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Drive Pinion and Ring Gear Replacement 8.6 and 9.5 Axles
Tools Required
J 22536 Pinion Driver
J 44421 Pinion Remover
Removal Procedure
1. Raise the vehicle.
2. Remove the tire and wheel assemblies.
3. Remove the brake calipers.
4. Remove the brake rotors.
5. Remove the axle shafts.
6. Remove the differential. Refer to Differential Replacement.
7. Remove the pinion yoke and the seal.
8. Install the J 22536 or the J 44421 as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion.
9. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing.
10. Remove the collapsible spacer from the pinion. Discard the spacer.
11. Remove the pinion bearings and the cups.
12. Remove the left handed threaded ring gear bolts. Discard the bolts.
13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
Installation Procedure
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.
2. Install 2 threaded studs into the ring gear on opposite sides.
3. Place the ring gear on the case. Align the studs with the holes in the case.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Install the new left-hand threaded ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten
6. Determine the selective shim thickness for the pinion gear.
7. Install the selective shim onto the pinion.
8. Install the inner pinion bearing to the pinion.
9. Install a new collapsible spacer.
10. Lubricate the pinion bearings with axle lubricant.
11. Install the pinion to the axle housing.
12. Install the outer pinion bearing onto the pinion.
13. Install a new pinion oil seal and the pinion yoke.
14. Install the differential. Refer to Differential Replacement .
15. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
16. Install the axle shafts.
17. Install the brake rotors.
18. Install the brake calipers.
19. Install the tire and wheel assemblies.
20. Fill the axle with lubricant.
21. Lower the vehicle.
Tools Required
J 22536 Pinion Driver
J 44421 Pinion Remover
Removal Procedure
1. Raise the vehicle.
2. Remove the tire and wheel assemblies.
3. Remove the brake calipers.
4. Remove the brake rotors.
5. Remove the axle shafts.
6. Remove the differential. Refer to Differential Replacement.
7. Remove the pinion yoke and the seal.
8. Install the J 22536 or the J 44421 as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion.
9. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing.
10. Remove the collapsible spacer from the pinion. Discard the spacer.
11. Remove the pinion bearings and the cups.
12. Remove the left handed threaded ring gear bolts. Discard the bolts.
13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
Installation Procedure
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.
2. Install 2 threaded studs into the ring gear on opposite sides.
3. Place the ring gear on the case. Align the studs with the holes in the case.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Install the new left-hand threaded 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).
6. Determine the selective shim thickness for the pinion gear.
7. Install the selective shim onto the pinion.
8. Install the inner pinion bearing to the pinion.
9. Install a new collapsible spacer.
10. Lubricate the pinion bearings with axle lubricant.
11. Install the pinion to the axle housing.
12. Install the outer pinion bearing onto the pinion.
13. Install a new pinion oil seal and the pinion yoke.
14. Install the differential. Refer to Differential Replacement .
15. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection .
16. Install the axle shafts.
17. Install the brake rotors.
18. Install the brake calipers.
19. Install the tire and wheel assemblies.
20. Fill the axle with lubricant.
21. Lower the vehicle.