Axle Disassembly

Fig. 1 Exploded view of model 60 rear axle:

Fig. 2 Exploded view of model 44 front axle:

Fig. 3 Installing axle housing spreader tool:

1. Raise and support vehicle, loosen cover bolts and break gasket seal, drain lubricant, then remove cover and gasket. It may be necessary to lower a spring only so spreader tool can be installed.
2. Remove axle shafts as outlined in service section.
3. Remove front shock at tie plate only.
4. Remove stabilizer bar connecting link to tie plate attaching nut, then U-bolts and tie plate.
5. Loosen nuts attaching rear spring shackle to spring, then support axle housing using suitable jack stands.
6. Remove bolts attaching spring shackle to spring and lower spring.
7. Mark differential bearing caps for assembly reference. Loosen but do not remove differential bearing cap bolts.
8. Install axle housing spreader tool J-24385-01, or equivalent. Be sure to install hold down clamps to keep spreader tool in position.
9. Mount a dial indicator on the axle housing. Zero indicator and make sure that indicator stylus contacts one side of opening in housing.
10. Using spreader tool, spread housing no more than 0.020 inch. Measure amount housing is spread using dial indicator mounted previously. Do not exceed the specified 0.020 inch when spreading housing. If housing is overspread, it could be distorted or damaged.
11. After housing has been spread 0.020 inch, remove dial indicator, then bearing caps. Tag caps for assembly reference.
12. Position pry bars under ring gear bolt head and under differential case, then remove differential assembly. Remove spreader tool immediately after removing the differential to avoid the possibility of distorting housing or causing it to take a set.
13. Remove and discard ring gear attaching bolts, then ring gear from differential case using a brass drift and hammer. Do not attempt to wedge off case, as case will be damaged in process.
14. Remove pinion mate shaft lockpin using a suitable punch, then pinion mate shaft and thrust block.
15. Rotate pinion gears until gears are aligned with case opening and remove pinion gears and thrust washers.
16. Remove side gears and thrust washers.

Fig. 4 Removing pinion nut:

17. Using tool J-8614-01 or equivalent remove and discard pinion nut.
18. Using tools J-8614-01, -02 and -03, or equivalent, remove pinion yoke.
19. Remove dust cap from pinion gear, then pinion gear. Strike end of gear using a rawhide hammer to force pinion out of pinion rear bearing and housing. The pinion bearing preload adjusting shims may remain on the pinion shaft, stick to the bearing remaining in housing or it may fall out. Tag and retain shims for assembly.
20. Using tool J-29721 or equivalent, remove pinion front bearing, slinger and seal. Use a 2X2 piece of wood to drive bearing, slinger and seal out of housing. Discard seal after removal.
21. On models 30 and 44 axles, remove pinion rear bearing as follows:
a. Install bearing remover set J-25100 or equivalent on bearing and gear.
b. Insert bearing remover adapters into remover base from top and position adapters 180 degrees apart.
c. Tighten remover tool forcing screw and remove bearing.
22. On model 60 axles, remove pinion rear bearing as follows:
a. Install bearing remover tool J-22912-01 or equivalent, on bearing and gear.
b. Position chamfered edges of tool between inner race and pinion head.
c. Tighten remover tool bolts until chamfered edges of tool are well under bearing race.
d. Position pinion gear and remover tool in arbor press and press pinion out of bearing.
23. On all models, remove pinion rear bearing cup using a brass drift and hammer to tap cup out of housing.
24. Remove pinion depth shims from rear bearing cup bore. Retain shims for assembly.
25. Remove pinion front bearing cup using a brass drift and hammer to tap cup out of housing.