Axle Shaft Assembly: Service and Repair

Rear Wheel Drive Shaft Replacement

Special Tools
* DT 48877 - Seal Protector
* J 44394 - Seal Protector

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
3. For vehicles equipped with the high performance brakes (Brembo) proceed to step 4. All other vehicles proceed to step 8.

Note: DO NOT place the drift or flat bladed screwdriver against the bottom of those vehicles equipped with the high performance brakes (Brembo). Damage to the bottom cross over tube could be damaged causing brake failure.

4. Insert a drift or large flat bladed screwdriver (3) in the cooling fins of the brake rotor against the brake caliper (1).
5. Place a clean shop towel (2) between the drift or large flat bladed screwdriver (3) brake caliper (1).
6. Using a breaker bar (5) and the proper size socket (4), loosen the wheel drive shaft nut.

Note: DO NOT re-use the wheel drive shaft nut, replace with NEW only.

7. Remove the wheel drive shaft nut (1) and discard.

8. Insert a drift or flat bladed screwdriver (2) in the cooling fins of the brake rotor (3) against the brake caliper mounting bracket (1).
9. Using a breaker bar and the proper size socket (4), loosen the wheel drive shaft nut.

Note: DO NOT re-use the wheel drive shaft nut, replace with NEW only.

10. Remove and discard the wheel drive shaft nut (1).
11. Using the appropriate tool, separate the wheel drive shaft from the knuckle.

Caution: J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the splines of the wheel drive shaft to cut the differential output seal.

12. Carefully install the J 44394 - protector for the 195 mm axle or the DT 48877 - protector for the 218 mm axle over the wheel drive shaft.
13. Carefully slide the J 44394 - protector for the 195 mm axle or the DT 48877 - protector for the 218 mm axle into the differential output shaft seal.
14. Remove the knuckle assembly. Refer to Knuckle Replacement (Rear Suspension).

15. Remove the wheel drive shaft (1) from the vehicle.

Note: If there is no washer present on the wheel drive shaft when removed, install the NEW washer

16. Remove the washer (1) from the wheel drive shaft (2) and discard. Replace with NEW only.

Installation Procedure

Note: DO NOT re-use the old washer, replace with NEW only.

1. Install the NEW washer (1) on the wheel drive shaft (2).

2. Install the wheel drive shaft (1) in the vehicle.

4. Carefully remove the J 44394 - protector for the 195 mm axle or the DT 48877 - protector for the 218 mm axle from the differential output shaft seal.
5. Install the wheel drive shaft until the it is fully seated in the rear differential.
6. Install the knuckle assembly. Refer to Knuckle Replacement (Rear Suspension).
7. For vehicles equipped with the high performance brakes (Brembo) proceed to step 4. All other vehicles proceed to step 7.

Note: DO NOT re-use the wheel drive shaft nut, replace with NEW only.

8. Install the NEW wheel drive shaft nut (1).

Note: DO NOT place the drift or flat bladed screwdriver against the bottom of those vehicles equipped with the high performance brakes (Brembo). Damage to the bottom cross over tube could be damaged causing brake failure.

9. Insert a drift or large flat bladed screwdriver (2) in the cooling fins of the brake rotor against the brake caliper (1).
10. Place a clean shop towel (3) between the drift or large flat bladed screwdriver (2) brake caliper (1).

11. Install the NEW wheel drive shaft nut (1).

12. Insert a drift or large flat bladed screwdriver (2) in the cooling fins of the brake rotor (1) against the brake caliper (3).

Caution: Refer to Fastener Caution (Fastener Caution).

Note: The following service procedure will cover the vehicles equipped with the high performance brakes (Brembo) and the standard brakes.

13. Using a torque wrench (5) and the proper size socket (4), tighten the wheel drive shaft nut to 270 Nm (199 lb ft).
14. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
15. Remove the support and lower the vehicle.