Rear Drive Axle/Differential

Axle Assembly

Special Service Tools






Axle oil seal remover

308-005(LRT-37-004/2)





Impulse extractor

100-012(LRT-99-004)





Installer halfshaft oil seal

308-626/1





Installer/Guide halfshaft oil seal

308-626/2

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. For additional information, refer to Specifications Battery and Charging System
2
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.
3 Remove both rear wheels and tires.
4 Remove the exhaust system. For additional information, refer to Exhaust System Service and Repair




5 Remove the fuel tank heat shield.
- Remove the 8 screws.
6 Drain the differential fluid. For additional information, refer to Differential Draining and Filling Rear Drive Axle/Differential




7
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 and discard the 6 bolts.
- Remove the 3 washers.
8
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
Disconnect the axle case breather line.




9
NOTE:
Use an additional wrench to prevent the component from rotating.
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.





12
NOTE:
Use an additional wrench to prevent the component from rotating.
NOTE:
LH illustration shown, RH is similar.
Release the RH tie rod.
- Remove and discard the nut.





13
NOTE:
LH illustration shown, RH is similar.
Release the RH lower arm.
- Using a suitable stand, support the lower arm.
- Remove and discard the nut and bolt.





14
NOTE:
LH illustration shown, RH is similar.
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.





16
WARNING: Secure the component to the transmission jack.
NOTE:
Remove and discard the axle assembly rear nut and bolt.
Remove the axle assembly.
- Using a transmission jack, support the axle.
- Remove the axle assembly front bolts.

17 With assistance, remove the axle from the transmission jack.





18
NOTE:
LH illustration shown, RH is similar.
Using the special tools, remove and discard both halfshaft seals.

Installation





1
CAUTION: The halfshaft seal protector must be left in place until the halfshaft has been installed.
Using the special tools, install new halfshaft seals.
- Clean the component mating faces.
2 With assistance, secure the axle to the transmission jack.
3
NOTE:
Make sure that new nuts and bolts are installed.
Install the axle assembly.
- Clean the component mating faces.
- Tighten the new nut and bolt to 120 Nm (89 lb.ft), then a further 180 degrees.
- Tighten the bolts to 100 Nm.
4 Vehicles with differential locking motor.
- Connect the electrical connectors.
- Secure the wiring harness clips.
5
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
Secure the RH lower arm.
- Install a new nut and bolt and tighten to 250 Nm (184 lb.ft).
6
NOTE:
Use an additional wrench to prevent the component from rotating.
Secure the RH tie rod.
- Install a new nut and tighten to 165 Nm (121 lb.ft).




7
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.
NOTE:
Do not fully engage the halfshaft until the oil seal protector has been removed.
With assistance, secure the LH halfshaft.
- Open the halfshaft seal protector and install the halfshaft.
- Release the halfshaft seal protector from the halfshaft seal.
- Break the halfshaft seal protector in to two pieces and remove the halfshaft seal protector.
- Fully install the halfshaft.
8 Repeat the above procedure for the other side.
9
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
Secure the LH lower arm.
- Install a new nut and bolt and tighten to 250 Nm (184 lb.ft).

10
NOTE:
Use an additional wrench to prevent the component from rotating.
Secure the LH tie rod.
- Install a new nut and tighten to 165 Nm (121 lb.ft).

11 Connect the axle case breather line.

12
NOTE:
Make sure that new bolts are installed.
Secure the driveshaft to the rear axle drive flange.
- Install the washers.
- Stage 1: Tighten the bolts to 45 Nm (33 lb.ft).
- Stage 2: Tighten the bolts a further 45 degrees.

13 Fill the differential with the correct amount of fluid. For additional information, refer to Differential Draining and Filling Rear Drive Axle/Differential

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

15 Install the exhaust system. For additional information, refer to Exhaust System Service and Repair

16 Install the wheels and tires.
- Tighten the wheel nuts to 140 Nm (103 lb.ft).

17 Connect the battery ground cable. For additional information, refer to Specifications Battery and Charging System