REAR AXLE

Axle Shaft, Bearing and Seal

REMOVAL & INSTALLATION

Pickups

1. Raise and support the rear end on jackstands.
2. Remove the wheel and brake drum.
3. Remove the brake shoes.
4. Remove the parking brake cable retainer.
5. Disconnect and cap the brake lines at the wheel cylinders.
6. Remove the bolts securing the backing plate and bearing housing.
7. Slide the axle shaft from the axle housing. Be careful to avoid damaging the oil seal with the shaft.
8. If the seal in the axle housing is damaged in any way, it must be replaced. The seal can be removed using a slide hammer and adapter.
9. Remove two of the backing plate bolts, diagonally from each other.
10. Using a grinding wheel, grind down the bearing retaining collar in one spot, until about 5mm (0.197 in.) remains before you get to the axle shaft. Place a chisel at this point and break the collar. Be careful to avoid damaging the shaft.

    CAUTION
    Wear some kind of protective goggles when grinding the collar and breaking the collar from the shaft!

11. Using a press or puller, remove the hub and bearing assembly from the shaft. Remove the spacer from the shaft.
12. Remove the bearing and seal from the hub.
13. Using a drift, tap the race from the hub.
14. Check all parts for wear or damage. If either race is to be replaced, both must be replaced. The race in the axle housing can be removed with a slide hammer and adapter. It's a good idea to replace the bearing and races as a set. It's also a good idea to replace the seals, regardless of what other service is being performed.

    To install:

15. The outer race must be installed using an arbor press. The inner race can be driven into place in the axle housing.
16. Pack the hub with lithium based wheel bearing grease.
17. Tap a new oil seal into the axle housing until it is flush with the end of the housing. Coat the seal lip with wheel bearing grease.
18. Install a new spacer on the shaft with the larger flat surface up.
19. Install a new seal in the hub.
20. Thoroughly pack the bearing with clean, lithium based, wheel bearing grease. If one is available, use a grease gun adapter meant for packing bearings. These are available at all auto parts stores.
21. Place the bearing in the hub, and, using a press, press the hub and bearing assembly onto the shaft.
22. Press the new collar onto the shaft. The press pressure for the collar is critical. Press pressures should be 9,240-13,420 lb. (4,200-6100 kg).
23. Install one shaft in the housing being very careful to avoid damaging the inner seal.
24. If only on shaft was being serviced, the other must now be removed to check bearing play on the serviced axle. If both shafts were removed, leave the other one out for now.
25. Tighten the backing plate bolts on the one installed axle to 80 ft. lbs.
26. Mount a dial indicator on the backing plate, with the pointer resting on the axle shaft flange. Check the axial play. Standard bearing play should be 0.65-0.95mm (0.0256-0.0374 in.).
27. If play is not within specifications, shims are available for correcting it.
28. Install the other shaft and torque the backing plate bolts. Check the play as on the first shaft. Play should be 0.05-0.25mm (0.0019-0.0098 in.). If not, correct it with shims.
29. Install the brake drums and wheels. Bleed the brake system.

MPV

1. Raise and support the rear end on jackstands.
2. Remove the wheel and brake drum.
3. Remove the brake shoes.
4. Remove the parking brake cable retainer.
5. Disconnect and cap the brake lines at the wheel cylinders.
6. Remove the bolts securing the backing plate and bearing housing.
7. Slide the axle shaft from the axle housing. Be careful to avoid damaging the oil seal with the shaft.
8. If the seal in the axle housing is damaged in any way, it must be replaced. The seal can be removed using a slide hammer and adapter.
9. Remove two of the backing plate bolts, diagonally from each other.
10. Using a grinding wheel, grind down the bearing retaining collar in one spot, until about 5mm remains before you get to the axle shaft. Place a chisel at this point and break the collar. Be careful to avoid damaging the shaft.

    CAUTION
    Wear some kind of protective goggles when grinding the collar and breaking the collar from the shaft!

11. Using a press or puller, remove the hub and bearing assembly from the shaft. Remove the spacer from the shaft.
12. Remove the bearing and seal from the hub.
13. Using a drift, tap the race from the hub.
14. Check all parts for wear or damage. If either race is to be replaced, both must be replaced. The race in the axle housing can be removed with a slide hammer and adapter. It's a good idea to replace the bearing and races as a set. It's also a good idea to replace the seals, regardless of what other service is being performed.

    To install:

15. The outer race must be installed using an arbor press. The inner race can be driven into place in the axle housing.
16. Pack the hub with lithium based wheel bearing grease.
17. Tap a new oil seal into the axle housing until it is flush with the end of the housing. Coat the seal lip with wheel bearing grease.
18. Install a new spacer on the shaft with the larger flat surface up.
19. Install a new seal in the hub.
20. Thoroughly pack the bearing with clean, lithium based, wheel bearing grease. If one is available, use a grease gun adapter meant for packing bearings. These are available at all auto parts stores.
21. Place the bearing in the hub, and, using a press, press the hub and bearing assembly onto the shaft.
22. Press the new collar onto the shaft. The press pressure for the collar is critical. Press pressures should be 9,240-13,420 lb. (4,200-6,100 kg).
23. Install one shaft in the housing being very careful to avoid damaging the inner seal.
24. If only on shaft was being serviced, the other must now be removed to check bearing play on the serviced axle. If both shafts were removed, leave the other one out for now.
25. Tighten the backing plate bolts on the one installed axle to 80 ft. lbs.
26. Mount a dial indicator on the backing plate, with the pointer resting on the axle shaft flange. Check the axial play. Standard bearing play should be 0.57mm.
27. If play is not within specifications, shims are available for correcting it. See the table below:
28. Install the other shaft and torque the backing plate bolts. Check the play as on the first shaft.
29. Install the brake drums and wheels. Bleed the brake system.

Navajo

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. Remove the rear wheels and brake drums.
4. Drain the rear axle lubricant.
5. For all axles except 3.73:1 and 4.10:1 ratio.
   1. Remove the differential pinion shaft lock bolt and differential pinion shaft.

      NOTE: The pinion gears may be left in place. Once the axle shafts are removed, reinstall the pinion shaft and lock bolt.

   2. Push the flanged end of the axle shafts toward the center of the vehicle and remove the C-lockwasher from the end of the axle shaft.
   3. Remove the axle shafts from the housing. If the seals and/or bearing are not being replaced, be careful not to damage the seals with the axle shaft splines upon removal.
6. For 3.73:1 and 4.10:1 ratio axles.
   1. Remove the pinion shaft lock bolt. Place a hand behind the differential case and push out the pinion shaft until the step contacts the ring gear.
   2. Remove the C-lockwasher from the axle shafts.
   3. Remove the axle shafts from the housing. If the seals and/or bearing are not being replaced, be careful not to damage the seals with the axle shaft splines upon removal.

      Fig. 6: Pull the pinion shaft out of the axle carrier. DO NOT rotate the axle with the pinion shaft removed!

      Fig. 7: Push in on the axle flange (wheel side) and remove the axle C-lock (A) from the end of the axle (B)

      Fig. 8: Slide the axle out of the axle tube. Use care to not damage the bearing or seal

7. Insert the wheel bearing and seal remover, T85L–1225–AH or equivalent, and a slide hammer into the axle bore and position it behind the bearing so the tanks on the tool engage the bearing outer race. Remove the bearing and seal as a unit.

   Fig. 9: Axle shaft seal and bearing removal

   To install:

8. If removed, lubricate the new bearing with rear axle lubricant and install the bearing into the housing bore. Use axle tube bearing replacer, T78P–1225–A or equivalent.

   Fig. 10: Axle shaft bearing and seal installation

9. Apply Multi-Purpose Long-Life Lubricant, C1AZ–19590–B or equivalent, between the lips of the axle shaft seal.
10. Install a new axle shaft seal using axle tube seal replacer T78P–1177–A or equivalent.

    NOTE: To permit axle shaft installation on 3.73:1 and 4.10:1 ratio axles, make sure the differential pinion shaft contacts the ring gear before performing Step 11.

11. Carefully slide the axle shaft into the axle housing, making sure not to damage the oil seal. Start the splines into the side gear and push firmly until the button end of the axle shaft can be seen in the differential case.
12. Install the C-lockwasher on the end of the axle shaft splines, then pull the shaft outboard until the shaft splines engage the C-lockwasher seats in the counterbore of the differential side gear.
13. Position the differential pinion shaft through the case and pinion gears, aligning the hole in the shaft with the lock screw hole. Install the lock bolt and tighten to 15–22 ft. lbs. (21–29Nm).
14. Clean the gasket mounting surface on the rear axle housing and cover. Apply a continuous bead of Silicone Rubber Sealant ESE–M4G195–A or equivalent to the carrier casting face.
15. Install the cover and tighten the retaining bolts to 25–35 ft. lbs. (20–34Nm).

    NOTE: The cover assembly must be installed within 15 minutes of application of the silicone sealant.

16. Add lubricant until it is ¹⁄₄ in. (6mm) below the bottom of the filler hole in the running position. Install the filler plug and tighten to 15–30 ft. lbs. (20–41Nm).