Rear Drive Axle/Differential

Drive Pinion Seal

Removal
1
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
2 Remove the exhaust system. For additional information, refer to Exhaust System




3 Remove the center heat shield.
- Remove the 8 nuts.




4 Remove the fuel tank heat shield.
- Remove the 8 screws.




5
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.
Release the driveshaft from the rear axle drive flange.
- Remove the 6 Torx bolts and washers.
- Discard the bolts.




6 Remove the 2 driveshaft center bearing mount nuts.
- With assistance, release the driveshaft and tie aside.




7 Measure the depth of the pinion nut on the pinion shaft.
- Note measurement for installation.




8
CAUTION: This step must be carried out to make sure that the drive pinion nut is correctly tightened on assembly.
Accurately scribe a line to mark the drive pinion shaft to the drive pinion nut and pinion flange.




9 Remove the drive pinion flange retaining nut.
- Using the special tool, counter hold the drive pinion flange.
- Note number of turns for installation.





10 Using a two legged puller remove the pinion flange.
- Check flange seal journal for any damage.
- Carefully remove and discard the oil seal.

Installation
1 Clean the drive pinion flange.
2 Clean the drive pinion seal mating faces.




3 Using the special tool, install the new drive pinion seal.




4 Remove the special tool.
- Install special tool 205-821-01 to the seal face.




5
CAUTION: Make sure adaptor is removed or damage to the vehicle may occur.
Using the special tool, install the new drive pinion seal.
- Remove the special tools.
6
CAUTION: Make sure the drive pinion flange scribed marks are aligned.
Install the drive pinion flange.




7
CAUTION: Make sure the mark on the drive pinion nut is never tightened short of the scribed mark on the drive pinion shaft.
CAUTION: Make sure the drive pinion flange has no end float and is free to rotate.
CAUTION: Make sure the scribed mark on the drive pinion nut is no more than a maximum of 5 degrees past the scribed mark on the drive pinion shaft.
Install the drive pinion flange retaining nut.
- Using the special tool, counter hold the drive pinion flange.
- Install nut to previously noted number of turns.
- Measure the depth of the pinion nut on the pinion shaft.
8
CAUTION: It is possible to fit the driveshaft incorrectly. The universal joint must be rearward of the center bearing when installed in the vehicle.
NOTE:
A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect the operation or durability of the joint.
Attach the driveshaft to the rear axle drive flange.
- Remove the cable tie.
- Clean the component mating faces.
- Align the driveshaft to the previously noted position.
- Tighten the Torx bolts to 44 Nm (32 lb.ft), then a further 45 degrees.
- Remove the cable tie.
9
CAUTION: Make sure the center bearing mount is not under tension and central within the slots.
Attach the driveshaft center bearing mount.
- Align the center bearing mount.
- Tighten the nuts to 21 Nm (15 lb.ft).

10 Install the fuel tank heat shield.
- Tighten the screws.

11 Install the center heat shield.
- Tighten the nuts.

12 Install the exhaust system. For additional information, refer to Exhaust System

13
CAUTION: Make sure the correct specification and quantity of oil is used.
Check the differential oil level and top up if necessary