Differential Assembly: Service and Repair

Axle Assembly





Special Service Tools

Removal
1. Remove both halfshafts.
2. Remove the exhaust system.





3. CAUTION: Under no circumstances must the flexible coupling (or its fixings) be loosened or removed from the driveshaft.

Detach the driveshaft from the differential flange.
^ Mark the position of the driveshaft in relation to the differential flange.
^ Mark the position of the balance nut in relation to the differential flange (if fitted).
^ Mark the position of each nut and bolt in relation to the driveshaft flexible joint.

4. CAUTION: When supporting the axle assembly, use a suitable packing material to prevent damage to the axle assembly.

Using the special tool HTJ1200-02, support the axle assembly.





5. Remove the axle assembly front retaining bolt.





6. NOTE: The axle assembly rear retaining bolts do not have to be fully removed for the axle assembly to be removed, slacken the rear retaining bolts alternately until the rear axle assembly is released.

Remove the axle assembly.

Installation





1. NOTE: Loosely tighten the axle assembly rear retaining bolts.

Install the axle assembly.





2. NOTE: Make sure the axle front retaining bolt washer and spacer are correctly installed.

Install the axle assembly front retaining bolt.

3. CAUTION: When supporting the axle assembly, use a suitable packing material to prevent damage to the axle assembly.

Remove the special tool HTJ1200-02, supporting the axle assembly.





4. Install the special tool.





5. CAUTION: Make sure the axle rear retaining bolts are tightened to the correct torque specification. Failure to follow this instruction may result in damage to the vehicle.

Using the special tool and a torque wrench, tighten the axle rear retaining bolts.
^ Tighten to 200 Nm.
^ To make sure the axle rear retaining bolts are torqued to the correct specification, using the special tool and a torque wrench the following calculation steps must be followed.





6. Tighten to 90 Nm.





7. NOTE: Make sure the driveshaft nuts and bolts are correctly installed.

Tighten to 88 Nm.
8. Install the exhaust system.
9. Install both halfshafts.