Front Axle Assembly

Front Axle Assembly

















Special Tool(s)

CAUTION: Any operation in which the pinion nut and washer were disturbed changes the differential pinion bearing preload. Carefully reset the preload during assembly.

1. Place the vehicle in NEUTRAL and position on a hoist.
2. Remove the front axle assembly from the vehicle.
3. Remove the components in the order indicated in the illustration and table.








4. To assemble, reverse the disassembly procedure.
5. Fill the axle to the specified fluid level with the fluid listed in Specifications.

Item 1: Pinion Nut and Washer Disassembly Note





1. Measure and record the pinion bearing torque preload.
^ Using a Nm (inch-pound) torque wrench, rotate the pinion. Measure the torque required to maintain pinion rotation.





2. Index-mark the pinion flange and the pinion stem.





3. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.

Item 2: Pinion Flange Disassembly Note





1. Using the special tool, remove the pinion flange.
2. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange if damaged.

Item 4: Pinion Oil Seal Disassembly Note





1. Using the special tool, remove the pinion seal.

Item 8: Axle Shaft Oil Seal Disassembly Note





1. Using the special tool, remove the axle seal.

Item 9: Axle Shaft Bearing Disassembly Note





1. Using the special tool. remove the axle shaft bearing.

Item 14: Differential Case Disassembly Note





1. Install the special tool.





2. Install the axle assembly into the bench fixture.





3. Install the special tools.





4. CAUTION: Overspreading can damage the differential housing.

Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the differential carrier spreader screw.
3 Remove the dial indicator.





5. CAUTION: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the housing.
1 Position the wood blocks.
2 Push downward on the pry bars.
3 Remove the differential assembly.
4 Remove the special tool.

Item 16: Inner Pinion Bearing Disassembly Note





1. Press the differential inner pinion bearing off the pinion.
1 Install special tool under the pinion bearing.
2 Using a shop press, remove the bearing from the pinion.

Item 17: Pinion Position Shim Disassembly Note





1. Measure and record the thickness of the pinion position shim for reference during assembly.

Item 18: Inner Pinion Bearing Cup Disassembly Note





1. To prevent it from cocking in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the cup with a brass drift.

Item 20: Outer Pinion Bearing Cup Disassembly Note





1. To prevent it from cocking in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the cup with a brass drift.

Item 24: Differential Bearing Disassembly Note





1. Assemble the special tools.





2. Position the special tool on the differential bearing.





3. Using the special tool, remove the bearing.

Item 32 and 33: Axle Isolator Bushing Disassembly Note





1. Place the special tool on the isolator and index-mark the housing in line with the arrow on the special tool.





2. Using a feeler gauge, measure the gap between the isolator flange and the axle housing.





3. Tap the special tool on, between the axle housing and the isolator flange.





4. Assemble the remaining special tools and remove and discard the isolator.

Item 32 and 33: Axle Isolator Bushing Assembly Note





1. Position the new isolator in the housing bore and install the special tools. Align the arrow on the special tool with the index mark on the housing.





2. Tighten the drawbolt to install the isolator.
^ Draw the isolator into the housing to the gap measured when the isolator was removed.

Item 25: Differential Bearing Shim Assembly Note





1. Install the special tool.





2. Install the differential case in the differential housing.





3. NOTE: Repeat this step until obtaining a consistent reading.

Measure the total end play.
1 Install the special tool.
2 Force the differential case as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.
3 Force the differential case as far as possible in the opposite direction.
4 Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this procedure.





4. Remove the special tool, then remove the differential case.
1 Remove the special tool.
2 Remove the differential case.





5. CAUTION: Do not reuse the original bolts.

Using a suitable press, install the differential ring gear.
1 Position the differential ring gear and the differential case. Start two or three new bolts to align the holes in the ring gear and the differential case.
2 Using a suitable press, install the differential ring gear.





6. Install the remaining new bolts. Tighten all of the bolts to specification.





7. Install the special tool, and position the assembly in the differential housing.
1 Install the special tool.
2 Position the assembly in the differential housing.





8. Position the special tool.





9. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.





10. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D in this procedure.





11. Remove the special tool.





12. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
13. Complete the worksheet, and select the appropriate thickness differential shims. New differential shims are available in 0.0762 mm (0.003 inch), 0.127 mm (0.005 inch), 0.254 mm (0.010 inch), and 0.762 mm (0.030 inch) thickness.





Differential Bearing Shim Selection Procedure Worksheet

Item 24: Differential Bearings Assembly Note





1. Install the differential shims and the differential bearing.
1 Position the differential shims and the differential bearing.
2 Using a suitable press, install the differential bearing.
^ Repeat this step for opposite side of the differential case.
^ Most axles will have the larger amount of shims on the ring gear side and the smaller amount on the case side.

Item 18 and 20: Inner and Outer Pinion Bearing Cup Assembly Note

1. CAUTION: Always install new differential pinion bearings when installing new differential drive pinion bearing cups.

Lubricate the new differential drive pinion bearing cups.





2. Using the special tools, install the differential drive pinion bearing cups.

Item 17: Pinion Position Shim and Item 16: Inner Pinion Bearing Assembly Note





1. NOTE: Apply a light film of oil to the differential pinion bearings before installing them.

Assemble and position the following in the differential housing.
1 Position the Screw.
2 Position the Aligning Adapter.
3 Position the inner differential pinion bearing.
4 Position the Gauge Disc.
5 Position the Gauge Block.
6 Position the outer differential pinion bearing.
7 Thread on the Handle.





2. Using a Nm (inch-pound) torque wrench, tighten the Handle.





3. NOTE: Offset the Gauge Block to obtain an accurate reading.

Rotate the Gauge Block several half turns to make sure the differential pinion bearings seat correctly. Position the special tool as shown.





4. Install the special tool and the paper shipping tags.
1 Position the special tool and the paper shipping tags.
2 Install the differential bearing caps.
3 Install the bolts.





5. NOTE: Use a feeler gauge, or flat, clean drive pinion position shims as a measuring device.

NOTE: Selection of a shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge, or a flat, clean drive pinion position shim, measure between the Gauge Block and the Gauge Tube. Record the measurement.
^ Remove the special tools after determining the correct shim thickness.








6. Select the correct thickness drive pinion position shim.
^ New drive pinion position shims are available in the following sizes:





^ If installing a new gearset, notice the plus (+), minus (-), or zero (0) etching on both the original and the new drive pinion, and adjust the thickness of the new shim according to the following charts. If etching is plus (+), subtract the number from the gauged shim thickness. If etching is minus (-), add the number to the gauged shim thickness.





7. Install the pinion position shim and the differential pinion bearing.
^ Using the special tool and a suitable press, seat the differential pinion bearing firmly against the pinion position shim.

Item 14: Differential Case Assembly Note





1. Install the special tools.
^ Position the clutch housing gauge needle in the differential carrier spreader adapter hole.





2. CAUTION: Overspreading can damage the differential housing.

Spread the differential housing to the specification.





3. Remove the special tools.





4. NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.

Install the differential bearing cups and the differential case in the differential housing.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential case in place.





5. CAUTION: Do not tighten the bolts to specification at this time.

Install the differential bearing caps in their original positions.
1 Position the differential bearing caps.
2 Install the bolts hand-tight.





6. Remove the special tools.





7. Tighten the bolts.
8. Verify that the differential case rotates freely.





9. Using the special tools, measure the backlash At three equally spaced points on the differential ring gear.
1 Mount the special tool.
2 Position the special tool.
3 Zero the indicator.
4 Turn the differential ring gear without turning the pinion gear. Record the measurement.
^ The backlash tolerance is 0.13 mm (0.005 inch) to 0.20 mm (0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.005 mm (0.002 inch) indicates gear/case runout.
^ If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.

Item 9: Axle Shaft Bearing Assembly Note





1. Using the special tools, install the axle tube bearing.

Item 8: Axle Shaft Oil Seal Assembly Note





1. Using the special tools, install the axle shaft oil seal.

Item 4: Pinion Oil Seal Assembly Note





1. NOTE: Lubricate the pinion seal.

Using the special tool, install the pinion seal.

Item 2: Pinion Flange Assembly Note





1. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools.

NOTE: Lubricate the pinion flange splines. Align the index marks.

Using the special tool, install the pinion flange.

Item 1: Pinion Nut and Washer Assembly Note





1. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.

Using the special tool to hold the pinion flange, tighten the nut to set the preload.
^ Tighten the nut, rotating the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during removal.