Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle)

Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle)

Special Tools

* GE-8092 - Universal Driver Handle - 3/4 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 InstallerJ 36609

* J-44215 - Rear Seal Installer

* J-45225 - Axle Seal Installer

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (8.6/9.25 Inch Axles) Front Axle Lubricant Replacement (8.6/9.25 Inch Axles).

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 Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles).

2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles).

3. Install the inner axle shaft housing into a vise.
Clamp only on the mounting flange of the inner axle shaft housing.

4. Install the J-2619-01 - slide hammer , 8.25 inch axle, or the J-29369-2 - bushing and bearing remover , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.




5. Install the J-2619-01 - slide hammer (2) to the J-29369-1 - bushing and bearing remover or the J-29369-2 - bushing and bearing remover (1).

6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J-2619-01 - slide hammer.





Note: Support the wheel drive shaft in order to not over flex the CV joint.

4. If only replacing the left side seal, perform the following steps:

1. Place an alignment mark between the inner axle shaft and the wheel drive shaft.

2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Removal and Installation Front Suspension.

3. Disconnect the wheel drive shaft (1) from the inner axle shaft.

4. Remove the inner axle shaft using a hammer and a brass drift.

5. Remove the inner axle shaft seal using a suitable seal remover tool.




5. If replacing both the left side seal and bearing, perform the following steps:

1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (2500 4WD) Differential Carrier Assembly Replacement (2500 4WD).

2. Place the differential carrier assembly into a vise.
Clamp only on the mounting flange of the differential carrier assembly case.

3. Remove the inner axle shaft using a hammer and a brass drift.

4. Install the J-29369-1 - bushing and bearing remover , 8.25 inch axle, or the J-29369-2 - bushing and bearing remover , 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 - slide hammer (2) to the J-29369-1 - bushing and bearing remover or the J-29369-2 - bushing and bearing remover.

6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J-2619-01 - slide hammer.

Installation Procedure




1. Install the right side bearing with the square shoulder in using the J-29369-1 - bushing and bearing remover (1) and the GE-8092 - universal driver handle (2).




2. Install the new axle shaft seal using the J-45225 - axle seal installer (1) and the GE-8092 - universal driver handle (2) if servicing the 8.25 inch axle, or J-44215 - rear seal installer if servicing the 9.25 inch axle.

3. Install the inner axle shaft into the inner axle shaft housing.
Carefully tap the inner axle shaft into place with a soft-faced mallet.

4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles).

5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles).




6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J-36609 - axle tube bearing installer (1) and the GE-8092 - universal driver handle (2).




7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J-45225 - axle seal installer (1) and the GE-8092 - universal driver handle (2) if servicing the 8.25 inch axle, or J-44215 - rear seal installer if servicing the 9.25 inch axle.

8. If both the left side bearing and seal was removed, perform the following step. 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.
Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.

9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (2500 4WD) Differential Carrier Assembly Replacement (2500 4WD).




10. If only the left side seal was removed, perform the following step. Install the seal using the J-45225 - axle seal installer (1) and a soft-faced mallet, if servicing the 8.25 inch axle, or J-44215 - rear seal installer if servicing the 9.25 inch axle.
Tap only on the center portion of the J-45225 - axle seal installer in order to drive the seal in evenly.




11. If only the left side seal was removed, perform the following step. Install the inner axle shaft (1) 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.
Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in
the differential case side gear.

12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Removal and Installation Front Suspension.

13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft.

Caution: Refer to Fastener Caution Fastener Caution.

14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft).

15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (8.6/9.25 Inch Axles) Front Axle Lubricant Replacement (8.6/9.25 Inch Axles).

16. Lower the vehicle.