Rear Drive Axle/Differential

Axle Assembly

Removal

CAUTION: Do not undo or remove the large protruding hexagon on the differential casing.
1
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.
2 Remove the rear wheels and tires.
3 Remove the exhaust system. For additional information, refer to Muffler
4 Drain the differential fluid. For additional information, refer to Differential Draining and Filling Rear Drive Axle/Differential
5 Remove the RH halfshaft. For additional information, refer to Rear Halfshaft Rear Drive Halfshafts




6 Remove the LH halfshaft retaining nut.
- Discard the nut.




7
CAUTION: Use a wrench on the hexagon provided to prevent the ball joint rotating.
Remove the LH stabilizer bar link and discard the nuts.




8 Release the LH parking brake cable from the lower arm.




9 Disconnect the LH toe link.
- Remove the bolt.





10
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
Release the LH knuckle from the lower arm.
- Remove the bolt.





11 Using the special tools, release the LH halfshaft from the wheel hub.

12 Position a container to collect the oil spillage.

13 Release the LH halfshaft from the differential housing.





14 With assistance, remove the LH halfshaft.
- Remove and discard the snap ring.





15
CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.
CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
Release the driveshaft from the rear axle drive flange.
- Remove and discard the 4 Torx bolts.
- Tie aside.





16 Vehicles with differential locking motor: Disconnect the 2 electrical connectors.
- Release the 2 wiring harness clips.

17 Using a transmission jack, support the differential.





18
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Remove the rear differential.
- Remove the 3 bolts.
- Disconnect the breather line.

Installation
1 Install the rear differential.
- Connect the breather line.
- Tighten the front mounting bolt to 275 Nm (203 lb.ft).
- Tighten the rear mounting bolts to 175 Nm (129 lb.ft).
2 Vehicles with differential locking motor: Connect the electrical connectors.
- Secure the wiring harness clips.
3 Attach the driveshaft to the rear axle drive flange.
- Clean the component mating faces.
- Tighten the new Torx bolts to 150 Nm (110 lb.ft).
4 Install the exhaust system. For additional information, refer to Muffler
5 Clean the components.
6 With assistance, install the LH halfshaft.
- Install the snap ring.
- Open the halfshaft oil seal protector.
- Make sure the snap ring is fully engaged and retains the halfshaft.




7
NOTE:
The oil seal protector is designed to break into two pieces.
NOTE:
RH illustration shown, LH is similar.
Remove and discard the halfshaft oil seal protector.
- Use pull ring to break seal protector as shown.




8 Using the special tools, install the LH halfshaft in the wheel hub.
9
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
Connect the LH lower arm to the wheel knuckle.
- Tighten to 275 Nm (203 lb.ft).

10 Install a new halfshaft retaining nut and lightly tighten.

11 Connect the LH toe link.
- Tighten the bolt to 175 Nm (129 lb.ft).

12 Secure the LH parking brake cable to the lower arm.

13 Install the LH stabilizer bar link.
- Tighten the new nuts to 115 Nm (85 lb.ft).

14 Tighten the LH halfshaft retaining nut to 350 Nm (258 lb.ft).
- Stake the nut to the halfshaft.

15 Install the RH halfshaft. For additional information, refer to Rear Halfshaft Rear Drive Halfshafts

16 Fill the differential with fluid.For additional information, refer to Differential Draining and Filling Rear Drive Axle/Differential

17 Install the wheels and tires.
- Tighten the wheel nuts to 140 Nm (103 lb.ft).