RPO JL4

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the wheel speed sensor. Refer to Wheel Speed Sensor Replacement.
4. Remove the brake caliper. Refer to Rear Brake Caliper Replacement.
5. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.



6. Remove the pinion shaft locking bolt.



7. On axles without a locking differential, remove the pinion shaft.



8. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.



9. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block opening (2).
10. Push the flange of the axle shaft into the axle housing.



11. Remove the rear axle shaft lock from the button end of the axle shaft.




Note: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make assembly difficult

12. Remove the axle shaft from the housing.

Note: Rotate the axle shaft as necessary in order to align the axle shaft splines with the differential side gear splines and engage the differential side gear and carefully insert the axle shaft in order to not damage the seal.

1. Install the axle shaft into the rear axle housing.



2. On axles without a locking differential, place the rear axle shaft lock on the button end of the axle shaft.



3. On axles with a locking differential, install the rear axle shaft lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2) as shown.
4. Pull the shaft flange outward in order to seat the rear axle shaft lock in the differential side gear.
5. Install the pinion shaft into the differential case.

Align the hole in the pinion shaft with the bolt hole in the differential case.

Caution: Refer to Fastener Caution in the Preface section.




6. Install the new pinion shaft locking bolt.

•	For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 N·m (27 lb ft).

•	For the 9.75 inch axle, tighten the pinion shaft locking bolt to 27 N·m (20 lb ft).

7. Install the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
8. Install the brake caliper. Refer to Rear Brake Caliper Replacement.
9. Install the speed sensor. Refer to Wheel Speed Sensor Replacement.
10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
11. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
12. Remove the support and lower the vehicle.

Rear Axle Shaft Replacement 8.6 Inch Axle W/RPO JL4

Special Tools

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement.
4. Remove the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
5. Remove the pinion shaft locking bolt.



6. Remove the pinion shaft.



7. Push the flange of the axle shaft (1) toward the differential.

Note: It may be necessary to tap the axle shaft toward the differential with a soft faced mallet to obtain the clearance needed to remove the C-lock.

8. Remove the C-lock (4) from the button end of the axle shaft (1).

Note: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligned the gears will make the assembly difficult.

9. Remove the axle shaft (1) from the housing (5) by pulling the axle shaft away from the differential.




Note: If the axle is difficult to remove, preform the following.

10. Using the J 45859 Axle Remover  (1) and the J 2619-01 Slide Hammer  (2), remove the rear axle shaft.

Note: Carefully insert the axle shaft in order to not damage the seal.

1. Install the axle shaft (1) into the rear axle housing (5).
2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.

It may be necessary to tap the end of the axle shaft with a soft faced mallet as it is being installed to seat the wheel speed sensor ring on the axle.

3. Place the lock (4) on the button end of the axle shaft (1).
4. Pull the shaft flange outward in order to seat the lock in the differential gear.



5. Align the hole in the pinion shaft with the bolt hole in the differential case.

Caution: Refer to Fastener Caution in the Preface section.

6. Install the new pinion shaft locking bolt and tighten to 36 N·m (27 lb ft)..
7. Install the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
8. Install the brake rotor. Refer to Rear Brake Rotor Replacement.
9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
10. Fill the rear axle. Refer to Rear Axle Lubricant Replacement.
11. Remove the support and lower the vehicle.

Rear Axle Shaft Replacement 9.5, 9.75Inch Axles

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the rear wheel speed sensor, if equipped. Refer to Wheel Speed Sensor Replacement.
4. Remove the brake rotor. Refer to Rear Brake Rotor Replacement.
5. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.



6. Remove the pinion shaft locking bolt.



7. On axles without a locking differential, remove the pinion shaft.




Note: Step 8 is for vehicles equipped with the locking differential.

8. Remove the shaft part way then rotate the case until the pinion shaft touches the housing.




Note: Step 9 is for vehicles equipped with the locking differential.

9. Use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block opening (2).
10. Push the flange of the axle shaft into the axle housing.



11. Remove the rear axle shaft lock from the button end of the axle shaft.




Note: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make assembly difficult.

12. Remove the axle shaft from the housing.

1. Rotate the axle shaft in order to align the axle shaft splines with the differential side gear splines

Note: Carefully insert the axle shaft in order to not damage the seal.

2. Install the axle shaft into the rear axle housing.




Note: Steps 3 is for those vehicles equipped the locking type differential.

3. Place the rear axle shaft lock on the button end of the axle shaft.




Note: Step 4 is for those vehicles equipped the locking type differential.

4. Install the rear axle shaft lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
5. Pull the shaft flange outward in order to seat the rear axle shaft lock in the differential side gear.

Note: Align the hole in the pinion shaft with the bolt hole in the differential case.

6. Install the pinion shaft into the differential case.

Caution: Refer to Fastener Caution in the Preface section.




7. Install the NEW pinion shaft locking bolt and tighten to:

•	For the 9.5 inch axle, tighten the bolt to 50 N·m (37 lb ft).

•	For the 9.75 inch axle, tighten the bolt to 27 N·m (20 lb ft).

8. Install the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
9. Install the brake rotor. Refer to Rear Brake Rotor Replacement.
10. Install the rear wheel speed sensor, if equipped. Refer to Wheel Speed Sensor Replacement.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
12. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
13. Remove the support and lower the vehicle.