Differential Case

Differential Case
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

Removal

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

WARNING: Make sure to support the vehicle with axle stands.
1 Raise and support the vehicle.
2 Remove the LH rear wheel and tire.
For additional information, refer to Wheel and Tire Service and Repair
3 With assistance, remove the rear muffler.
For additional information, refer to Exhaust System Service and Repair

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.

4 Remove the LH rear halfshaft.
For additional information, refer to Rear Halfshaft LH Rear Halfshaft LH
5 Using a transmission jack, support the differential case.

CAUTION: Mark the components to aid installation.
Discard the bolts.

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

7 Carefully lower and remove the differential case.

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

Installation

CAUTION: Make sure that the area around the component is clean and free of foreign material.
1 Install a new O-ring seal to the active on-demand coupling.

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

CAUTION: Make sure that new bolts are installed.
2 Align the active on-demand coupling to the differential and tighten the bolts.
Torque to: 24 Nm
3 Install the rear differential support bracket.
Torque to: 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.

CAUTION: Make sure that the installation marks are aligned.

CAUTION: Make sure that new bolts are installed.
7 Install the rear differential front bush retaining bolts.
Torque to: 175 Nm

CAUTION: Make sure that the installation marks are aligned.

CAUTION: Make sure that new bolts are installed.
8 Install the rear differential rear bush retaining bolts.
Torque to: 110 Nm
9 Install the LH halfshaft.
For additional information, refer to Rear Halfshaft LH Rear Halfshaft LH

10 Connect the Active On-demand Coupling module electrical connector.

11 Install the driveshaft rear support bracket.
Torque to: 35 Nm

CAUTION: Make sure that new bolts are installed.

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

13 Install the rear muffler.
For additional information, refer to Exhaust System Service and Repair

14 Install the LH rear wheel and tire.
For additional information, refer to Wheel and Tire Service and Repair

15 Check and top-up the active on-demand coupling fluid level.
For additional information, refer to Active On-Demand Coupling Filling Active On-Demand Coupling Filling

16 Fill the differential case with fluid.
For additional information, refer to Differential Draining and Filling Rear Drive Axle/Differential