Replacement
REMOVAL
Exc. 201 Series
1. Drain fluid from axle assembly.
2. On vehicles without starting torque compensation, remove brake caliper(s) attaching pin bolts. Using a suitable piece of wire, suspend brake caliper assembly. Do not allow caliper to hang by its brake lines.
3. On vehicles equipped with starting torque compensation, disconnect and cap brake lines from caliper line holder, if necessary.
4. Loosen the M12 or M8 rear axle shaft to rear axle shaft flange attaching bolts.
5. Using a suitable puller, force rear axle shaft out of axle shaft flange. When removing the puller, ensure to hold rear axle shaft in place. Do not allow rear axle shaft to drop, since this will damage the synchromesh joint and result in leaks. On vehicles with starting torque compensation, loosen rear axle center piece (differential and lower unit until studs are out of the rear axle carrier assembly. Gently swivel rear axle center piece (differential) to its side until rear axle shaft(s) can be removed.
6. Support rear axle housing with a suitable jack.
7. Loosen attaching bolts from rubber bearing.
Fig. 2 Disassembled view of rear axle & suspension components.:
8. Wipe clean axle housing, then remove rear axle housing cover, Fig. 2.
9. Using suitable pliers, remove snap ring located between inner synchromesh joint and side gear assembly.
10. Pull rear axle shaft and spacer out of side gear.
INSTALLATION
Exc. 201 Series
The rear axle shafts are provided with oil return threads (twists) on the contact surface of the radial sealing ring, which are different for the left and right sides. For identification, the axle shaft faces are marked with either an R or L marking. The R marking represents right side and the L marking represents left side. Do not attempt to interchange the axle shafts from side to side or serious damage will result.
Fig. 3 Rear axle shafts.:
1. Using 180 grit emery cloth, refinish oil return feed thread, if necessary at an angle of 20° for a length of .787-1.18 inch (20-30 mm) Fig. 3. When installing a radial sealing ring with an alternating feed thread, refinishing of the oil feed thread is not necessary.
Fig. 2 Disassembled view of rear axle & suspension components.:
2. If a new rear axle shaft is installed, place previously removed spacer ring on to inner synchromesh joint, Fig. 2.
3. Place complete rear axle shaft into side gear and insert a new snap ring not synchromesh joint groove. If the axle shaft assembly cannot be inserted into the differential housing up to the contact surface, contract both joints first. Then, using a plastic head hammer, gently tap outer spider gear to knock rear axle shaft against differential housing contact surface. Do not strike stop sleeve assembly. Do not allow rear axle shaft to drop or bend sharply, since this will damage the synchromesh housing assembly.
4. Check endplay between inner spider gear and differential housing assembly. There should be no noticeable endplay. The snap ring should just barely be able to turn in its groove. If necessary, install a thicker or thinner spacer ring.
5. Telescope rear axle shaft completely, then using puller tool 05a-05c or equivalent, insert assembly into rear axle shaft flange.
Fig. 4 Operating range of wheel carrier protective sleeve.:
6. Rear axle shaft assemblies using M 12 bolts, torque bolts to 70 ft. lbs. (95 Nm). Rear axle shaft assemblies using the M8 bolts with clamping disc and spacing sleeve, torque bolts to 22 ft. lbs. (30 Nm). When installing a new or reconditioned rear axle shaft with one piece protective sleeve on outer joint, check semi-trailing arm in its operating range of protective sleeve for weld residue. Remove weld beads. Check installed rear axle shaft for wiping noises. If wiping noise are heard when rotating rear axle shaft, refinish wheel carrier in operating range of protective sleeve, Fig. 4.
7. Place suitable sealer on to end cover, and install end cover assembly. Torque end cover attaching bolts to 33 ft. lbs. (45 Nm).
8. On 107 and 123 series only, proceed as follows:
a. Lift rear axle housing and install rubber bearing to frame floor.
b. Torque hex head attaching bolts to 18 ft. lbs. (25 Nm) or self-locking bolts to 22 ft. lbs. (30 Nm).
9. On 126 series only, lift rear axle center piece (differential) up to frame floor and attach rubber bearing to frame floor. Torque attaching bolts to 22 ft. lbs. (30 Nm).
10. On vehicles equipped with starting torque compensation, connect brake line(s) and bleed brake system.
11. Lower and remove jack supporting rear axle housing.
12. On vehicles without starting torque compensation, install caliper onto brake disc. Install new locking plate or self-locking bolts. Torque attaching bolts to 66 ft. lbs. (90 Nm).
13. Fill rear axle housing with suitable lubricant and up to specifications.