Differential Assembly: Service and Repair

Axle Assembly

Special Service Tools






Power train assembly jack HTJ

1200-2

Removal
1 Remove the cover and disconnect the battery ground cable. For additional information, refer to Specifications
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. For additional information, refer to Rear Halfshaft Service and Repair
4 Remove the exhaust system. For additional information, refer to Exhaust System Service and Repair




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 14mm bolts to 163 Nm (120 lb.ft).
- Tighten the 12mm 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 degrees.
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. For additional information, refer to Exhaust System Service and Repair
7 Install both the halfshafts. For additional information, refer to Rear Halfshaft Service and Repair
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. For additional information, refer to Specifications