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Section 14 (Drive Axle - 7.5", 7.625", 8.5" & 9.5"): Overhaul: Disassembly

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NOTE: Check and record ring gear backlash and pinion bearing preload before disassembly.
  1. Remove axle shafts as previously described. Roll out differential pinions and thrust washers. Mark pinions and thrust washers (left and right) for reassembly. Remove side gears and thrust washers. Mark side gears and thrust washers (left and right) for reassembly.
  2. Mark differential bearing caps and housing for reassembly. Loosen bearing cap bolts and tap bearing cap surfaces to loosen caps. Using pry bar inserted in differential carrier, pry against housing at differential window to remove carrier.
    NOTE: Be careful, as carrier bearings are preloaded. Carrier will fall free after being pried past a certain point.
  3. After removing carrier, place shims with appropriate bearing cups. Install bearing caps onto housing in their original position before removal. Using Differential Side Bearing Remover (J-22888) and Adaptor (J-8107-2) for 7 1/2" and 7 5/8" ring gears, (J-8107-4) for 8 1/2" and (J-8107-3) for 9 1/2" ring gear, remove differential side bearings.
    NOTE: Ring gear bolts have left-hand threads.
  4. Remove ring gear bolts. Tap ring gear off carrier using a soft drift and hammer. Using an INCH lb. torque wrench, check torque required to rotate drive pinion. If no preload reading is obtained, check for looseness of pinion assembly. Looseness indicates pinion bearings should be replaced.
  5. Install Companion Flange Holder (J-8614-01) on flange, with holder notches toward flange. Remove pinion nut and washer. Remove flange. Install pinion nut halfway on pinion. Install differential cover using 2 bolts. Tap end of pinion (using soft drift and hammer) to remove pinion.
    NOTE: DO NOT  damage pinion bearings when removing pinion from differential housing.
  6. Remove differential cover and pinion assembly. Remove pinion oil seal and front bearing from housing. Remove collapsible spacer from pinion. Remove inner bearing and shim from pinion. Using Bearing Remover (J-25320 for 7 1/2" and 7 5/8" ring gear, J-8612-B for 8 1/2" ring gear and J-22912-01 on 9 1/2" ring gear), press bearing from pinion.
  7. Remove bearing cups from axle housing using hammer and punch in slotted areas. Inspect bearings and bearing cups, and replace them as required. Discard oil seal, pinion nut and collapsible spacer.
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