Rear Differential
Axle AssemblyService Repair No - 51.15.01
Special Service Tools
Removal
CAUTION: Do not allow halfshafts to hang unsupported at one end or joint damage will occur.
CAUTION: Do not store or install halfshafts with joints at maximum articulation or damage may occur to the joint.
CAUTION: Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining mechanism and can separate.
1. Disconnect the battery ground cable.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2. Raise and support the vehicle.
3. Remove both rear wheels and tires.
4. Remove the exhaust system.
5. Drain the differential fluid.
6. Remove the fuel tank heat shield.
^ Remove the 8 screws.
CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.
CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
7. Release the driveshaft from the rear axle drive flange.
^ Remove and discard the 6 bolts.
^ Remove the 3 washers.
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
8. Disconnect the axle case breather line.
NOTE:
Use an additional wrench to prevent the component from rotating.
9. Release the LH tie rod.
^ Remove and discard the nut.
10. Release the LH lower arm.
^ Using a suitable stand, support the lower arm.
^ Remove and discard the nut and bolt.
11. With assistance, release the LH halfshaft.
^ Remove and discard the snap ring.
NOTE:
Use an additional wrench to prevent the component from rotating.
NOTE:
LH illustration shown, RH is similar.
12. Release the RH tie rod.
^ Remove and discard the nut.
NOTE:
LH illustration shown, RH is similar.
13. Release the RH lower arm.
^ Using a suitable stand, support the lower arm.
^ Remove and discard the nut and bolt.
NOTE:
LH illustration shown, RH is similar.
14. With assistance, release the RH halfshaft.
^ Remove and discard the snap ring.
15. Vehicles with differential locking motor.
^ Release the 2 wiring harness clips.
^ Disconnect the 2 electrical connectors.
WARNING: Secure the component to the transmission jack.
16. Remove the axle assembly.
^ Using a transmission jack, support the axle.
^ Remove and discard the nut and bolt.
^ Remove and discard the 2 bolts.
17. With assistance, remove the axle from the transmission jack.
NOTE:
LH illustration shown, RH is similar.
18. Using the special tools, remove and discard both halfshaft seals.
Installation
CAUTION: The halfshaft seal protector must be left in place until the halfshaft has been installed.
1. Using the special tools, install new halfshaft seals.
^ Clean the component mating faces.
2. With assistance, secure the axle to the transmission jack.
NOTE:
Make sure that new bolts are installed.
3. Install the axle assembly.
^ Clean the component mating faces.
^ Tighten the new bolts to 100 Nm ( 74 ft. lbs.).
^ Tighten the new nut and bolt to 120 Nm (89 ft. lbs.), then a further 180 degrees.
4. Vehicles with differential locking motor.
^ Connect the electrical connectors.
^ Secure the wiring harness clips.
CAUTION: Pull on the halfshaft inboard joint to make sure the clip has fully engaged and retains the halfshaft inboard joint within the axle case.
5. With assistance, secure the RH halfshaft.
^ Clean the component mating faces.
^ Install a new snap ring.
^ Open the halfshaft oil seal protector.
NOTE:
The halfshaft seal protector is designed to break into two pieces.
NOTE:
LH illustration shown, RH is similar.
6. Remove and discard the halfshaft seal protector.
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
7. Secure the RH lower arm.
^ Install a new nut and bolt and tighten to 250 Nm (184 ft. lbs.).
NOTE:
Use an additional wrench to prevent the component from rotating.
8. Secure the RH tie rod.
^ Install a new nut and tighten to 165 Nm (121 ft. lbs.).
CAUTION: Pull on the halfshaft inboard joint to make sure the clip has fully engaged and retains the halfshaft inboard joint within the axle case.
9. With assistance, secure the LH halfshaft.
^ Clean the component mating faces.
^ Install a new snap ring.
^ Open the halfshaft seal protector.
NOTE:
The halfshaft seal protector is designed to break into two pieces.
10. Remove and discard the halfshaft seal protector.
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
11. Secure the LH lower arm.
^ Install a new nut and bolt and tighten to 250 Nm (184 ft. lbs.).
NOTE:
Use an additional wrench to prevent the component from rotating.
12. Secure the LH tie rod.
^ Install a new nut and tighten to 165 Nm (121 ft. lbs.).
13. Connect the axle case breather line.
NOTE:
Make sure that new bolts are installed.
14. Secure the driveshaft to the rear axle drive flange.
^ Clean the component mating faces.
^ Install the washers.
^ Stage 1: Tighten the bolts to 45 Nm (33 ft. lbs.).
^ Stage 2: Tighten a further 45 degrees.
15. Install the fuel tank heat shield.
^ Tighten the screws.
16. Fill the differential with the correct amount of fluid.
17. Install the exhaust system.
18. Install the wheels and tires.
^ Tighten the wheel nuts to 140 Nm (103 ft. lbs.).
19. Connect the battery ground cable.