Differential Carrier Assembly Disassemble 8.25 Inch Axle Lock Ring Style

Tools Required

Perform the following before disassembling the axle:

1. Remove the drain plug from the axle.
2. Drain the axle lubricant.
3. Inspect the oil and the case for metal chips.

Determine the source of the metal chips, such as a broken gear or bearing cage.

4. Check the ring gear backlash. Refer to Backlash Inspection and Adjustment.

This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.

Determine the cause of the axle problem before disassembly, if possible.

1. Install the differential carrier assembly in a vise.



2. Remove the front axle actuator, S4WD axle only.



3. Remove the left side inner axle shaft bearing and the inner axle shaft seal by performing the following steps:

3.1.	Install the J 29369-1 (1) behind the inner axle shaft bearing.

3.2.	Install the J 2619-01 (2) to the J 29369-1 (1).

3.3.	Using the J 2619-01 remove the inner axle shaft bearing and the seal.

4. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift, F4WD axle only.
5. Remove the inner axle shaft, F4WD axle only.
6. Remove the inner axle shaft housing to differential carrier assembly bolts.
7. Remove the inner axle shaft housing, F4WD axle only.



8. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly, S4WD axle only.



9. Remove the inner axle housing to differential carrier gasket



10. Remove the following components from the inner axle shaft housing, S4WD axle only:

10.1.

The clutch fork inner spring (10)

10.2.

The clutch fork assembly (11)

10.3.

The clutch shaft shim (9)

10.4.

The clutch shaft sleeve (8)

10.5.

The front drive axle clutch gear (6) by doing the following:

10.5.1.

Clamp the inner axle shaft housing (4) in a vise.

Clamp only on the mounting flange.

10.5.2.

Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).

10.6.

Remove the front drive axle clutch gear (6)

10.7.

Remove the thrust washer (5)

10.8.

Remove the inner axle shaft (1)




11. Remove the right side inner axle shaft bearing and the inner axle shaft seal by performing the following steps:

11.1.

Place the differential carrier assembly into a vise.

Clamp only on the mounting flange of the differential carrier assembly case.

11.2.

Install the J 29369-1  (1) behind the inner axle shaft bearing.

11.3.

Install the J 2619-01  (2) to the J 29369-1  (1).

11.4.

Using the J 2619-01  (2), remove the inner axle shaft bearing and the inner axle shaft seal.

12. Remove the differential carrier assembly from the vise.
13. Remove the front drive axle clutch shaft (S4WD only).



14. Using the J 34011 , remove the clutch shaft bearing (S4WD only).



15. Remove the vent connector.



16. Remove the differential carrier assembly bolts (1).
17. Separate the left carrier case half from the right carrier case half (2) by tapping on the on the carrier case with a hammer and a brass drift.
18. Remove the differential carrier housing (2) and the differential carrier housing gasket (3).
19. Remove the differential case assembly.



20. Using a suitable remover, remove the differential bearing adjuster nut locks.



21. Using the J 36614 , remove the differential bearing adjuster nuts and the differential bearing cups.



22. Install the J 8614-01 as shown.

Remove the pinion nut while holding the J 8614-01 .

23. Remove the washer.



24. Install the J 8614-2  (2) and the J 8614-3  (3) into the J 8614-01  (1) as shown.
25. Remove the pinion yoke by turning the J 8614-3  (3) clockwise while holding the J 8614-01  (1).
26. The steps below explain how to remove the drive pinion and pinion bearing cups using the J 36598 or the J 45765 and the J-45858 . Follow the appropriate steps depending on what tool is available.
27. Install the J 36598 into a vise.



28. Install the left differential carrier case half onto the J 36598 and the J 36598 - (only 3 of the 4 mounting bolts will be used).
29. While holding the forcing screw of the J 36598 , turn the handle of the J 36598 counterclockwise in order to remove the pinion with the following components:

•	The pinion gear selectable shim

•	The inner pinion bearing

•	The collapsible spacer




30. Install the J 36598-5 (3) behind the inner pinion bearing cup.
31. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3) until fully seated.
32. While holding the forcing screw of the J 36598  (1), turn the handle of the J 36598  (2) counterclockwise and press the inner bearing cup out from the differential carrier case.



33. Install the J 36598-5 (2) behind the outer pinion bearing cup.
34. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2).
35. While holding the forcing screw of the J 36598 , turn the handle of the J 36598 clockwise in order to remove the following components:

•	The pinion oil seal

•	The pinion outer bearing

•	The pinion outer bearing cup




36. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown.
37. Turn the forcing screw of the J 45765 clockwise to remove the following components from the left side differential carrier case half:

•	The drive pinion gear

•	The pinion gear selectable shim

•	The inner pinion bearing

•	The collapsible spacer

38. Remove the drive pinion seal using a suitable seal remover.
39. Remove the outer pinion bearing from the differential carrier case half.



40. Install the J 45858-4 over the inner pinion bearing cup.



41. Install the forcing screw (1) of the J-45858 into the J 45858-4 (2).
42. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.



43. Install the J 45858-3 (3), the thrust bearing and the washer (2), and the forcing screw (1) over the outer pinion bearing cup bore.



44. Install the J 45858-5 into the pinion bearing bore behind the outer pinion bearing cup.

Slowly turn the forcing screw clockwise until the J 45858-5 is evenly seated behind the outer pinion bearing cup bore and the J 45858-3 is evenly seated over the outer pinion bearing cup bore.

45. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
46. Remove the collapsible spacer from the drive pinion.



47. Install the J 22912-B between the pinion bearing and the drive pinion.
48. Using the J 22912-B and a hydraulic press, remove the inner pinion bearing
49. Remove the pinion gear selectable shim.

Differential Carrier Assembly Disassemble 9.25 Inch Axle

Special Tools

Perform the following before disassembling the axle:

1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips.

Determine the source of the metal chips, such as a broken gear or bearing cage.

5. Check the ring gear backlash. Refer to Backlash Inspection and Adjustment.

This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.

Determine the cause of the axle problem before disassembly, if possible.

1. Using the J 36616-2 (1), J 33791-1 (2), thrust bearing (3), and the J 21474-18 (4), remove the upper differential carrier assembly bushing.



2. Using the J 21474-18 (1), thrust bearing (2), J 33791-1 (3), and the J 36616-2 (4), remove the lower differential carrier assembly bushing.



3. Remove the front axle actuator.
4. Remove the inner axle shaft housing to differential carrier assembly bolts.



5. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly.



6. Remove the following components from the inner axle shaft housing (4):

6.1.	The clutch fork inner spring (9)

6.2.	The clutch fork assembly (10)

6.3.	The clutch shaft shim (9)

6.4.	The clutch shaft sleeve (7)

6.5.	The retainer ring (6)

6.6.	The thrust washers (5)




7. Remove the inner axle shaft (2).




Important: To remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps.

8. Install the inner axle shaft housing into a vise.
9. Clamp only on the mounting flange of the inner axle shaft housing.
10. Using the J 29369-2  (1) and the J 2619-01  (2), remove the inner axle shaft bearing and the seal.
11. Remove the inner axle shaft housing from the vise.
12. Remove the front drive axle clutch shaft.



13. Use the J 34011 , remove the clutch shaft bearing.



14. Clamp only on the mounting flange of the differential carrier assembly, install the differential carrier assembly into a vise.
15. Using a hammer and a brass drift, remove the inner axle shaft.
16. Using the J 2619-01  (2)  and the J 29369-2  (1), remove the inner axle shaft bearing and the inner axle seal bearing and the seal.
17. Remove the differential carrier assembly from the vise.



18. Remove the vent connector.
19. Remove the differential carrier assembly bolts.



20. Using a hammer and a brass drift, separate the left carrier case half from the right carrier case half.
21. Remove the differential case assembly.
22. Disconnect the right side differential bearing adjuster nut lock from the differential bearing adjuster nut by prying up on the lock.



23. Remove the left side differential bearing adjuster nut lock and the bolt.



24. Using the J 36615 and turning it counterclock wise, remove the left side differential bearing adjuster.



25. Using the J 36599-A and turning it counterclock wise, remove the right side differential bearing adjuster.
26. Using a hammer and brass drift, remove the right side differential bearing adjuster nut sleeve.



27. Using the J 8614-01 to hold the differential yoke, remove the pinion nut and washer.



28. Using the J 8614-01  (1), (2) and turning (3) clockwise, remove the differential yoke.



29. Using the J 45765 and turning the bolt clockwise, remove the drive pinion gear, pinion gear selectable shim, inner pinion bearing, and the collapsible spacer.
30. Using a suitable tool, remove the drive pinion seal.
31. Remove the outer pinion bearing from the differential carrier case half.



32. Position the J 45754-3 over the inner pinion bearing cup.



33. Using the J 45754 , bolt (1), plate (2) and by tapping the bolt (1) with a hammer, remove the inner pinion bearing cup.




Important: Before removing the outer pinion bearing cup, ensure that the tool is evenly seated behind the outer pinion bearing cup bore and over the outer pinion bearing cup bore.

34. Using the J 45754  (1), (2), and turning the (3) clockwise, remove the outer pinion bearing cup.



35. Using the J 22912-B and a press, remove the inner pinion bearing.
36. Remove the pinion gear selectable shim.