Differential: Service and Repair
DIFFERENTIAL BEARING RETAINER O-RINGTOOLS REQUIRED
- J44015 Steering Linkage Installer
- SA91 100C Tie Rod Separator
- SA91112T Axle Seal Protector Tool
REMOVAL
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
1. Raise vehicle.
2. Remove left wheel and tire assembly.
3. Drain transaxle lubricant by removing transaxle drain plug (1).
4. Remove tie rod end nut and discard.
NOTICE: Do not attempt to separate the joint using a wedge-type tool because the seal may be damaged.
5. Using Tie Rod Separator SA91100C (or equivalent), separate tie rod end from steering knuckle.
6. Remove lower control arm to steering knuckle nut and bolt.
NOTICE: Be careful not to allow steering knuckle to contact ball stud seal. Contact may cause the seal to tear, requiring ball stud replacement.
IMPORTANT: Place a cloth over the ball stud boot protecting it from damage caused by contact with the steering knuckle.
7. Separate lower control arm from steering knuckle.
NOTICE: To prevent damage to the CV Joint boots, be careful not to allow them to contact other parts during the removal/installation process. Also, never pull on the shaft assembly.
8. Using a pry bar, remove drive axle from transaxle.
9. Leave axle in the steering knuckle, and tie drive axle out of the way.
NOTICE: Use caution not to damage machined surfaces of bearing retainer and transaxle case when removing retainer.
10. Remove differential bearing retainer fasteners and carefully remove retainer.
11. Remove O-ring from differential bearing retainer.
INSTALLATION
NOTICE: Make sure differential bearing shims are in case bore prior to installing differential bearing retainer.
1. Clean seal bore in transaxle case.
2. Install new O-ring on differential bearing retainer. Lubricate O-ring with transaxle lubricant and install bearing retainer.
3. Install differential bearing retainer fasteners.
Torque:
Differential Bearing Retainer-to-Transaxle Bolts: 24 Nm (18 ft.lbs.)
NOTICE: Use caution not to damage seal while installing axle into transaxle.
4. Install Axle Seal Protector Tool SA91112T inside seal.
5. Install axle into transaxle.
6. After shaft splines clear the seal but before snapping axle into place, remove seal protector tool.
7. Push axle all the way into the transaxle.
NOTICE: Take care not to damage rubber boot when installing ball joint to knuckle.
8. Insert lower control arm ball stud into steering knuckle.
9. Install lower control arm ball stud retaining bolt and nut.
Torque:
Lower Control Arm Ball Stud Bolt and Nut-to-Steering Knuckle: 100 Nm (75 ft. lbs.)
IMPORTANT: The tie rod ends must be thoroughly cleaned before installing and tightening.
10. Install tie rod end into steering knuckle.
11. Using Steering Linkage Installer J44015, seat tie rod end into steering knuckle.
Torque:
Linkage Installer J44015 to Seat Tie Rod Ends: 45 Nm (35 ft. lbs.)
NOTICE: Use a new nut. Torque retention of old nut may not be sufficient.
12. Remove linkage installer and install a new tie rod end nut.
Torque:
Tie Rod End-to-Steering Knuckle: 60 Nm (45 ft. lbs.)
13. Clean and apply thread sealant (P/N 21485278) to the transaxle drain plug (1) and install.
Torque:
Transaxle Drain Plug: 50 Nm (37 ft. lbs.)
14. Remove the transaxle level plug (2) and, using a funnel with a flexible spout or a quart bottle hand pump, add manual transaxle lubricant (P/N 21018899) until lubricant begins to flow out of the level plug opening.
15. Clean and apply thread sealant (P/N 21485278) to transaxle level plug (2) and install.
Torque:
Transaxle Fill Plug: 50 Nm (37 ft. lbs.)
NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.
16. Position wheel onto hub.
17. Install wheel bolts and tighten in a star pattern.
17.1 Hand tighten all five wheel bolts.
17.2 Use a torque wrench to tighten wheel bolts using a star pattern.
Torque:
Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
17.3 Use a torque wrench to final tighten wheel bolts using a star pattern.
Torque:
Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
18. Lower vehicle from hoist.