Differential Assembly: Service and Repair

RENEW

Remove the passenger side dash liner.

Remove the fuel pump relay from the multi plug (second relay from the left, red multi plug).

Crank the engine for 10 seconds to depressurize the fuel system.

Remove the rear road wheels.

From below, cut the ratchet straps securing the fuel pump feed hose to the axle carrier.

Fit pipe clamps to the feed hose, slacken the clip securing the feed hose to the fuel pump and disconnect the hose.

From above, slacken the filter hose union at the pump and disconnect.

Fit plugs to the pump and hose.

Remove the nuts securing the fuel pump to the axle carrier and position the pump upwards and forwards away from its mounting.

Peel back the rubber insulation boots from the pump terminals and remove the nuts securing the feed wires to the terminals and remove the fuel pump.

Slacken the clamp securing the mounting clamp to the pump and remove the clamp.

Remove the mounting rubber and non-return valve from the pump.

Remove the caliper lower securing bolt, pivot the caliper for access to the brake pads and remove the outer brake pad.

Disconnect the inner pad wear sensor block connector.

Remove the remaining caliper securing bolt and secure the caliper to the bump stop.

Repeat the procedure for the second caliper.

Cut the ratchet straps securing the wear sensors to the suspension unit.

Fig.1:

Remove the split pin (2, Fig.1) and clevis (1, Fig.1) securing the handbrake cable (3, Fig.1) to the yoke (4, Fig.1), collect the washer.

Disconnect the rear cables at the joiner and remove the yoke from the cable.

Remove the bolts (5, Fig.1) securing the propeller shaft (6, Fig.1) to the differential drive flange and separate the flanges.

Remove the bolts securing the over-axle pipe mountings to the subframe.

Take the weight of the rear suspension on a jack.

Remove the bolts securing the front mounting to the body, collect the mounting bracket, bolt and spacer. Disconnect the rubber from the body mounting peg.

Remove the bolt securing the tie bar to the body. Remove the bracket and spacer.

Fig.1:

Fig.2:

Disconnect the subframe mounting rubber from the body mounting peg, remove the rear strut to body securing bolt (1, Fig.1) and shock absorber lower securing bolt and nut (1, Fig.2).

Repeat the procedure for the other side.

Lower the unit from the vehicle on the jack and manoeuvre from beneath the vehicle.

Remove the nuts and bolts securing the drive shaft to the differential output flange.

Remove the circlip securing the handbrake outer cable to the frame and remove the cable from the frame.

Disconnect the drive shaft from the output shaft and collect the camber shim.

Remove the lower wishbone fulcrum bolt securing nut and drift out the bolt.

Fig.3:

Remove the fulcrum tube (1, Fig.3), spacing washers (2, Fig.3) and remove the lower wishbone / drive shaft assembly (3, Fig.3).

Repeat the procedure for the second side.

Invert the assembly and remove the nuts securing the differential to the carrier.

Remove the spacers and rear carrier assembly.

Remove the subframe lower securing bolts and rear bracket.

Remove the bolts securing the final drive nose plate.

Remove the nuts securing the final drive to the front carrier / front frame.

Fig.1:

Remove the nuts and bolts securing the the bar to the final drive (1,2, Fig.1).

Remove the subframe assembly.

Remove the front frame to front carrier spacers and remove the front carrier. Remove the nose plate securing studs and the rear pendulum bolts.

Clean all components and check for wear and distortion.

Note: Ensure, upon removal of any encapsulated bolt (a bolt pre-coated with sealant / fixative), that the used bolt is replaced with a new one.

Reverse the removal procedure to fit the replacement differential unit, ensuring where necessary, fixings/fastenings are torque tightened to the specified tollerances.

Ensure the differential unit is filled with new oil.

Refit and torque tighten the rear road wheels.

Refit the relay and dash liner.

Secure the dash liner with the fixing screws.

OILS / GREASES / SEALANTS

Caliper to carrier bolts/guide pins Molykote 111

Differential oil Shell Spirax Super 90

Lower shock absorber bolt and lower wishbone to differential pendulum shaft A proprietary Multipurpose, Lithium based grease. N.L.G.I. Consistency No. 2.