Output Shaft: Service and Repair

OUTPUT SHAFT END FLOAT

CHECK AND ADJUST
- Jack up the vehicle and place on two stands.
- Road wheel - one - remove and refit.



- Fit and align the magnetic dial gauge to the lower plate repositioning the dial gauge to the output shaft flange (Fig 1).
- Tighten the dial gauge adjusting nuts and, using a suitable lever, check and note the output shaft end float.
- Displace and remove the dial gauge assembly.
- Turn the drive shaft for access to the first securing nut.
- Undo and remove the drive shaft to the output flange securing nut.
- Repeat the procedure outlined above for the remaining securing nuts.
- Turn the drive shaft for access.
- Undo and remove the remaining securing nuts.
- Place suitable stand to the front and reposition the drive shaft from the flange and position hub onto the stand.
- Ensure that the brake hose is not stressed and displace and remove the spacer from the output flange.
- Undo and remove the output shaft securing bolt.
- Reposition the flange for access.
- Repeat above procedure for the remaining securing bolts.
- Undo and remove the securing bolts.
- Reposition the flange for access.
- Displace and remove the output shaft assembly and remove and discard "0" ring seal.
- Displace and remove shims and clean shaft and final drive faces.
- Measure the shims and place aside.
- Select new shim and measure.
- Fit and align shims to the final drive.
- Apply "Welseal" to the output flange gasket face and fit and align with new "0" ring seal to the output shaft.
- Fit and align the output shaft assembly.
- Apply "Studloc" to the flange securing bolts and fit and tighten first securing bolt.
- Turn shaft for access.
- Repeat above procedure for the remaining bolts.
- Fit and tighten securing bolts.
- Reposition the flange for access.
- Fit and align the dial gauge to the lower panel/drive flange face.
- Check output flange end float.
- Displace and remove and dial gauge.
- Undo and remove the dial gauge adjusting nuts and reposition the gauge on the stand.
- Place the gauge assembly aside, fitting and aligning spacer to the output flange.
- Reposition the drive shaft to the flange and fully seat onto the studs.
- Fit and tighten the first securing nut and turn drive shaft for access.
- The above procedure is to be repeated for the remaining securing nuts.
- Fit and tighten the remaining securing nuts and turn the drive shaft for access.
- Displace and remove the stand and refit the road wheel.
- Finally, lower the vehicle from the stands.

TORQUE FIGURES
Oil seal housing to gear case 51 - 58 Nm
Half shaft to differential output shaft 78 - 95 Nm

TOLERANCES
Output flange end float 0.004 in

SPANNER SIZES
17mm
22 mm

11/16"AF

OILS/SEALANTS/LUBRICANTS
Output flange securing bolts Studloc