Drive Axle: Removal & Installation Geo Tracker I

Removal & Installation

1. Using pinion Flange Holder (J-8614-01 ), hold pinion flange stationary. Unstake and remove flange nut. Remove pinion flange. Using Oil Seal Remover (J-26941 ) and Slide Hammer (J-2619-01 ), remove pinion oil seal. CAUTION: DO NOT overtighten pinion nut or collapsible spacer will require replacement.
2. Install pinion oil seal using Seal Installer (J-25273 ). Install pinion flange and nut. Tighten pinion nut gradually to specification and restake. See «TORQUE SPECIFICATIONS»(ref-55901-S04611800232001041000000) table.

1. Raise and support vehicle. Drain differential fluid. Mark front drive shaft position for installation reference. Remove front drive shaft.
2. Remove the right and the left front axle shafts. See «FRONT AXLE SHAFTS»(ref-55901-S06369776132001041000000) . Remove 4 bolts from left differential mounting bracket. Remove 2 bolts from rear differential mounting bracket.
3. Remove 3 bolts from right differential mounting bracket. Support differential carrier. Remove front differential carrier-to-axle housing mounting nuts. Lower differential carrier.
4. To install, reverse removal procedure. Apply sealant to differential carrier and axle housing mating surfaces. Align marks made on drive shaft during removal procedure. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-55901-S04611800232001041000000) table. Fill differential.

1. Raise and support vehicle. Drain differential fluid. Mark rear drive shaft position for installation reference. Remove rear drive shaft.
2. Remove the right and the left rear axle shafts. See «REAR AXLE SHAFTS»(ref-55901-S06884092622001041000000) . Remove rear wheel speed sensor cover from differential carrier. Disconnect wheel speed sensor electrical harness.
3. Remove 4 bolts from upper rear suspension arm. Support differential carrier. Remove rear differential carrier-to-axle housing mounting nuts. Lower differential carrier.
4. To install, reverse removal procedure. Apply sealant to differential carrier and axle housing mating surfaces. Align marks made on drive shaft during removal procedure. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-55901-S04611800232001041000000) table. Fill differential.

See AXLE SHAFTS - FRONT article in the DRIVE AXLES section for removal and overhaul procedures.

1. Raise and support vehicle. Remove wheels. Remove rear brake drums. Drain differential fluid. Remove rear wheel bearing retaining nuts from axle housing. Using axle shaft Puller (J-37781 ) with slide hammer, remove axle shaft.
2. To install, reverse removal procedure. Install NEW inner oil seal. See «REAR AXLE INNER OIL SEAL»(ref-55901-S35182005712001041000000) . Apply wheel bearing grease to inner oil seal lip. Apply sealant to mating surface of wheel bearing retainer and brake backing plate. Tighten wheel bearing retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-55901-S04611800232001041000000) table.Fill differential.

1. Raise and support vehicle. Remove rear axle shafts. See «REAR AXLE SHAFTS»(ref-55901-S06884092622001041000000) . Remove bearing retainer ring from axle shaft using a grinder to flatten 2 sides of bearing retainer ring.
2. Remove bearing retainer with a cold chisel and hammer. Using a press, remove wheel bearing from axle shaft. Remove axle shaft bearing retainer and pry outer axle shaft seal from retainer. To install, reverse removal procedure.

Raise and support the vehicle. Remove rear axle shafts. See REAR AXLE SHAFTS . Using a slide hammer and Seal Remover Hook (J-23907 ), remove axle shaft inner oil seal from differential axle housing. Install new inner axle seal using Seal Installer (J-29039 ). To complete installation, reverse removal procedure.

1. Raise and support vehicle. Drain differential fluid. Remove wheels and brake drums. Disconnect brake lines from wheel cylinders. Remove rear axle shafts. See «REAR AXLE SHAFTS»(ref-55901-S06884092622001041000000) .
2. Disconnect metal brake line from flexible hose and "E" clip. Remove brake lines from axle housing. Remove breather hose from axle housing. Remove rear drive shaft.
3. Support center of rear axle housing. Remove ball joint bracket from differential carrier. Remove differential carrier assembly. See «REAR CARRIER ASSEMBLY»(ref-55901-S32275351802001041000000) . Remove rear mount nuts from trailing rods. DO NOT remove bolts.
4. Remove shock absorber lower mount bolts. Lower differential housing until suspension coil spring tension becomes loose. Remove trailing rod mount bolts. Remove coil springs. Lower rear axle housing. To install, reverse removal procedure.

Scheme 9

1. Mount differential carrier in Holding Fixture (J-34162-A ) and Adapter (J-37769 ). Match mark differential side bearing caps for installation reference. see scheme 8or see scheme 9.
2. Remove side bearing lock plates and caps. Remove side bearing adjusters and outer bearing races. On rear differentials, remove rear wheel speed sensor. On front or rear differentials, remove ring gear assembly.
3. On rear differentials, separate differential case halves. Using a copper hammer, remove exciter ring. Tap evenly along outer edge of exciter ring.
4. On front or rear differentials, turn differential carrier in fixture 90 degrees. Using pinion Flange Holder (J-8614-01 ), remove pinion flange nut. Remove pinion flange. Remove pinion shaft. Using Oil Seal Remover (J-26941 ) and Slide Hammer (J-2619-01 ), remove pinion oil seal.
5. Remove outer pinion bearing from differential carrier. Remove outer and inner pinion bearing races. Using side bearing Puller (J-22888-D ) and Side Bearing Pilot (J-8107-4 ), remove differential side bearings.
6. Mount differential case in vise. Using arbor punch and hammer, remove roll pins. (Scheme 9) Remove differential side gears, selective shims, pinion gears, thrust washers, and shafts.
7. Using Inner Pinion Bearing separator (J-22912-01 ), remove collapsible spacer and inner pinion bearing. Discard collapsible spacer. NOTE: Ring gear, pinion and taper roller bearings and races must be replaced as a set.