Seals and Gaskets: Service and Repair

REMOVAL PROCEDURE

^ Tools Required
- J 8614-01 Pinion Flange Remover and Installer





1. Raise and suitably support the vehicle.
2. Remove the propeller shaft.
3. Mark the position of the following components before disassembly:
(This action will ensure that the correct drive pinion gear inner and outer bearing preload can be maintained.)
^ The drive pinion gear yoke (1)
^ The drive pinion gear
^ The drive pinion gear nut (1)





4. Use the J 8614-01 in order to remove the following components:
^ The drive pinion gear nut (1)
^ The drive pinion gear washer (2)
Use a suitable container in order to hold any fluid that may drain from the rear axle.





5. Use the J 8614-01 in order to remove the drive pinion gear yoke (1).





6. Use a blunt chisel in order to drive the drive pinion gear seal (1) out of the rear axle housing.
^ Remove the drive pinion gear seal (1).

IMPORTANT: Do not damage the rear axle housing when removing the drive pinion gear seal.

7. Inspect the drive pinion gear seal surface of the drive pinion gear yoke for the following conditions:
^ Tool marks
^ Nicks
^ Damage, such as a groove worn by the drive pinion gear seal.

8. If the drive pinion gear yoke is damaged, replace the drive pinion gear yoke.
9. Inspect the housing bore for burrs.
Burrs might cause leaks around the Outer Diameter (OD) of the drive pinion gear seal (1).
Remove any burrs that might cause leaks around the outer diameter (OD) of the drive pinion gear seal (1).

INSTALLATION PROCEDURE

^ Tools Required
- J 8614-01 Pinion Flange Remover and Installer
- J 23911 Pinion Oil Seal Installer





1. Use the J 23911 in order to install a new drive pinion gear seal (1).
2. Apply chassis lubricant or an equivalent to the following components:
^ The outside diameter of the drive pinion gear yoke
^ The sealing lip of the new drive pinion gear seal
Refer to Rear Axle With ABS and With Drum Brakes or Rear Axle With ABS and TCS





3. Install the drive pinion gear yoke (1).
4. Install the following components:
^ The drive pinion gear washer (2)
^ The drive pinion gear nut (1)
Finger tighten the drive pinion gear nut.





5. While holding the drive pinion gear yoke (1), use the following specifications:
Use the following steps in order to tighten the drive pinion gear nut:
5.1. Hold the drive pinion gear yoke.
Use the J 8614-01 in order to tighten the drive pinion gear nut to the position that was marked.

5.2. Use the J 8614-01 in order to tighten the drive pinion gear nut to 1.59 mm (1/16 inch) beyond the alignment mark.

6. Install the propeller shaft.
7. Measure the rear axle lubricant level. Add lubricant, if lubricant is required.
8. Lower the vehicle.
9. Inspect for correct operation of the rear axle.