Complete disassembly and reassembly of a IFS front axle.

Discussion in 'Lifted Suspension & Offroad' started by Country Boy, Feb 3, 2009.

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  1. Country Boy

    Country Boy haz 12"s!

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    This is straight from the GM Tech manual on how they do it. If you are mechanically inclined, you dont need the Jxxxxx tools as they are Kent More (expensive) tools.

    Please noone post until I have finished all the posts. It will be a long and cover 8.25 and 9.25 axles. Pictures will come at a later date!
     
  2. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Lubricant Level Inspection - Front Drive Axle

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Make sure the vehicle is level.
    3. Inspect the front axle for leaks. Repair as necessary.
    4. Clean the area around the front axle fill plug.

    [​IMG]

    5. Remove the front axle fill plug (1).
    6. Inspect the oil level.
    Specification
    * For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 in) below the fill plug opening.
    * For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening.
    7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 in) for the 8.25 inch axle or 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Sealers, Adhesives, and Lubricants .
    Notice

    Refer to Fastener Notice in Cautions and Notices.
    8. Install the fill plug.
    Tighten

    Tighten the plug to 33 N·m (24 lb ft).
    9. Lower the vehicle.
     
  3. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Lubricant Replacement - Front Drive Axle
    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Remove the front differential carrier shield, if equipped. Refer to Shield Replacement .
    3. Clean the area around the front axle fill plug and the drain plug.
    4. Remove the fill plug.

    [​IMG]

    5. Remove the drain plug.
    6. Drain the fluid from the front differential carrier assembly.

    Installation Procedure

    Notice

    Refer to Fastener Notice in Cautions and Notices.

    [​IMG]

    1. Install the drain plug.
    Tighten

    Tighten the drain plug to 33 N·m (24 lb ft).
    2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication and Sealers, Adhesives, and Lubricants .
    3. Install the fill plug.
    Tighten

    Tighten the fill plug to 33 N·m (24 lb ft).
    4. Install the front differential carrier shield, if equipped. Refer to Shield Replacement .
    5. Lower the vehicle.
     
  4. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Shield Replacement
    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    [​IMG]

    2. Remove the front differential carrier shield bolts.
    3. Remove the front differential carrier shield.

    Installation Procedure


    [​IMG]

    1. Install the front differential carrier shield.

    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.
    2. Install the front differential carrier shield bolts.
    Tighten

    Tighten the front differential carrier shield bolts to 20 N·m (15 lb ft).
    3. Lower the vehicle.
     
  5. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Electric Motor Actuator Replacement
    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Remove the front differential carrier shield, if equipped. Refer to Shield Replacement .
    3. Disconnect the electrical connector from the actuator.

    [​IMG]

    4. Remove the electric motor actuator (3) by turning the actuator counterclockwise.

    Installation Procedure

    1. Apply sealant to the threads of the electric motor actuator. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
    Notice

    Refer to Fastener Notice in Cautions and Notices.

    [​IMG]

    2. Install the electric motor actuator (3).
    Tighten

    Tighten the actuator to 20 N·m (15 lb ft).
    3. Connect the electrical connector to the actuator.
    4. Install the front differential carrier shield, if equipped. Refer to Shield Replacement .
    5. Lower the vehicle.
     
  6. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Vent Hose Replacement
    Removal Procedure


    [​IMG]

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Remove the front differential carrier shield, if equipped. Refer to Shield Replacement .

    Important

    Make note of the routing in order to aid in reassembly.
    3. Remove the vent hose (1) from the wiring bundle (2), S4WD axles only.
    4. Remove the vent hose from the retainer clips, all axles.

    [​IMG]

    5. Remove the vent hose from the differential carrier assembly.
    6. Remove the vent hose from the vehicle.

    Installation Procedure


    [​IMG]

    1. Install the vent hose to the vehicle.
    * Route the vent hose the same way as when removed.
    * Ensure the hose is free of kinks and routes clear of sharp components.
    * Ensure the vent hose is not plugged.
    2. Connect the vent hose to the differential carrier assembly.

    [​IMG]

    3. Install the vent hose (1) to the wiring bundle (2), S4WD axles only.
    4. Install the vent hose to the retainer clips, all axles.
    5. Install the front differential carrier shield, if equipped. Refer to Shield Replacement .
    6. Lower the vehicle.
     
  7. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Vent Hose Connector Replacement - Front Drive Axle
    Removal Procedure

    1. Raise the vehicle. Refer Lifting and Jacking the Vehicle in General Information.

    [​IMG]

    2. Disconnect the vent hose from the vent hose connector.

    [​IMG]

    3. Remove the vent hose connector from the differential carrier assembly.

    Installation Procedure


    [​IMG]

    1. Install the vent hose connector into the differential carrier assembly.
    Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent onto the threads.
    Notice

    Refer to Fastener Notice in Cautions and Notices.
    2. Tighten the vent hose connector.
    Tighten

    Tighten the vent hose connector to 28 N·m (21 lb ft).

    [​IMG]

    3. Connect the vent hose to the vent hose connector.
    4. Lower the vehicle.
     
  8. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Inner Shaft and/or Housing Replacement - Front Drive Axle 8.25 S4WD and 9.25 Axles
    Removal Procedure


    [​IMG]

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
    3. Disconnect the electrical connector from the electric motor actuator.

    [​IMG]

    4. Disconnect the wire harness from the inner axle shaft housing.
    5. Remove the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    [​IMG]

    6. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
    Disconnect the wheel drive shaft from the inner axle shaft.

    [​IMG]

    7. Remove the inner axle shaft housing nuts from the bracket.

    [​IMG]

    8. For 25/35 series vehicles, perform the following steps in order to provide additional clearance so the inner axle housing can be removed from the vehicle:
    1. Remove the front axle mounting bracket to frame nuts.
    2. Slide the front axle mounting bracket towards the engine. It may be necessary to pull down on the inner axle housing and/or push up on the mounting bracket in order to gain clearance.

    [​IMG]

    9. Remove the inner axle shaft housing bolts from the differential carrier case.

    [​IMG]

    Important

    Keep the open end of the inner axle shaft housing up.
    10. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.

    [​IMG]

    11. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
    1. The clutch fork inner spring (10)
    2. The clutch fork assembly (11)
    3. The clutch shaft shim (9)
    4. The clutch sleeve (8)
    5. The clutch gear (6) by doing the following:
    1. Clamp the inner axle shaft housing (4) in a vise.
    2. Clamp only on the mounting flange. 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).
    6. The thrust washer (5)

    [​IMG]

    12. For the 9.25 inch axle, remove the following components from the inner axle shaft housing:
    1. The clutch fork inner spring (10)
    2. The clutch fork assembly (11)
    3. The clutch shaft shim (9)
    4. The clutch sleeve (8)
    5. The retainer ring (7)
    6. The thrust washers (5, 6)

    [​IMG]

    13. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
    14. Remove the inner axle seal and the bearing from the axle housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .

    Installation Procedure

    1. Install the new inner axle shaft bearing and the seal to the axle housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .

    [​IMG]

    2. Install the inner axle shaft (2) into the inner axle shaft housing (1).
    3. Carefully tap the inner axle shaft into place with a soft-faced mallet. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.

    [​IMG]

    4. For the 8.25 inch axle, install the following components into the inner axle shaft housing:

    Important

    Use chassis grease in order to hold the thrust washer in place.
    1. The thrust washer (5)
    2. Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The retainer ring (7) into the clutch gear (6).
    3. The clutch gear (6) onto the inner axle shaft (1).
    4. Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5. The clutch gear shim (9)
    6. The clutch sleeve (8)
    7. The clutch fork assembly (11)
    8. The clutch fork inner spring (10)

    [​IMG]

    5. For the 9.25 inch axle, install the following components into the inner axle shaft housing:

    Important

    Use chassis grease in order to hold the thrust washer in place.
    1. The thrust washer (5)
    2. Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The second thrust washer (6)
    3. The retainer ring (7) onto the inner axle shaft (1).
    4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5. The clutch gear shim (9)
    6. The clutch sleeve (8)
    7. The clutch fork assembly (11)
    8. The clutch fork inner spring (10)
    6. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .

    [​IMG]

    7. Install the inner axle shaft housing assembly to the differential carrier assembly.
    Notice

    Refer to Fastener Notice in Cautions and Notices.

    [​IMG]

    8. Install the inner axle shaft housing bolts.
    Tighten

    Tighten the inner axle shaft housing bolts to 40 N·m (30 lb ft).

    [​IMG]

    9. For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
    1. Slide the front axle mounting bracket towards the frame.
    2. Install the front axle mounting bracket studs into the inner shaft housing mounting flange. It may be necessary to push up on the front axle mounting bracket and/or pull down on the inner axle housing in order to gain enough clearance to install the mounting bracket studs into the inner shaft housing. Install the front axle mounting bracket to frame nuts.
    Tighten

    Tighten the inner axle shaft housing mounting bracket to frame nuts to 90 N·m (67 lb ft).

    [​IMG]

    10. Install the inner axle shaft housing washers and nuts to the bracket.
    Tighten

    Tighten the inner axle shaft housing nuts to 100 N·m (75 lb ft).
    11. Connect the wheel drive shaft inboard flange to the inner axle shaft.

    [​IMG]

    12. Install the wheel drive shaft inboard flange to the inner axle shaft bolts.
    Tighten

    Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N·m (58 lb ft).
    13. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    [​IMG]

    14. Connect the wire harness to the inner axle shaft housing.

    [​IMG]

    15. Connect the electrical connector to the front axle actuator.
    16. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
    17. Lower the vehicle.
     
  9. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Inner Shaft and/or Housing Replacement - Front Drive Axle 8.25 F4WD Axle
    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
    3. Remove the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    Object Number: 763646 Size: SH
    Click here for detailed picture of above image.
    4. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
    5. Disconnect the wheel drive shaft from the inner axle shaft.

    Object Number: 763648 Size: SH
    Click here for detailed picture of above image.
    6. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift.

    Object Number: 763653 Size: SH
    Click here for detailed picture of above image.
    7. Remove the inner axle shaft housing nuts from the bracket.

    Object Number: 763644 Size: SH
    Click here for detailed picture of above image.
    8. Remove the inner axle shaft housing bolts from the differential carrier assembly.
    9. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
    10. Remove the inner axle shaft from the inner axle shaft housing.
    11. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .

    Installation Procedure

    1. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .
    2. Install the inner axle shaft into the inner axle shaft housing.
    3. Do not install the inner axle shaft completely into the inner axle shaft housing at this time. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
    4. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.
    Notice

    Refer to Fastener Notice in Cautions and Notices.

    Object Number: 763644 Size: SH
    Click here for detailed picture of above image.
    5. Install the inner axle shaft housing bolts.
    Tighten

    Tighten the inner axle shaft housing bolts to 40 N·m (30 lb ft).

    Object Number: 763653 Size: SH
    Click here for detailed picture of above image.
    6. Install the inner axle shaft housing nuts to the bracket.
    Tighten

    Tighten the inner axle shaft housing nuts to 100 N·m (75 lb ft).
    7. Install the inner axle shaft into the differential case side gear by doing the following:
    1. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
    2. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
    3. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    8. Install the wheel drive shaft inboard flange to the inner axle shaft.

    Object Number: 763646 Size: SH
    Click here for detailed picture of above image.
    9. Install the wheel drive shaft inboard flange to inner axle shaft bolts.
    Tighten

    Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N·m (58 lb ft).
    10. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    11. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
    12. Lower the vehicle.
     
  10. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Clutch Fork Replacement - Front Drive Axle
    Removal Procedure


    Object Number: 890589 Size: SH
    Click here for detailed picture of above image.
    1. Remove the inner axle shaft and housing assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
    2. Remove the clutch fork assembly (2) from the inner axle shaft housing (1).
    3. Remove the clutch fork inner spring from the differential carrier case assembly, if necessary.

    Installation Procedure


    Object Number: 890589 Size: SH
    Click here for detailed picture of above image.
    1. Install the clutch fork inner spring into the differential carrier case assembly, if necessary.
    2. Install the clutch fork assembly (2) into the inner axle shaft housing (1).
    3. Install the inner axle shaft and housing assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle
     
  11. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Clutch Fork Inspection - Front Drive Axle

    * Inspect the carrier connector for damaged splines and teeth. Replace as required.
    * Inspect the shift fork for wear, scoring, and damage to the thrust surfaces. Replace as required.
    * Inspect the differential sleeve and the inner output shaft for damaged splines and teeth. Replace as required.
    * Inspect the damper spring for breakage. Replace or repair the damper spring as needed.
    * Inspect the differential actuator and the engagement switch for damage and frayed wiring.
     
  12. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Clutch Shaft Bearing Replacement - Front Drive Axle

    * Tools Required J 34011 Pilot Bearing Remover
    * J 33842 Pilot Bearing Installer

    Removal Procedure

    1. Remove the inner axle shaft and housing assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
    2. Remove the clutch shaft from the differential carrier assembly.

    Object Number: 680254 Size: SH
    Click here for detailed picture of above image.
    3. Remove the clutch shaft pilot bearing using the J 34011 .

    Installation Procedure

    1. Lubricate the bearing with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.

    Object Number: 695745 Size: SH
    Click here for detailed picture of above image.
    2. Install the clutch shaft pilot bearing using the J 33842 .
    3. Install the clutch shaft to the differential carrier assembly.
    4. Install the inner axle shaft and housing assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
     
  13. Country Boy

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Inner Axle Seal and/or Bearing Replacement - Front Drive Axle

    * Tools Required J 8092 Universal Driver Handle - ¾ in - 10
    * J 2619-01 Slide Hammer
    * J 29369-1 Bushing and Bearing Remover
    * J 29369-2 Bushing and Bearing Remover (2-3 inch)
    * J 36609 Axle Tube Bearing Installer
    * J 45225 Axle Seal Installer

    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
    3. Remove the right side seal and/or bearing by performing the following steps:
    1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
    2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
    3. Install the inner axle shaft housing into a vise.
    4. Clamp only on the mounting flange of the inner axle shaft housing. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.

    Object Number: 834245 Size: SH
    Click here for detailed picture of above image.
    5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1).
    6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 .

    Object Number: 1332786 Size: SH
    Click here for detailed picture of above image.
    4. Remove the left side seal and/or bearing by performing the following steps:
    1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
    2. Place the differential carrier assembly into a vise.
    3. Clamp only on the mounting flange of the differential carrier assembly case. Remove the inner axle shaft using a hammer and a brass drift.
    4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 .
    6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 .

    Installation Procedure


    Object Number: 834254 Size: SH
    Click here for detailed picture of above image.
    1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).

    Object Number: 1486575 Size: SH
    Click here for detailed picture of above image.
    2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2).
    3. Install the inner axle shaft into the inner axle shaft housing.
    4. Carefully tap the inner axle shaft into place with a soft-faced mallet. Install the clutch fork assembly components. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
    5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .

    Object Number: 1332722 Size: SH
    Click here for detailed picture of above image.
    6. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).

    Object Number: 1486568 Size: SH
    Click here for detailed picture of above image.
    7. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2).
    8. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
    9. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    10. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
    11. Fill the differential carrier assembly. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
    12. Lower the vehicle.
     
  14. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Inner Axle Shaft Shim Adjustment

    * Tools Required J 34672 Depth Micrometer
    * J 8001 Dial Indicator Set

    The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced:

    * The inner axle shaft
    * The inner axle shaft housing
    * The output shaft
    * The differential carrier case
    * The ring and pinion gears
    * The differential case assembly
    * The differential bearings
    * The carrier connector

    Front drive axle clutch shims are available in the following sizes:

    8.25 Inch Axle


    9.25 Inch Axle

    1.27 mm (0.05 in)


    1.30 mm (0.05 in)

    1.52 mm (0.06 in)


    1.52 mm (0.06 in)

    1.78 mm (0.07 in)


    1.80 mm (0.07 in)

    2.03 mm (0.08 in)


    2.03 mm (0.08 in)

    2.29 mm (0.09 in)


    2.30 mm (0.09 in)

    2.54 mm (0.10 in)


    2.54 mm (0.10 in)

    2.70 mm (0.11 in)


    2.80 mm (0.11 in)

    3.05 mm (0.12 in)


    3.05 mm (0.12 in)

    3.30 mm (0.13 in)


    3.30 mm (0.13 in)

    3.56 mm (0.14 in)


    3.55 mm (0.14 in)

    3.81 mm (0.15 in)


    3.80 mm (0.15 in)

    --


    4.05 mm (0.16 in)

    --


    4.30 mm (0.17 in)

    --


    4.55 mm (0.18 in)

    --


    4.80 mm (0.19 in)

    1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .

    Object Number: 674729 Size: SH
    Click here for detailed picture of above image.
    2. Install the following components into the inner axle shaft housing, 8.25 inch axle:
    1. Install the inner axle shaft (1) into the front drive axle housing (4).
    2. Install the thrust washer (5).
    3. Install the retaining ring (7) into the front drive axle clutch gear (6).
    4. Install the front drive axle clutch gear (6) onto the inner axle shaft (1).
    Drive the front drive axle clutch gear (6) into place with a plastic hammer.
    Object Number: 694347 Size: SH
    Click here for detailed picture of above image.
    3. Install the following components into the inner axle shaft housing, 9.25 inch axle:
    1. Install the inner axle shaft (1) into the front drive axle housing (4).
    2. Install the thrust washers (5, 6).
    3. Install the retaining ring (7) into the inner axle shaft (1).

    Important

    In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.
    4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.

    Object Number: 675816 Size: SH
    Click here for detailed picture of above image.
    5. Using the J 34672 , measure the distance from the edge of the front drive axle clutch gear to the machined flange surface of the inner axle housing.

    Object Number: 674843 Size: SH
    Click here for detailed picture of above image.
    6. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
    7. Subtract the measurement obtained in step 6 from the measurement obtained in step 7.
    8. The correct shim size will be one size smaller than the figure obtained in the previous step.
    Note the following examples:
    * If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim.
    * If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim.

    Alternate Adjustment Method

    Important

    Use this method only if the proper tools for calculating the shim size are unavailable.
    1. Install the original shim to the shaft.
    2. Use the chassis grease in order to hold the shim in place. Install the assembled axle tube and the shaft to the carrier.
    Do not use sealer at this time.
    Notice

    Refer to Fastener Notice in Cautions and Notices.
    3. Install the bolts.
    Tighten

    Tighten the bolts to 40 N·m (30 lb ft).

    Object Number: 206841 Size: SH
    Click here for detailed picture of above image.
    4. Measure the shaft end play using the following procedure:
    1. Install the J 8001 or the equivalent on the axle tube end.
    2. The plunger of the indicator must be at a right angle to the axle flange. Move the shaft back and forth and read the end play.
    3. The correct end play is 0.03-0.51 mm (0.001-0.020 in). If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.
     
  15. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front

    * Tools Required J 8614-01 Flange and Pulley Holding Tool
    * J 36366 Pinion Oil Seal Installer

    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    3. Remove the brake calipers. Refer to Brake Caliper Replacement - Front in Disc Brakes.
    4. Remove the differential carrier assembly shield, if equipped. Refer to Shield Replacement .
    5. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.

    Object Number: 363785 Size: SH
    Click here for detailed picture of above image.
    6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1).

    Notice

    When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint.
    7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1).
    8. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft and move out of the way as necessary.

    Object Number: 157174 Size: SH
    Click here for detailed picture of above image.
    9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components:
    * The pinion bearings
    * The pinion seal
    * The carrier bearings
    * The axle bearings
    * The axle seals

    Object Number: 788905 Size: SH
    Click here for detailed picture of above image.
    10. Scribe an alignment line between the pinion shaft and the pinion yoke.

    Object Number: 664065 Size: SH
    Click here for detailed picture of above image.
    11. Install the J 8614-01 onto the pinion as shown.
    12. Remove the pinion nut while holding the J 8614-01 .

    Object Number: 664070 Size: SH
    Click here for detailed picture of above image.
    13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
    14. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).

    Important

    Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case.
    15. Remove the oil seal using a suitable seal removal tool.

    Installation Procedure


    Object Number: 664080 Size: SH
    Click here for detailed picture of above image.
    1. Install the oil seal by doing the following:
    1. Position the oil seal over the seal bore.
    2. Install the J 36366 over the oil seal.
    3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface.
    2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke.
    3. Install the pinion yoke.
    Align the reference marks made during removal.
    Notice

    Refer to Pinion Flange/Yoke Installation Notice in Cautions and Notices.
    4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
    5. Install the washer and a new pinion nut.

    Object Number: 664065 Size: SH
    Click here for detailed picture of above image.
    6. Install the J 8614-01 onto the pinion yoke as shown.
    Notice

    Refer to Fastener Notice in Cautions and Notices.

    Important

    If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
    7. Tighten the pinion nut while holding the J 8614-01 .
    Tighten

    Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
    8. Measure the rotating torque of the pinion using an inch-pound torque wrench.
    Compare the measurement with the rotating torque recorded earlier. Tighten

    Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 N·m (3-5 lb in) greater than the torque recorded during removal.
    9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.

    Object Number: 363785 Size: SH
    Click here for detailed picture of above image.
    10. Install the propeller shaft universal joint (2) to the pinion yoke (1).
    11. Align the reference marks made during removal. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1).
    Tighten

    Tighten the yoke retainer bolts to 25 N·m (18 lb ft).
    12. Inspect the axle lubricant level, and add, if necessary. Refer to Lubricant Level Inspection - Front Drive Axle .
    13. Install the differential carrier assembly shield, if equipped. Refer to Shield Replacement .
    14. Install the brake calipers. Refer to Brake Caliper Replacement - Front in Disc Brakes.
    15. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    16. Lower the vehicle.
     
  16. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Differential Carrier Assembly Bushing Replacement

    * Tools Required J 33791 Carrier Bushing Remover/Installer
    * J 36616 Axle Mount Bushing Remover/Installer

    Removal Procedure

    1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .

    Object Number: 893247 Size: SH
    Click here for detailed picture of above image.
    2. Remove the upper differential carrier assembly bushing by performing the following steps:
    1. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown.
    2. Remove the upper differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18.

    Object Number: 892847 Size: SH
    Click here for detailed picture of above image.
    3. Remove the lower differential carrier assembly bushing by performing the following steps:
    1. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown.
    2. Remove the lower differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18.

    Installation Procedure


    Object Number: 892851 Size: SH
    Click here for detailed picture of above image.
    1. Install the lower differential carrier assembly bushing by performing the following steps:
    1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
    2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.

    Object Number: 893253 Size: SH
    Click here for detailed picture of above image.
    2. Install the upper differential carrier assembly bushing by performing the following steps:
    1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown.
    2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore.
    3. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
     
  17. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Differential Carrier Assembly Replacement
    Removal Procedure

    1. Turn the steering wheel all the way to the left.
    2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    3. Place jack or utility stands at the rear end of the vehicle.
    4. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
    5. Remove the front differential carrier assembly shield, if equipped. Refer to Shield Replacement .
    6. Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
    7. Disconnect the front propeller shaft from the differential carrier assembly. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
    8. Remove the relay rod. Refer to Relay Rod Replacement in Steering Linkage.
    9. Support the differential carrier assembly with a transmission jack or equivalent.

    Object Number: 763646 Size: SH
    Click here for detailed picture of above image.
    10. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft, both sides.

    Object Number: 834234 Size: SH
    Click here for detailed picture of above image.
    11. Disconnect the electrical connector from the front axle actuator, S4WD axle only.

    Object Number: 924830 Size: SH
    Click here for detailed picture of above image.
    12. Disconnect the wire harness from the inner axle shaft housing, S4WD axle only.

    Object Number: 924846 Size: SH
    Click here for detailed picture of above image.
    13. Disconnect the wire harness from the differential carrier assembly, S4WD axle only.

    Object Number: 834272 Size: SH
    Click here for detailed picture of above image.
    14. Disconnect the vent hose from the differential carrier assembly.

    Object Number: 834241 Size: SH
    Click here for detailed picture of above image.
    15. Remove the inner axle housing nuts and washers from the bracket.

    Object Number: 834276 Size: SH
    Click here for detailed picture of above image.
    16. Remove the differential carrier assembly upper mounting bolt and the nut.
    17. Pivot the differential carrier assembly forward and down on the lower mount bolt while it is being supported by the transmission jack.
    18. Secure the differential carrier assembly to the jack.

    Object Number: 834278 Size: SH
    Click here for detailed picture of above image.
    19. Remove the differential carrier assembly lower mounting bolt and the nut.
    20. Remove the differential carrier assembly.

    Installation Procedure

    1. Install the differential carrier assembly.

    Object Number: 834278 Size: SH
    Click here for detailed picture of above image.
    2. Install the differential carrier assembly lower mounting bolt and the nut.
    3. Do not tighten the bolt at this time. Pivot the differential carrier assembly up and back on the lower mount bolt while it is being supported by the transmission jack.

    Object Number: 834276 Size: SH
    Click here for detailed picture of above image.
    4. Install the differential carrier assembly upper mounting bolt and the nut.
    Notice

    Refer to Fastener Notice in Cautions and Notices.

    Object Number: 834241 Size: SH
    Click here for detailed picture of above image.
    5. Install the inner axle housing washers and nuts to the bracket.
    Tighten
    * Tighten the inner axle housing nuts to 100 N·m (75 lb ft).
    * Tighten the upper and the lower differential carrier assembly bolts to 100 N·m (75 lb ft).

    Object Number: 834272 Size: SH
    Click here for detailed picture of above image.
    6. Connect the vent hose to the differential carrier assembly.
    7. Remove the transmission jack.

    Object Number: 924846 Size: SH
    Click here for detailed picture of above image.
    8. Connect the wire harness to the differential carrier assembly, S4WD axle only.

    Object Number: 924830 Size: SH
    Click here for detailed picture of above image.
    9. Connect the wire harness to the inner axle shaft housing, S4WD axle only.

    Object Number: 834234 Size: SH
    Click here for detailed picture of above image.
    10. Connect the electrical connector to the front axle actuator, S4WD axle only.

    Object Number: 763646 Size: SH
    Click here for detailed picture of above image.
    11. Install the wheel drive shaft inboard flange to inner axle shaft bolts, both sides.
    Tighten

    Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N·m (58 lb ft).
    12. Install the relay rod. Refer to Relay Rod Replacement in Steering Linkage.
    13. Install the front propeller shaft to the differential carrier assembly. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
    14. Fill the differential carrier assembly. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
    15. Install the front differential carrier assembly shield, if equipped. Refer to Shield Replacement .
    16. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
    17. Remove the utility stands.
    18. Lower the vehicle.
     
  18. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Bracket Replacement 15 HD, 25, 35 Series
    Removal Procedure

    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
    3. Remove the air conditioning compressor-(4.8 L, 5.3 L and 6.0 L engines. Refer to Compressor Replacement in HVAC Systems with A/C-Manual.

    Object Number: 365933 Size: SH
    Click here for detailed picture of above image.
    4. Remove the nuts and the washers from the bracket.
    5. Remove the bracket from the vehicle.

    Installation Procedure


    Object Number: 365933 Size: SH
    Click here for detailed picture of above image.
    1. Install the bracket to the vehicle.
    Notice

    Refer to Fastener Notice in Cautions and Notices.
    2. Install the washers and the nuts to the bracket.
    Tighten

    Tighten the bracket to frame nuts to 90 N·m (67 lb ft).
    3. Install the air conditioning compressor -4.8 L, 5.3 L and 6.0 L engines. Refer to Compressor Replacement in HVAC Systems with A/C-Manual.
    4. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
    5. Lower the vehicle.
     
  19. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Bracket Replacement 15 LD Series
    Removal Procedure


    Object Number: 395143 Size: SH
    Click here for detailed picture of above image.
    1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    2. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
    3. Remove the nuts and the washers from the bracket.
    4. Remove the bolt from the bracket.
    5. Remove the bracket from the vehicle.

    Installation Procedure


    Object Number: 395143 Size: SH
    Click here for detailed picture of above image.
    1. Install the bracket to the vehicle.
    2. Install the bolt to the frame and the bracket.

    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.
    3. Install the washers and the nuts to the bracket.
    Tighten

    Tighten the nuts to 90 N·m (70 lb ft).
    4. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement .
    5. Lower the vehicle.
     
  20. Country Boy

    Country Boy haz 12"s!

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    Re: Complete disassembly and reassembly of a IFS front assembly.

    Differential Carrier Assembly - Disassemble 8.25 Inch Axles

    * Tools Required J 22912-01 Split-Plate Bearing Puller
    * J 2619-01 Slide Hammer
    * J 29369-1 Bushing and Bearing Remover
    * J 33791 Carrier Bushing Remover/Installer
    * J 34011 Pilot Bearing Remover
    * J 36598 Holding Fixture
    * J 36599-A Side Bearing Nut Wrench
    * J 36616 Axle Mount Bushing Remover/Installer
    * J 45765 Pinion Remover
    * J-45858 Front Axle Bearing Race Remover/Installer - 8.25 Inch Axle
    * J 8614-01 Flange and Pulley Holding Tool

    Inspection Procedure

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


    Object Number: 893247 Size: SH
    Click here for detailed picture of above image.
    1. Remove the upper differential carrier assembly bushing by performing the following steps:
    1. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown.
    2. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.

    Object Number: 892847 Size: SH
    Click here for detailed picture of above image.
    2. Remove the lower differential carrier assembly bushing by performing the following steps:
    1. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown.
    2. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.

    Object Number: 893264 Size: SH
    Click here for detailed picture of above image.
    3. Remove the front axle actuator, S4WD axle only.
    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.

    Object Number: 893259 Size: SH
    Click here for detailed picture of above image.
    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.

    Object Number: 892810 Size: SH
    Click here for detailed picture of above image.
    9. Remove the following components from the inner axle shaft housing, S4WD axle only:
    1. The clutch fork inner spring (10)
    2. The clutch fork assembly (11)
    3. The clutch shaft shim (9)
    4. The clutch shaft sleeve (8)
    5. The front drive axle clutch gear (6) by doing the following:
    1. Clamp the inner axle shaft housing (4) in a vise.
    2. Clamp only on the mounting flange. 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).
    6. Remove the front drive axle clutch gear (6)
    7. Remove the thrust washer (5)
    8. Remove the inner axle shaft (1)

    Object Number: 834245 Size: SH
    Click here for detailed picture of above image.
    10. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Install the inner axle shaft housing into a vise.
    2. Clamp only on the mounting flange of the inner axle shaft housing. Install the J 29369-1 (1) behind the inner axle shaft bearing.
    3. Install the J 2619-01 (2) to the J 29369-1 (1).
    4. Remove the inner axle shaft bearing and the seal using the J 2619-01 .

    Object Number: 1332786 Size: SH
    Click here for detailed picture of above image.
    11. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
    1. Place the differential carrier assembly into a vise.
    2. Clamp only on the mounting flange of the differential carrier assembly case. Install the J 29369-1 (1) behind the inner axle shaft bearing.
    3. Install the J 2619-01 (2) to the J 29369-1 .
    4. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01 .
    12. Remove the differential carrier assembly from the vise.
    13. Remove the front drive axle clutch shaft, S4WD axle only.

    Object Number: 680254 Size: SH
    Click here for detailed picture of above image.
    14. Use the J 34011 in order to remove the clutch shaft bearing, S4WD axle only.

    Object Number: 847064 Size: SH
    Click here for detailed picture of above image.
    15. Remove the vent connector.

    Object Number: 1332740 Size: SH
    Click here for detailed picture of above image.
    16. Remove the differential carrier assembly bolts.

    Object Number: 1332738 Size: SH
    Click here for detailed picture of above image.
    17. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case with a hammer and a brass drift.
    18. Remove the differential case assembly.
    Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut by prying up on the locks, S4WD axle - both sides, F4WD axle - left side.
    Object Number: 680101 Size: SH
    Click here for detailed picture of above image.
    19. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following, S4WD axle - both sides, F4WD axle - left side:
    1. Install the J 36599-A onto the differential bearing adjuster nut.
    2. Turn the J 36599-A clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore.
    20. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift, S4WD axle - both sides, F4WD axle - left side.

    Object Number: 664065 Size: SH
    Click here for detailed picture of above image.
    21. Install the J 8614-01 as shown.
    22. Remove the pinion nut while holding the J 8614-01 . Remove the washer.

    Object Number: 664070 Size: SH
    Click here for detailed picture of above image.
    23. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
    24. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
    25. 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.
    26. Install the J 36598 into a vise.

    Object Number: 680106 Size: SH
    Click here for detailed picture of above image.
    27. Install the left differential carrier case half onto the J 36598 and the J 36598-6.
    28. 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

    Object Number: 890234 Size: SH
    Click here for detailed picture of above image.
    29. Install the J 36598-5 (3) behind the inner pinion bearing cup.
    30. Thread the forcing screw of the J 36598 (1) onto the J 36598-5 (3) until fully seated.
    31. 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.

    Object Number: 680114 Size: SH
    Click here for detailed picture of above image.
    32. Install the J 36598-5 (2) behind the outer pinion bearing cup.
    33. Install the forcing screw of the J 36598 (1) to the J 36598-5 (2).
    34. 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

    Object Number: 1486597 Size: SH
    Click here for detailed picture of above image.
    35. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown.
    36. 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
    37. Remove the drive pinion seal using a suitable seal remover.
    38. Remove the outer pinion bearing from the differential carrier case half.

    Object Number: 1486598 Size: SH
    Click here for detailed picture of above image.
    39. Install the J 45858-4 over the inner pinion bearing cup.

    Object Number: 1486602 Size: SH
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    40. Install the forcing screw (1) of the J 45858 into the J 45858-4 (2).
    41. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.

    Object Number: 1486596 Size: SH
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    42. 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.

    Object Number: 1486591 Size: SH
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    43. Install the J 45858-5 into the pinion bearing bore behind the outer pinion bearing cup.
    44. 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. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
    45. Remove the collapsible spacer from the drive pinion.

    Object Number: 680110 Size: SH
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    46. Install the J 22912-01 between the pinion bearing and the drive pinion.
    47. Remove the inner pinion bearing using the J 22912-01 and a hydraulic press.
    48. Remove the pinion gear selectable shim.
     

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