Differential Assembly: Service and Repair

Axle Assembly

Special Service Tools





Removal
1. Remove the cover and disconnect the battery ground cable.

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 the rear halfshafts.
4. Remove the exhaust system.

5. CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.

CAUTION: Under no circumstances must the flexible coupling (or it's fixings) be loosened or removed from the driveshaft.

Release the driveshaft from the rear axle drive flange.

^ Remove the 3 nuts and bolts.





6. Remove the exhaust rear heat shield.

^ Remove the 4 nuts.





7. With assistance: Remove the body K-frame.

^ Using a jack, support the differential.
^ Remove the 8 bolts.
^ Remove the 4 Torx bolts.





8. Install the 2 sub-frame mounting bolts and remove the support jack.





9. Using a transmission jack, support the differential.

10. CAUTION: Note the fitted position of the special washers.

Remove the rear differential.

^ Remove the 3 bolts.





Installation

1. NOTE: Align to the position noted on removal.

Install the rear differential.

^ Tighten the 14 mm bolts to 163 Nm (120 lb.ft).
^ Tighten the 12 mm bolt to 90 Nm (66 lb.ft).

2. With assistance, install the K-frame.

^ Remove the 2 bolts.
^ Tighten the M10 bolts to 40 Nm (30 lb.ft).
^ Tighten the M12 bolts to 133 Nm (98 lb.ft).
^ Tighten the sub frame bolts to 60 Nm (44 lb.ft), then a further 240°.

3. Remove the transmission jack.
4. Install the heat shield.

^ Tighten the nuts to 10 Nm (7 lb.ft).

5. NOTE: Align to the position noted on removal.

Install the driveshaft.

^ Tighten the nuts and bolts to 88 Nm (65 lb.ft).

6. Install the exhaust system.
7. Install both the halfshafts.
8. Check and top-up the differential case.

^ Tighten the filler plug to 34 Nm (25 lb.ft).

9. Connect the battery ground cable and install the cover.