Differential Assembly - Front Differential
Differential assembly - V854.10.01
Remove
1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove air intake plenum.
4. Remove viscous fan.
5. Place container beneath PAS pump, remove pipe union and allow fluid to drain. Plug connections.
6. Discard "O" ring from PAS pipe.
7. Remove 2 nuts securing engine brackets to mountings
8. Connect chain to lilting bracket and take weight of engine.
9. Drain oil from differential.
10. Remove front propeller shaft.
11. Remove RH drive shaft seal.
12. Remove differential oil seal.
13. Remove Torx bolt from steering column lower clamp.
14. Rotate steering wheel to straight ahead position, align pinion timing marks and remove ignition key.
CAUTION: Do not turn the steering wheel with the intermediate shaft or universal joint disconnected as damage to the rotary coupler and the steering wheel switches may occur.
15. Disconnect column from pinion.
16. Note fitted position for relit then remove cable ties securing height sensor harness to sub frame and sensors.
17. Disconnect height sensor multiplugs.
18. Disconnect multiplug from PAS rack pinion sensor.
19. Remove 2 speed nuts securing each anti-roll bar heatshield to body and 2 bolts securing each heatshield to sub-frame. Remove heat shields.
20. Use a transmission jack to support the sub frame.
21. Remove 6 bolts securing sub-frame. Remove 2 bolts securing sub-frame to cross member (bolts arrowed).
22. Remove 4 bolts securing differential and with assistance, remove differential. Remove and discard "O" ring.
23. With assistance, lower and remove sub-frame assembly.
24. Remove differential breather hose. Remove 4 Differential securing bolts and with assistance, remove differential. Discard "O" ring.
NOTE: Securing bolt above pinion remains captive to differential.
Refit
1. Clean differential and mating face.
2. Fit new "O" ring to differential housing and lubricate with petroleum jelly.
3. With assistance, carefully fit differential. Tighten bolts to 45 Nm (33 ft. lbs.).
4. Connect breather hose to differential.
5. Clean sub-frame and body mating faces.
6. With assistance, fit sub-frame assembly.
7. Tighten 6 bolts securing sub-frame to body to 165 Nm (122 ft. lbs.). Tighten 2 rear bolts a further 90°.
8. Tighten 2 bolts securing sub-frame to front cross member to 132.5 Nm (97 ft. lbs.).
9. Fit anti-roll bar heat shields to body and tighten 2 bolts and speed nuts.
10. Lower engine onto mountings.
11. Tighten nuts securing engine brackets to mountings to 100 Nm (74 ft. lbs.).
12. Connect multiplug to PAS rack pinion sensor.
13. Connect height sensor multiplugs.
14. Correctly position height sensor harness and secure with cable ties.
15. Clean PAS pump and pipe union.
16. Fit new "O" ring to high pressure pipe, align to PAS pump and tighten union to 25 Nm (18 ft. lbs.).
17. Check alignment and connect column to PAS rack. Fit and tighten new clamp bolt to 24 Nm (18 ft. lbs.).
18. Fit differential oil seal.
19. Fit RH drive shaft seal.
20. Fit front propeller shaft.
21. Fill differential to correct level with oil.
22. Fit viscous fan.
23. Fit air intake plenum.
24. Connect battery earth lead.
25. Bleed PAS system.
26. Check and if necessary adjust wheel alignment.