Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6, 9.5 Inch Axles)
Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6, 9.5 Inch Axles)
Special Tools
* J 8614-01 - Flange and Pulley Holding Tool
* J 38694 - Extension Housing Oil Pump/Seal Installer
Removal Procedure
Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
3. Remove the rear brake calipers. Refer to Rear Brake Caliper Replacement (With Single Rear Wheel) (Rear Brake Caliper Replacement (With Single Rear Wheel))Rear Brake Caliper Replacement (Dual Rear Wheel) (Rear Brake Caliper Replacement (Dual Rear Wheel)).
4. Remove the rear propeller shaft.
* For the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (One-Piece Propeller Shaft Replacement).
* For the 2 piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
5. Using an inch pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components:
* The pinion bearings
* The pinion oil seal
* The differential case bearings
* The axle bearings
* The axle seals
6. Scribe an alignment line between the pinion shaft and the pinion yoke.
7. Using the J 8614-01 - holding tool , remove and discard the pinion nut.
8. Remove the washer.
Note: Use a clean container in order to retrieve the lubricant.
9. Using the J 8614-01 - holding tool (1), (2) and (3), remove the pinion yoke.
10. Using a suitable tool, remove and discard the pinion oil seal.
Installation Procedure
1. Using the J 38694 - installer , install the NEW pinion seal
2. Apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers ([1][2]Drive/Propeller Shaft).
Caution: Refer to Pinion Flange/Yoke Installation Caution (Pinion Flange/Yoke Installation Caution).
3. Align the reference marks and install the pinion yoke.
Note: Proceed to step 5 if the new pinion nut cannot be installed.
4. Install the washer and the NEW pinion nut.
5. Perform the following steps in order to seat the pinion yoke onto the pinion.
1. Remove the pinion nut washer.
2. Install the old pinion nut.
3. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed.
4. Remove the old pinon nut.
5. Install the pinion nut washer
6. Install the new pinion nut.
Caution: Refer to Fastener Caution (Fastener Caution).
Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
6. Using the J 8614-01 - holding tool , tighten the pinion nut until the pinion end play is just taken up.
7. Rotate the pinion while tightening the nut to seat the bearings.
Note: Tighten the pinion nut in small increments until the proper torque is reached.
8. Using a inch pound torque wrench, measure and the rotating torque of the pinion. The rotating torque is 0.40-0.57 Nm (3-5 lb in) is greater than the rotating torque recorded during removal and compare that to the measurement taken during the 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.
10. Align the reference marks and install the propeller shaft (3) to the pinion yoke (4).
11. Install the propeller shaft.
* For the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (One-Piece Propeller Shaft Replacement).
* For the 2 piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
12. Install the rear brake calipers. Refer to Rear Brake Caliper Replacement (With Single Rear Wheel) (Rear Brake Caliper Replacement (With Single Rear Wheel))Rear Brake Caliper Replacement (Dual Rear Wheel) (Rear Brake Caliper Replacement (Dual Rear Wheel)).
13. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
14. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 Inch Axle) (Rear Axle Lubricant Level Inspection (8.6, 9.5 Inch Axle))Rear Axle Lubricant Level Inspection (9.75, 10.5 and 10.75 Inch Axle) (Rear Drive Axle).
15. Remove the support and lower the vehicle.