Differential Case: Service and Repair

Differential Case

Service Repair No - 51.15.01

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Remove the LH rear wheel and tire.
3. With assistance, remove the rear muffler.

4. WARNING: Do not lever the driveshaft joints to release from the power transfer unit or the rear differential flanges.

CAUTION: Mark the components to aid installation.

CAUTION: Make sure that the driveshaft is supported with suitable retaining straps.

Discard the bolts.

7. Remove the LH rear halfshaft.
8. Using a transmission jack, support the differential case.

9. CAUTION: Mark the components to aid installation.

Discard the bolts.

10. CAUTION: Mark the components to aid installation.

Discard the bolts.

11. Carefully release the RH inboard halfshaft joint from the differential and tie aside.

12.

13. Carefully lower and remove the differential case.

14. NOTE: Do not disassemble further if the component is removed for access only.

15.

Installation

1. CAUTION: Make sure that the area around the component is clean and free of foreign material.

Install a new O-ring seal to the active on-demand coupling.

2. CAUTION: Make sure that the area around the component is clean and free of foreign material.

CAUTION: Make sure that new bolts are installed.

Align the active on-demand coupling to the differential and tighten the bolts.
Torque:
24 Nm

3. Install the rear differential support bracket.

Torque:
35 Nm

4. Using a transmission jack, carefully raise the assembly.
5. Connect the differential breather lines.
6. Secure the RH inner halfshaft joint to the differential.

7. CAUTION: Make sure that the installation marks are aligned.

CAUTION: Make sure that new bolts are installed.

Install the rear differential front bush retaining bolts.
Torque:
175 Nm

8. CAUTION: Make sure that the installation marks are aligned.

CAUTION: Make sure that new bolts are installed.

Install the rear differential rear bush retaining bolts.
Torque:
110 Nm

9. Install the LH halfshaft.
10. Connect the Active On-demand Coupling module electrical connector.
11. Install the driveshaft rear support bracket.

Torque:
35 Nm

12. CAUTION: Make sure that new bolts are installed.

Connect the driveshaft to the rear flange.
Torque:
40 Nm

13. Install the rear muffler.
14. Install the LH rear wheel and tire.
15. Check and top-up the active on-demand coupling fluid level.
16. Fill the differential case with fluid.