Axle Shaft Assembly: Service and Repair

Rear Wheel Drive Shaft Replacement

Special Tools

* DT 48877 - Seal Protector

* J 44394 - Seal Protector

* J 45859 - Wheel Hub Remover

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 (w RT2) Tire and Wheel Removal and Installation (w RT2)Tire and Wheel Removal and Installation (w/o RT2) Tire and Wheel Removal and Installation (w/o RT2).

Caution: Make sure that the wheel drive shaft nut is fully un-staked to avoid damage to the wheel drive shaft threads during the removal of the wheel drive shaft nut. Failure to follow these instructions could result in wheel, nut, and/or stud damage.

3. If equipped with a staked nut, using a chisel tool (2) and a hammer (3), unstake the drive shaft nut collar (1) from the drive shaft slot.

4. With the aid of an assistant, apply the brakes.

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

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

6. Using J 45859 - remover, separate the wheel drive shaft from the knuckle.

7. Remove the knuckle assembly. Refer to Knuckle Replacement Service and Repair.

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.

Note: Move the axle shaft out of the differential enough to install the seal protector.

8. Carefully install the J 44394 - protector (1) for the 195 mm axle or the DT 48877 - protector (1) for the 218 mm axle and 250 mm axle over the wheel drive shaft.

9. Carefully slide the J 44394 - protector (1) for the 195 mm axle or the DT 48877 - protector (1) for the 218 mm axle and 250 mm axle into the differential output shaft seal.

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

11. 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.

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

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 and 250 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 Service and Repair.

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

7. Install and hand tighten the NEW wheel drive shaft nut (1).

8. With the aid of an assistant, apply the brakes.

Caution: Refer to Fastener Caution Fastener Caution.

9. Using a torque wrench and the proper size socket, tighten the wheel drive shaft nut to 270 Nm (199 lb ft).

Note: Ensure that the drive shaft nut is fully staked. The collar should contact the bottom of the drive shaft slot or be evenly split into the center of the drive shaft slot. Holding the rotor from turning will ease the process.

10. If equipped with a staked nut, using a chisel tool (1) and a hammer, stake the drive shaft nut collar (2) into the drive shaft slot.

11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (w RT2) Tire and Wheel Removal and Installation (w RT2)Tire and Wheel Removal and Installation (w/o RT2) Tire and Wheel Removal and Installation (w/o RT2).

12. Remove the support and lower the vehicle.