Rear Final Drive and Drive Shafts Page 4B1-1

Page 4B1-1

Section 4B1

Rear Final Drive and Drive Shafts

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Description ...............................................................................................................................4

1.1 Final Drive Assembly Identification ..................................................................................................................... 7

Final Drive Applications........................................................................................................................................ 7

1.2 Final Drive Assembly Maintenance...................................................................................................................... 8

Maintenance........................................................................................................................................................... 8

Drive Shaft Bearings and Constant Velocity Joints ............................................................................................ 8

Differential Carrier Assembly.............................................................................................................................. 8

Final Drive Assembly Breather........................................................................................................................... 8

Limited Slip Differential Warnings........................................................................................................................ 8

Lubrication ............................................................................................................................................................. 9

2 Minor Service Operations....................................................................................................................10

2.1 General Information............................................................................................................................................. 10

Important Service Requirements........................................................................................................................ 10

2.2 Checking Differential Carrier Lubricant Level................................................................................................... 11

2.3 Changing/Flushing Rear Axle Lubricant............................................................................................................ 12

2.4 Trailing Arm Outer Rear Wheel Driveshaft Assembly Hub............................................................................... 13

Check for Run-Out............................................................................................................................................... 13

If Run-out is Within Specification....................................................................................................................... 15

If the Run-out Check, Exceeds Specification.................................................................................................... 15

2.5 Trailing Arm Outer Rear Wheel Driveshaft Assembly Hub Studs.................................................................... 16

Replace................................................................................................................................................................. 16

2.6 Limited Slip Differential....................................................................................................................................... 20

Torque Check....................................................................................................................................................... 20

2.7 Drive Shaft Assembly.......................................................................................................................................... 23

Remove................................................................................................................................................................. 23

Reinstall................................................................................................................................................................ 23

2.8 Drive Shaft and/or Constant Velocity Joints ..................................................................................................... 24

Disassemble......................................................................................................................................................... 24

Inspect .................................................................................................................................................................. 26

Drive Shaft and Boots ...................................................................................................................................... 26

Constant Velocity Joints................................................................................................................................... 26

Reassemble.......................................................................................................................................................... 27

Constant Velocity Joints................................................................................................................................... 27

Drive Shaft and Boots ...................................................................................................................................... 31

2.9 Inner Axle Shaft Seal ........................................................................................................................................... 33

Replace................................................................................................................................................................. 33

Techline

Rear Final Drive and Drive Shafts Page 4B1-2

Page 4B1-2

2.10 Pinion Oil Seal...................................................................................................................................................... 35

Replace (Vehicles With a Rear Rubber Coupling)............................................................................................. 35

Replace (Vehicles With a Rear Constant Velocity Joint).................................................................................. 38

2.11 Pinion Flange ....................................................................................................................................................... 41

Replace (Vehicles With a Rear Rubber Coupling)............................................................................................. 41

Using Old Oil Seal............................................................................................................................................ 41

Replace (Using New Oil Seal).......................................................................................................................... 43

Replace (Vehicles With a Rear Constant Velocity Joint).................................................................................. 47

Using Old Oil Seal............................................................................................................................................ 47

Using New Oil Seal .......................................................................................................................................... 49

3 Major Service Operations....................................................................................................................53

3.1 Outer Rear Wheel Driveshaft Flange Outer Rear Wheel Driveshaft Assembly and/or Wheel Bearing......... 53

Remove................................................................................................................................................................. 54

Reinstall................................................................................................................................................................ 60

To Install a New Bearing.................................................................................................................................. 60

To Reinstall Outer Rear Wheel Drive Shaft...................................................................................................... 61

3.2 Final Drive Assembly........................................................................................................................................... 65

Remove................................................................................................................................................................. 65

Reinstall................................................................................................................................................................ 70

3.3 Removed Final Drive Assembly.......................................................................................................................... 75

Disassemble......................................................................................................................................................... 76

For AWD Wagon Models.................................................................................................................................. 79

For RWD VZ Models........................................................................................................................................ 80

All VZ Models with IRS..................................................................................................................................... 81

Differential Case............................................................................................................................................... 83

Inspect .................................................................................................................................................................. 85

Differential Case............................................................................................................................................... 85

Differential Side Gears and Pinion Gears......................................................................................................... 85

Ring Gear and Pinion....................................................................................................................................... 86

Bearings........................................................................................................................................................... 86

Differential Carrier............................................................................................................................................ 86

Screw Adjusters and Inner Axle Shafts............................................................................................................ 87

Rear Cover....................................................................................................................................................... 87

Reassemble.......................................................................................................................................................... 88

Differential Case............................................................................................................................................... 88

Differential Case Side Bearing Pre-Load Setting ............................................................................................. 91

Hypoid Pinion Positioning Shim Selection ........................................................................................................ 92

MY 2005 VZ Series Vehicles with the 3.08:1 Ratio Axle Assembly..................................................................92

MY 2005 VZ Series Vehicles with Other Ratio Axle Assemblies...................................................................... 93

Pinion Installation................................................................................................................................................ 95

For VZ AWD Models ........................................................................................................................................ 96

For All RWD Models......................................................................................................................................... 97

For All Models .................................................................................................................................................. 98

For AWD Models.............................................................................................................................................. 98

For All RWD Models......................................................................................................................................... 99

For All Models .................................................................................................................................................. 99

Differential Backlash Setting .............................................................................................................................. 99

Ring Gear and Pinion Contact Pattern............................................................................................................. 100

Tooth Marking Nomenclature......................................................................................................................... 100

Ideal Contact.................................................................................................................................................. 102

Acceptable Heel Contacts.............................................................................................................................. 102

Acceptable Toe Contacts ............................................................................................................................... 103

Rear Final Drive and Drive Shafts Page 4B1-3

Page 4B1-3

3.4 Limited Slip Differential..................................................................................................................................... 104

Disassemble....................................................................................................................................................... 104

Inspect ................................................................................................................................................................ 107

Differential Case............................................................................................................................................. 107

Differential Side Gears and Pinion Gears....................................................................................................... 107

Ring Gear and Pinion..................................................................................................................................... 107

Bearings......................................................................................................................................................... 108

Reassemble........................................................................................................................................................ 108

3.5 Rear Axle ............................................................................................................................................................ 112

Reassemble........................................................................................................................................................ 112

4 Diagnosis ............................................................................................................................................113

4.1 General Information........................................................................................................................................... 113

Road Test ........................................................................................................................................................... 113

Tyre Noise .......................................................................................................................................................... 113

Front Wheel Bearings........................................................................................................................................ 113

Transmission Rear Bearing (Manual Transmission) ...................................................................................... 114

Backlash Clunk.................................................................................................................................................. 114

Drive-Line Snap.................................................................................................................................................. 114

Engine and Other Contributing Factors........................................................................................................... 114

4.2 Final Drive Assembly Noise.............................................................................................................................. 115

Gear Related Noise............................................................................................................................................ 115

Ring Gear and Pinion Noise........................................................................................................................... 115

Differential Side Gear and Pinion Noise......................................................................................................... 115

Common Causes of Gear Related Noises ..................................................................................................... 115

Bearing Related Noise....................................................................................................................................... 116

Differential Pinion Gear Bearings................................................................................................................... 116

Outer Rear Wheel Drive Shaft Wheel Bearings ............................................................................................. 116

Differential Side Bearings............................................................................................................................... 116

Common Causes of Bearing Related Noises................................................................................................. 116

4.3 LSD Noise........................................................................................................................................................... 117

4.4 Final Drive Bearing Diagnosis.......................................................................................................................... 118

5 Specifications.....................................................................................................................................121

6 Torque Wrench Specifications..........................................................................................................123

7 Special Tools ......................................................................................................................................124

Rear Final Drive and Drive Shafts Page 4B1-4

Page 4B1-4

1 General Description

Independent rear suspension (IRS) is fitted as standard equipment on all MY 2005 VZ Series vehicles except for those

fitted with rear leaf spring suspension. All are fitted with a rear final drive assembly with a four pinion type differential

assembly. The ring gear diam eter and ratio varies with different applications;

refer to 1.1 Final Drive Assembly Identification, in this Section.

Production option G80, Limited Slip Differential (LSD), (also referred to as Spin Resistant Differential – SRD) is avai lable

on selected models. While the majority of illustrations shown in this Section relate to vehicles fitted with the ABS braking

system, service procedures are the same for vehicles equipped with standard brakes, unless otherwise noted.

The final drive assembly is mounted directly to a crossmember which is rubber mounted to the vehicle u nderbody. The

differential case and drive pinion are mounted in opposed taper roller bearings in the carrier. Differential case side

bearing pre-load adj ustment is provided by scre w adjusters in the sides of the case, while pinion bearing pre-load is

provided by a collapsible spacer. Torque is transferred from the propeller shaft to the final drive assembl y via the pinion

flange which is splined to the hypoid pinion. T he torque is then transferred from the pinion through the ring gear,

differential case, differential pinion cross shafts, differential pinions, side gears and then via splines, to the inner axle

shafts and drive shafts.

The final drive assembl y shou ld be removed from the vehicle for all service operati ons other than for the removal of the

inner axle shafts, inner axle shaft oil seals, pinion oil seal or the rear cover. Two drive shaft assemblies are used, each

consisting of a shaft which is splined at each end into a ball type constant velocity joint. The inner constant velocity joint

is bolted to the inner axle shaft flange at the differential carrier, with the outer joint bolted to the outer rea r wheel

driveshaft flange at the rear trailing arm.

Figure 4B1 – 1

Legend

1 Drive Shaft

2 Rear Suspension Stabiliser Bar

3 Final Drive Assembly

4 Constant Velocity Joints

5 Trailing Arm

6 Rear Suspension Crossmember

7 Rear Stabiliser Bar to Trailing Arm Link

Rear Final Drive and Drive Shafts Page 4B1-5

Page 4B1-5

When fitted, the Limited Slip Differential (LSD) performs the same functions as the conventional type differential but in

addition, transfers driving force to the wheel with traction, should the opposite wheel begin to spin. The differential case

houses two cone type clutches behind the side gears, that are splined to the inner axle shafts. The tapered clutch face s

contact corresponding faces in the differenti al case. The cones form an integral part of the side gears.

The four pinion type Limited Slip Differential has three pre-load springs enclosed in the centre of the pinion cross shaft.

The Limited Slip Differential directs the major driving force to the wheel with the great er amount of traction, but will not

interfere with steering characteristics or differential action. The partial locking action, due to the spring load on the cones,

is automatically increased by the inherent separating forces between the side gears and pinions, which progressively

increases the resistance in the differenti al as applied torque is increased.

When the rear wheels are under extremely unbalanced conditions, such a s a wheel on a dry road and the other in mud

or ice, with the standard differential, wheel spin easily occurs if over-acceleration is attempted. However, with a Limited

Slip Differential, when the tendency for wheel spin occurs, the friction gen erated inside the case, transfers driving force to

the non-spinning wheel. In the event of continued spinning, a whirring sound from the over-running cones ma y be

produced but this condition/sound does not indicate failure of the unit.

The final drive assembly fitted to the AWD Wago n, is the

same 3.46:1 ratio assembly (non LSD) fitted to other VZ

applications with this ratio, except for these changes:

1 The rear mount has a spacer (1) fitted.

2 The pinion flange (2) is redesigned to cater for the rear

propeller shaft constant velocity joint.

3 The front of the rear crossmember mounts have an

increased length centre boss. These are also fitted

with a snubber bush on each side.

4 The drive shafts have a plunge joint at both the inner

and outer ends, unlike other IRS assemblies, that

have a plunge joint at the inner end an d a fixed joint at

the outer.

NOTE

Coupe models also have drive shafts with

plunge joints at the inner and outer ends. Figure 4B1 – 2

Rear Final Drive and Drive Shafts Page 4B1-6

Page 4B1-6

Figure 4B1 – 3

Legend

1 LH Inner Axle Shaft

2 Pinion Flange

3 RH Inner Axle Shaft

4 Identification Label

5 Drain Plug

6 Rear Cover

7 Breather

8 Filler Plug

9 Lubrication Tag

Rear Final Drive and Drive Shafts Page 4B1-7

Page 4B1-7

1.1 Final Drive Assembly Identification

The type of differential fitted to this final drive assembly can be identified by referring to the label (1) attached to the RHS

of the carrier housing and the lubric ation tag (2) under the filler plug (3) on the rear cover.

The locations of the identific ation label and lubrication tag are as shown in F igure 4B1-4.

The identification label (1) carries the final drive assembly pa rt number for the final drive ratio and the se rial number of

the assembly.

The code number and bar co de is used for production identification of the final drive as sembly.

Figure 4B1 – 4

Final Drive Applications

Body Type Engine Transmission Ratio ABS LSD Lubricant I.D. Code

VZ Wagon,

Sedan, Utility

HFV6

'Alloytec'

(P/O LE0 / LW2)

Automatic

'4L60-E'

(P/O M30) 3.08:1 N

Mineral

Synthetic +

ZFJ

ZFL

ZFM

VZ Sedan, Utility

HFV6

'Alloytec'

(P/O LE0)

HFV6

'Alloytec 190'

(P/O LY7)

Manual 'D173'

(P/O MV5)

Automatic

'5L40'

(P/O M82)

2.87:1 N

Synthetic

Synthetic +

VZ Wagon,

Sedan, Utility GEN III V8

(P/O LS1)

Automatic

'4L60-E'

(P/O M30) 3.07:1 Y

Y N

Y Synthetic

Synthetic + ZFF

ZFH

VZ Wagon, Utility GEN III V8

(P/O LS1) Manual 'T56'

(P/O MM6) 3.46:1 Y

Y N

Y Synthetic

Synthetic + ZFT

ZFC

VZ AWD Wagon

HFV6

'Alloytec 190'

(P/O LY7)

GEN III V8

(P/O LS1)

Automatic

'5L40'

(P/O M82)

Automatic

'4L60-E'

(P/O M30)

3.46:1 Y N Synthetic AAA

VZ Sedan GEN III V8

(P/O LS1) Manual 'T56'

(P/O MM6) 3.73:1 Y

Y N

Y Synthetic

Synthetic + AX

ZFS

Coupe GEN III V8

(P/O LS1+)

Automatic

'4L60-E'

(P/O M30)

Manual 'T56'

(P/O M12)

3.46:1 Y Y

Synthetic + ZFC

‘+’ indicates that an additive is added to the lubricant. Refer to Lubrication, in 1.2 Final Drive Assembly Maintenance.

Table 1

Where fitted, the information on the lubrication tag (2) under the filler plug (‘3’ in Figure 4B 1-4), will be:

With GEN III V8 or HFV6 'Alloytec 190' vehicles, fitted with the conventiona l differential;

“HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY”

With GEN III V8 or HFV6 'Alloytec 190' vehicles, fitted with LSD;

“LSD - HIGH PERFORMANCE. USE APPROVED LUBRICANT AND FRICTION MODIFIER”

Rear Final Drive and Drive Shafts Page 4B1-8

Page 4B1-8

1.2 Final Drive Assembly Maintenance

Maintenance

Drive Shaft Bearings and Cons tant Velocity Joints

The drive shaft constant velocity joints are lubricated for life and therefore require no periodic mainten ance.

The constant velocity joint boots are to be inspected at every maintenance service. If there is any evidence of damage to

boots, remove drive shaft and inspect constant velocity joints, refer to 2.7 Drive Shaft Assembly and to

2.8 Drive Shaft and/or Constant Velocity Joints, in this Section.

Differential Carrier Assembly

Check for lubricant leaks at every maintena nce service. If there is evidence of leakage, correct the leak and add l ubricant

as necessary. (Refer to 2 Minor Service Operations, in this Section).

At the time or distance interval specified in the appropriate Owner's Handbook, check to ensur e that the lubricant level is

to the bottom of the filler plug hole when the differential carrier assembly is COLD.

Final Drive Assembly Breathe r

The breather hose (1) should be checked regularly to

ensure that it is not blocked, is correctly routed and not

kinked.

The top end of the breather hose should b e in serted at least

25 mm into the vehicle underbody crossmember hole (2).

Figure 4B1 – 5

Limited Slip Differential Warnings

• When servicing a vehicle fitted with a

Limited Slip Differential, never run the

engine with the transmission in gear and

one wheel raised. The driving force to the

wheel on the ground may cause the

vehicle to move.

• 'On Car' type wheel balancers are not

recommended for use on the rear wheels

of cars equipped with a Limited Slip

Differential. One rear wheel will drive if in

contact with the ground when the opposite

wheel is raised and rotated.

• This type of balancer may be used by

removing the road wheel opposite to the

one being spun, the vehicle raised and

supported on safety stands. Refit wheel

nuts, reversed, to retain brake disc.

Rear Final Drive and Drive Shafts Page 4B1-9

Page 4B1-9

Lubrication

The lubricant level should be checked and topped up (if required), at the time or distance intervals

outlined in the appropri ate Owner's Handbook with the differential carrier COLD;

refer to 2.2 Checking Differential Carrier Lubricant Level in this Section. At this temperature, the lubricant should be level

with the bottom of the filler plug hole. This service operation also details the recommended lubricants for all final drives.

Never use any other than the stated and

recommended lubricant.

NOTES

• The lubricant for vehicles with the 3.08:1 ratio

assembly, with the standard, open or

conventional differential, is an approved

mineral oil. Using a straight run mineral oil in

an LSD final drive ass embly, will cause ‘stick-

slip’ chatter to occur when turning corners.

Alternatively, if a synthetic type lubricant is

used in any c onventional rear a xle of a 3.08:1

ratio assembly, oil seal deterioration with the

possibility of lubricant leakage may occur.

• The lubricant used in all other ratio rear axle

assemblies, is a synthetic product. The oil

seals in these assemblies have been speciall y

formulated to tolerate this lubricant. It must

also be noted that, using a mineral type

lubricant in any of these final drives, may

cause gear set and/or bearing damage under

high load driving conditio ns.

• When a Limited Slip Different ial (LSD) is fitted

to any rear axle, an approv ed additive such as

Sturaco 7098 MUST also be used, in

conjunction with a synthetic hypoid gear oil.

• If the incorrect lubricant is accide ntall y used i n

the rear axle of any MY 2005 VZ Series

vehicle, then the rear axle should be drained,

flushed (with the recomm ended lubricant) and

then refilled with the correct lubricant. The

procedure for this operation is detailed in

2.3 Changing/Flushi ng Rear Axle Lu bricant , in

this Section.

Rear Final Drive and Drive Shafts Page 4B1-10

Page 4B1-10

2 Minor Service Operations

2.1 General Information

Important Service Requirements

1 Whenever a road wheel and/or brake disc is removed from the vehicle, the relationsh ip of the road wheel and the

disc to the hub MUST be marked with a felt tipped pen or similar, in order for those parts to be reinstalled in their

original positions. This is critical to maintain the brake disc and road wheel runout dimension to a minimum.

2 When reinstalling road wheels, do not use an impact

gun to tighten wheel nuts unless the impact gun is

fitted with a torque limiter socket (Tool No. AU 534 or

a commercial equivalent). Failure to correctly tighten

wheel nuts to the correct torque specification and in

the correct order, may result in a distorted brake disc,

leading to the development of brake shudder.

Road wheel attaching nut

torque specification..............................110 – 140 N.m

For a complete description of the method used to measure

both brake disc and outer rear wheel driveshaft assembly

runout and correction, refer to

Section 5A Service and Park Braking Systems.

Figure 4B1 – 6

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. W h ere specified in this section, fasteners MUST be rep laced with parts of the

same part number or an approved equivalent. Do not use fasten ers of an inferior quality or substitute desig n.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be repl aced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanic al thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

Rear Final Drive and Drive Shafts Page 4B1-11

Page 4B1-11

2.2 Checking Differential Carrier Lubricant

Level

1 Ensure vehicle is level.

2 Clean area around filler plug (1).

3 Remove filler plug (1) from rear cover (3) (do not lose

the lubrication tag (2) from the plug, if fitted).

4 The lubricant level is to be maintaine d at the bottom

edge of the filler plug hole, when COLD. Use only the

recommended lubricant, detail ed in the following table.

Figure 4B1 – 7

Application Recommended Lubricant

All With Non-LSD Differential All With LSD Differential

All with the V6 engine and

4L60-E automatic transmission.

1.6 litre Mineral Hypoid Gear Oil )

SAE 90 LSD such as;

AMPOL Gear Lube LSD 90,

CASTROL LSX90,

SHELL Helix Limited Slip Diff. Oil

VALVOLINE HP Gear Oil LS90

1.5 litre Synthetic Hypoid Gear Oil,

SAE 80W-140 such as;

MOBIL Mobilube SHC ID, or

CASTROL SAF-XA

PLUS;

0.1 litre of Sturaco 7098 Oil Additive

All With Non-LSD Differential All With LSD Differential

All with the V6 engine and

manual transmission or 5L40-E

automatic transmission

All GEN III V8 engines and manual or

automatic transmission.

1.6 litre Synthetic Hypoid Gear Oil,

SAE 80W-140 such as;

MOBIL Mobilube SHC ID or

CASTROL SAF-XA

1.5 litre Synthetic Hypoid Gear Oil,

SAE 80W-140 such as;

MOBIL Mobilube SHC ID or

CASTROL SAF-XA,

PLUS;

0.1 litre of Sturaco 7098 Oil Additive

) If towing heavy loads for an extended time, it is recommended that Synthetic Hypoid Gear oil is used. If towing

between 1,600 kg and 2,100 kg at speeds over 80 km/h with a V6 naturally aspirated engine, it is strongly

recommended that synthetic gear oil be us ed.

Table – 2

5 Inspect filler plug (1) for damage, if OK, reinstall to the rear cover (3) (includi ng the lubrication tag (2). If damaged,

replace plug.

6 Tighten filler plug (1) to the correct torque specification.

Filler plug

torque specification..............................................30 N.m

Rear Final Drive and Drive Shafts Page 4B1-12

Page 4B1-12

2.3 Changing/Flushing Rear Axle Lubricant

1 To drain lubricant from differential carrier assembly, remove filler (1) and drain plugs (4) (refer Figure 4B1-7) and

allow (preferably warm) lubricant to drain into a suitable container.

2 If flushing is required, use an undiluted quantity of the recommended lubricant for the operatio n.

3 When the draining and flushing (if required), operation is co mpleted, apply thread sealing tape to rear cover drain

plug (4) thread. Install and tighten drain pl ug (4) to the correct torque specification.

Rear axle drain plug

torque specification..............................................30 N.m

4 Fill the final drive assembly with either 1.6 litres of the recommended lubric ant or 1.5 litres of the recommended

lubricant plus 0.1 litre of Sturaco 7098 oi l additive; refer to Table – 2. Install the filler pl ug (1) and lubrication tag (2)

(if fitted) and tighten to the correct torque specification.

Filler plug

torque specification..............................................30 N.m

Rear Final Drive and Drive Shafts Page 4B1-13

Page 4B1-13

2.4 Trailing Arm Outer Rear Wheel

Driveshaft Assembly Hub

LT Section No: 05-290

ATTENTION

Vehicle must be at curb weight before final tightening.

 Lower shock absorber mounting bolt.

Check for Run-Out

1 Raise the rear of the vehicle and sup port in a safe manner. Refer to Section 0A General Information for the location

of recommended lifting and support poi nts.

2 Remove rear wheel cover (steel wheels) or wheel nut covers (alloy wheels) on that side of the vehic le where the

outer rear wheel driveshaft is to be checked.

3 Mark relationship of wheel to mounti ng flange. Remove road wheel attaching nuts and re move wheel.

Refer to 2.1 General Information in this Section for more information.

4 Disconnect rear shock absorber lower mounting bolt (1) from trailing arm (2), and pull lower end of shock absorber

(3) from trailing arm.

NOTE

View ‘A’ in Figure 4B1-8 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 8

5 Remove brake caliper anchor plate to trailing arm

attaching bolts (1), remove caliper (2) from disc.

Figure 4B1 – 9

Rear Final Drive and Drive Shafts Page 4B1-14

Page 4B1-14

6 Using tie wire (1), secure caliper to lower end of shock

absorber upper mounting. DO NOT ALLOW CALIPER

TO HANG BY BRAKE HOSE.

7. Mark the brake disc position to outer rear wheel

driveshaft assembly, using a felt tipped pen or similar,

then remove the brake disc from the outer rear wheel

driveshaft assembly (Shown already removed in

Figure 4B1-10).

NOTE

If necessary, loosen the park brake shoe

adjustment. Refer to 3.9 Park Brake Shoe,

Adjust, in Section 5A Service and Park Braking

Systems.

Figure 4B1 – 10

8 If the park brake shoe adjustment needs to be

released to allow disc removal, adopt the following

method:

a Remove the access hole plug (1) from the hole

provided in the disc.

b Using a suitable lever such as a screwdriver,

loosen the park brake shoe screw adjuster, until

the disc is freed.

c After disc removal, reinstall the access hole plug

to prevent loss.

Figure 4B1 – 11

9 Clean the rear outer rear wheel driveshaft face by

rubbing lightly with fine emer y paper.

10 Mount the pre-fabricated mounting plate (refer

7 Special Tools in this Section for details) to the brake

caliper mounting points on the rear traili ng arm, using

the caliper mounting bolts.

11 Mount a magnetic based dial indicator stand, install a

dial indicator, positioning the pointer at a distance of 5

mm in from the outer edge (‘A’).

12 Using the wheel studs, carefully rotate outer rear

wheel driveshaft assembly hub, noting th e points of

maximum and minimum lateral run-out. The difference

between these two dimensio ns is the Total Indicated

Runout (TIR).

Maximum outer rear wheel driveshaft

assembly hub, total indicated runout............... 0.060 mm

Figure 4B1 – 12

Rear Final Drive and Drive Shafts Page 4B1-15

Page 4B1-15

If Run-out is Within Specification

1 Reinstall brake disc over the o uter rear wheel driveshaft wheel studs, ensuring that the alignment marks made prior

to disassembly, are aligned.

2 Clean the threads of the brake caliper attaching bolts

(1) and apply a thread sealant such as Loctite 243 (or

equivalent).

3 Reinstall the brake caliper a nchor plate (2) and secure

with the attaching bolts (1), tightened to the correct

torque specification.

Brake caliper anchor plate to trailing

arm bolt torque specification................................85 N.m

Figure 4B1 – 13

Vehicle must be at curb weight and on all four

wheels before the shock absorber mounting

bolt torque is applied.

4 Reinstall shock absorber to trailing arm, fit washer to the lower mounting bolt, install bolt and tighten to the correct

torque specification.

z Shock absorber lower mounting

bolt torque specification.....................................115 N.m

NOTE

View ‘A’ in Figure 4B1-14 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 14

5 Reinstall road wheel, aligning marks made prior to removal, install and tig hten attaching nuts.

6 Remove safety stand and lo wer vehicle.

7 Tighten road wheel attaching nuts to the correct torque specification and in the correct sequence

(refer to Important Service Requirements in 2.1 General Information, in this Section).

Road wheel attaching nut

torque specification..................................110 – 140 N.m

8 Refit wheel cover/wheel nut caps.

If the Run-out Check, Exceeds Specification

1 The outer rear wheel drivesha ft assembly must be replaced,

refer to 3.1 Trailing Arm Outer Rear Wheel Drive Shaft Flange and/or Wheel Bearing, in this Section.

Rear Final Drive and Drive Shafts Page 4B1-16

Page 4B1-16

2.5 Trailing Arm Outer Rear Wheel

Driveshaft Assembly Hub Studs

LT Section No: 05-290

ATTENTION

Vehicle must be at curb weight before final tightening.

 Lower shock absorber mounting bolt.

Replace

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove rear wheel cover or wheel nut caps o n that side of the vehicle where the stud/s are to be replaced.

3 Mark relationship of wheel to mounti ng flange. Loosen then remove road wheel attaching nuts. Remove the road

wheel. Refer to 2.1 General Information in this Section for more information.

4 Loosen and disconnect rear shock absorber lower mounting bolt (1) from trailing arm (2) and pull lower end of

shock absorber (3) from trailing arm (2).

NOTE

View ‘A’ in Figure 4B1-15 shows the sedan and

coupe, lower shock absorber mounting, while

view ‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 15

5 Loosen and remove brak e caliper anchor plate to

trailing arm attaching bolts (1) and remove calip er (2)

from disc.

Figure 4B1 – 16

Rear Final Drive and Drive Shafts Page 4B1-17

Page 4B1-17

6 Using tie wire (1), secure the brake caliper to lower

end of shock absorber upper mounting. DO NOT

ALLOW CALIPER TO HANG BY BRAKE HOSE.

7 Mark the brake disc position to outer rear wheel

driveshaft assembly, using a felt tipped pen or similar,

then remove the brake disc from the outer rear wheel

driveshaft assembly (Shown already removed in

Figure 4B1-16).

Figure 4B1 – 17

8 If the park brake shoe adjustment needs to be

released to allow disc removal, adopt the following

method:

a Remove the access hole plug (1) from the hole

provided in the disc.

b Using a suitable lever such as a screwdriver,

loosen the park brake shoe screw adjuster, until

the disc is freed.

c After disc removal, reinstall the access hole plug

to prevent loss.

Figure 4B1 – 18

The use of a hammer and punch to remove a

wheel stud is not permitted, as distortion of

the outer rear wheel driveshaft assembly will

most likely occur. This would subsequently

result in brake shudder.

9 Use Tool No. C4150-C, remove the wheel stud (1) to

be replaced.

Figure 4B1 – 19

Rear Final Drive and Drive Shafts Page 4B1-18

Page 4B1-18

10 Install Tool No. KM468-B holding bar, with two wheel

nuts to the outer rear wheel driveshaft assembly hub

studs. Install a new stud into hub. Assemble some

suitable size washers and a reversed wheel nut, onto

stud. Tighten wheel nut to draw in stud. When stud is

fully installed, remove wheel nut and washers.

11 Install any remaining studs in the same manner.

12 Remove holding bar, T ool No. KM-468-B.

Figure 4B1 – 20

13 Reinstall brake disc (1) over the outer re ar wheel

driveshaft wheel studs, ensuring that the marks made

prior to disassembly, are aligned.

14 Clean the threads of the brake caliper attaching bolts

(1) and apply a thread sealant such as Loctite 243 (or

equivalent).

15 Reinstall brake calip er (3) anchor plate to trailing arm

attaching bolts (2) and tighten to the correct torque

specification.

Brake caliper anchor plate

torque specification..............................................85 N.m

Figure 4B1 – 21

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

16 Reinstall shock absorber to trailing arm, fit washer to the lower mounting bolt, install bolt and tighten to the correct

torque specification.

z Shock absorber lower mounting

bolt torque specification.....................................115 N.m

Rear Final Drive and Drive Shafts Page 4B1-19

Page 4B1-19

NOTE

View ‘A’ in Figure 4B1-22 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 22

17 Reinstall road wheel, aligning marks made prior to removal, install and tig hten attaching nuts.

18 Remove safety stand and lo wer vehicle.

19 Tighten road wheel attaching nuts to the correct torque specification and in the correct sequence

(refer Important Service Requirements in 2.1 Genera l Information, in this Section).

Road wheel attaching nut

torque specification..................................110 – 140 N.m

20 Refit wheel cover/wheel nut caps.

Rear Final Drive and Drive Shafts Page 4B1-20

Page 4B1-20

2.6 Limited Slip Differential

LT Section No. – 05-290

ATTENTION

Vehicle must be at curb weight before final tightening.

 Lower shock absorber mounting bolt.

Torque Check

1 Place transmission in neutral with engine turned OFF .

2 Jack up one rear wheel and supp ort trailing arm on a safety stand. Release park brake lever to fully OFF position.

3 Remove rear wheel cover (steel wheels) or wheel nut caps (alloy wheels) on that side of the vehicle where the

stud/s are to be replaced.

4 Mark relationship of wheel to mounti ng flange. Loosen then remove road wheel attaching nuts. Remove the road

wheel.

5 Loosen and disconnect rear shock absorber lower mounting bolt from trailing arm an d pull lower end of shock

absorber from trailing arm.

NOTE

View ‘A’ in Figure 4B1-23 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 23

6 Loosen, then remove brake caliper anchor plate to

trailing arm attaching bolts (1) and remove calip er (2)

from disc.

Figure 4B1 – 24

Rear Final Drive and Drive Shafts Page 4B1-21

Page 4B1-21

7 Using tie wire (1), secure the brake caliper to lower

end of shock absorber upper mounting. DO NOT

ALLOW CALIPER TO HANG BY BRAKE HOSE.

8 Mark the brake disc position to outer rear wheel

driveshaft assembly, using a felt tipped pen or similar,

then remove the brake disc from the outer rear wheel

driveshaft assembly (Shown already removed in

Figure 4B1-25).

Figure 4B1 – 25

9 Install Tool No. 7208 to the outer rear wheel driveshaft

assembly, securing with three wheel nuts.

10 Lock the forcing screw with the lock nut provided.

11 Using a torque wrench (1) and a suitable size d socket,

rotate the outer rear wheel driveshaft in a forward

direction (clockwise).

NOTE

• If the LSD assembly is operating

satisfactorily, a torque reading of

approximately 70 N.m should be obtained

while turning the outer rear wheel driveshaft

assembly, with the opposite wheel remaining

stationary.

• If a torque reading of less than 45 Nm

is obtained, remove differential case

and inspect case internal components

and repair as necessary, refer to

3.4 Limited Slip Differential in this Section. Figure 4B1 – 26

12 Reinstall brake disc (1) over the outer re ar wheel

driveshaft wheel studs, ensuring that the marks made

prior to disassembly, are aligned.

13 Clean the threads of the brake caliper attaching bolts

(1) and apply a thread sealant such as Loctite 243 (or

equivalent).

14 Reinstall brake calip er (3) anchor plate to trailing arm

attaching bolts (2) and tighten to the correct torque

specification.

Brake caliper anchor plate to trailing

arm bolt torque specification................................85 N.m

Figure 4B1 – 27

Rear Final Drive and Drive Shafts Page 4B1-22

Page 4B1-22

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

15 Reinstall shock absorber to trailing arm, fit washer to the lower mounting bolt, install bolt and tighten to the correct

torque specification.

z Shock absorber lower mounting

bolt torque specification.....................................115 N.m

NOTE

View ‘A’ in Figure 4B1-28 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 28

16 Install road wheel, aligning marks made pr ior to removal, install and tighten attaching nuts.

17 Remove safety stand and lo wer vehicle.

18 Tighten road wheel attaching nuts to the correct torque specification and in the correct sequence

(refer ‘Important Service Requirements’ in 2.1 General Information, in this Section).

Road wheel attaching nut

torque specification..................................110 – 140 N.m

19 Refit wheel cover/wheel nut caps.

Rear Final Drive and Drive Shafts Page 4B1-23

Page 4B1-23

2.7 Drive Shaft Assembly

LT Section No: 05-290-1

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 All removed driveshaft constant velocity joint attaching bolts.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Use a felt tipped pen or similar, to identify the

driveshaft as being either right or left and also, which

constant velocity joint is the outer.

NOTE

It is important that the drive shaft orientation is

marked, to maintain the shaft ‘wind-up’ direction

when reinstalled.

3 With the park brake firmly applied, use an 8 mm Allen

key socket and suitable socket equipm ent (3) remove

drive shaft inner constant velocity joint to inner axle

shaft and outer constant velocity joint to outer rear

wheel driveshaft flange attaching bo lts (2) (six places)

and plates, remove drive shaft (1).

NOTE

During drive shaft removal and reinstallati on, the

drive shaft must be supported to keep constant

velocity joint deflection to a minimum. Figure 4B1 – 29

Reinstall

Reinstallation of the drive shaft is reversal of the removal procedure, noting the following points.

1 When reinstalling the driveshaft, ensure that either constant velocity joint is not deflected excessively and that the

orientation is the same as before remov al, u sing the identification marks previously applied.

2 Reinstall the driveshaft, then six NEW bolts and three plates at each end, tightening to the correct torque

specification.

 Drive shaft constant velocity joint

bolt torque specification.......................................50 N.m

plus 90° turn angle

Rear Final Drive and Drive Shafts Page 4B1-24

Page 4B1-24

2.8 Drive Shaft and/or Constant Velocity

Joints

LT Section No: 05-290-1

There are three repair kits available for drive shaft constant velocity joint repairs:

a A ‘Boot Kit’, which consists of a boot, boot clamps and retaining circlip, common for both the plunge and fixed

designs.

b A ‘Constant Velocity Joint Kit’, which contains the same items as the Boot Kit plus a 'fixe d' design constant velocit y

joint and lubricant of the correct type and quantity.

c A ‘Constant Velocity Joint Kit’, which contains the same items as the Boot Kit plus a 'plunge' design constant

velocity joint and lubricant of the correct type and quantity.

NOTE

• Sealant for the constant velocity joint covers

is not supplied in any kit. The correct sealant

however, is available in 75 gram tubes.

• Both the dust cap and the dust shield are

available as separate items and not included

in any of the available kits.

Disassemble

NOTE

Except where noted differences apply, the

following procedures apply to either the fixed or

plunge type of constant velocity joint.

1 Remove drive shaft assembly,

refer to 2.7 Drive Shaft Assembly in this Section.

2 Clean outside of assembly with a suitable solvent

before disassembling.

3 Clamp assembly, by drive shaft (1), in a vice fitted with

soft metal jaws.

4 Using tin snips or other suitable cutting tool, cut boot

clamps (2) in raised crimped area and remo ve clamps.

Figure 4B1 – 30

Rear Final Drive and Drive Shafts Page 4B1-25

Page 4B1-25

5 Using a suitable drift (1) and hammer, tap end dust

shield cap (3) from the outer end of the constant

velocity joint. being disassembled.

6 After changing the clamping, use a simil ar procedure

to dislodge the inner dust shield (2) from the constant

velocity joint.

Figure 4B1 – 31

7 Using suitable circlip pliers, remove the circlip (1) from

the end of drive shaft where the constant velocity joint

is to be removed. Discard the removed circlip.

NOTE

Do not re-use circlips once they have been

removed. Always use new snap rings on

reassembly.

8 Wipe the excess lubricant from the outer joint surfaces

then apply correction fluid across the inner race, ball

carrier and outer race as indic ated b y 'A'.

NOTE

This step is necessary to maintain the original

relationship of these three components.

9 Remove assembly from vice. Slide inner dust shield

and boot towards the centre of the driveshaft. Figure 4B1 – 32

10 Using suitable press plates (such as Tool No. J22912-

01), supporting inner race (1), press drive sha ft from

constant velocity joint, using a suitable drift (2).

NOTE

While the press plates must support the inner

race, if clamped too tight to the drive shaft, then

the shaft splines will foul against the press

plates.

11 Repeat process to remove remaining constant velocity

joint, as required.

12 Remove boots and dust shields from drive shaft,

ensuring boots are not dam aged on edges of shaft

splines. Figure 4B1 – 33

Rear Final Drive and Drive Shafts Page 4B1-26

Page 4B1-26

Inspect

Drive Shaft and Boots

1 Clean shaft and boot/s in a suitable cleaning solvent.

2 Inspect drive shaft for twisting, cracking or excessive spline wear.

NOTE

As the drive shaft is not serviced separately, if

found to be defective, then the complete drive

shaft must be replaced.

3 Inspect boots and replace if split, fatigued, cracked or worn.

Constant Velocity Joints

Complete disassembly of the constant

velocity joints is not recommended. The

internal components are a precision fit and

develop their own characteristic wear

patterns. Intermixing components could

result in looseness, binding and/or premature

failure of the joint.

1 Inspect grease in joint and, if obviously contaminated

and/or has been subjected to dirt/water ingress, the

joint has probably suffered damage and should be

replaced.

2 If inspection reveals that the joint has not been

contaminated, clean joint by soaking in a suitable

cleaning solvent.

3 Once grease has been removed, insp ect internal

components by tilting inner race to one si de to expose

each ball.

NOTE

Take care not to pivot the inner race too sharply,

as the balls can become dislodged. If this does

occur and the origi nal location of the balls is lost,

then the constant velocity joint should be

replaced.

Figure 4B1 – 34

4 Replace the constant velocity joint assembly if there is severe pitting, galling, play between balls and the cage

windows, any cracking or damage to ca ge, outer race, pitting or galling or chips in raceways.

Rear Final Drive and Drive Shafts Page 4B1-27

Page 4B1-27

Reassemble

Constant Velocity Joints

NOTES

• During the removal, cleaning and inspection

of a constant velocity joint, it is possible for

the joint to become disassembled. Should the

disassembly of a constant velocity (CV) joint

be required and, notwithstanding the earlier

recommendation, it is possible to reassemble

the CV joint, provided the foll owing procedure

is followed EXACTLY.

• All components, including the individual balls,

MUST be maintained in their original

relationship to each other, to minimise the

creation of a noisy or binding joint.

• Under no circumstances are components

from one constant velocity joint to be mixed

with components from another CV joint.

Shown in Figure 4B1 – 35, are exploded views of each constant velocity joint t ype; view 'A' is the plunge design, while

view 'B' shows the fixed design.

With the plunge joint ('A'), note the ide ntification groove (5) on the outer race and the ide ntificatio n step (6) on the inner

race (1). Conversely, the fixed joint ('B') has two grooves (4) on the outer race, a chamfer on the cage (2) and straight

ball raceways on the inner race (1).

Figure 4B1 – 35

Rear Final Drive and Drive Shafts Page 4B1-28

Page 4B1-28

Plunge Type

1 Place the inner race (1) into the cage (2) and position

centrally.

Figure 4B1 – 36

2 Place the inner race and cage assembly (2) into the

outer race (1). Make sure that the identification groove

(1) and step (2) are on opposite sides of the assembly,

as shown.

Figure 4B1 – 37

3 Align the thick sections (A) on the outer race (1) , with

the narrow ones (B) on the inner race (2), aligning the

three marks made before disassembly.

Figure 4B1 – 38

Rear Final Drive and Drive Shafts Page 4B1-29

Page 4B1-29

4 Tilt the cage and inner race, as shown and fit one ball

(1).

Repeat this process for the remaining five balls.

Figure 4B1 – 39

5 When assembly of the constant velocity joint is

complete, check for plunge movement of the inner

members, as indicated by ‘A’. If NO plunge movement

can be achieved, then the constant velocity joint has

NOT been correctly assembled.

If such a situation occurs, the constant velocity joint

must be disassembled and the assemb ly process

repeated until such time that the required plunge

movement is achieved.

Figure 4B1 – 40

Fixed Type

1 With the inner race (1) at 90° to the ball cage (2),

insert one 'leg' (3) of the inner race into one of the ball

holes, then manipulate the inner race unti l installed

inside the ball cage. Check that the relatio nship marks

are both on the same side.

NOTE

The fine groove on the inner edge of the ball

cage and the chamfered spline edge, should

both be opposite the relationship marks.

Figure 4B1 – 41

Rear Final Drive and Drive Shafts Page 4B1-30

Page 4B1-30

2 Reinstall the ball cage and in ner race into the outer

race, following this next procedure:

a Locate the two reliefs in the ball grooves in the

outer race, indicated by 'A'. There will be similar

reliefs on the opposite side.

Figure 4B1 – 42

b With the ball cage and inner race at 90° to the

outer race, install at the relief points (as shown),

then manipulate the ball cage to fit inside the

outer race. Ensure that the relationship marks

are all on the same side and aligned.

Figure 4B1 – 43

3 Tilt the ball cage and inner race as shown, and fit the

balls, in their correct order, one at a time.

4 Check that the three relationship marks (1) are in

alignment.

5 Check that axial movement is minimal.

Figure 4B1 – 44

Rear Final Drive and Drive Shafts Page 4B1-31

Page 4B1-31

Drive Shaft and Boots

1 Remove old sealing bead of silicon from dust shields, dust caps and constant velocity joints.

2 Slide a NEW small boot clamp over the driveshaft, then ins tall both dust shield and boot assemblies onto

driveshafts, ensuring that boots are not damaged by sharp edges on each end by the shaft splines.

3 Position a NEW large boot clamp over boot (2) and

place boot over dust shield (1). Using Tool No.

J22610, securely crimp boot clamp, ensuring the crimp

is positioned mid-way between two bolt holes (3, in

view ‘A’).

Figure 4B1 – 45

4 Pack inside section of joint and boot with one tube of grease (40 grams) and pack half tube (20 grams) to outside

section of joint. Work the joint by hand to distribute grease onto all surfaces, inside the joint.

5 Using a suitable size tube (3) (or socket), press the

constant velocity joint (2) onto the drive shaft, ensuring

that the press load is taken by the inner race (1).

NOTE

While the plunge type constant velocity joint Is

shown, the procedure for either t ype is similar.

6 Install a NEW circlip to secure the constant velocity

joint, at each end.

Figure 4B1 – 46

7 Apply a 2 mm bead (1) of Loc tite 510 High

Temperature Gasket Eliminator sealant or equivalent,

to dust caps/shields. Take care not to contaminate the

constant velocity joint grease with sealant.

Figure 4B1 – 47

Rear Final Drive and Drive Shafts Page 4B1-32

Page 4B1-32

8 Position dust caps and dust shields ont o constant

velocity joints, ensuring that all bolt holes align.

NOTE

Temporarily install three of the retaining bolts to

assist with the alignment.

9 Using a suitable punch and hammer, tap caps and

shields into place.

Figure 4B1 – 48

10 Locate small ends of boots into boot grooves on drive

shafts, ensuring that boots are not twisted.

With each joint, pr y up the small e nds of boots from

the shaft (1) to equalise air pressure inside and

outside of boots and work out any dim ples before

crimping the small clamp/s.

The location distance ’A’, only applies to the

plunge type constant velocity joint and

should be set at 81 mm before tightening the

small clamp. Figure 4B1 – 49

11 Position small clamps over ends of boots an d using

Tool No. J22610, crimp ends of clamps unti l a gap

between the clamp 'ears' of 1 to 2 mm is achieved.

12 Reinstall drive shaft, refer to

2.7 Drive Shaft Assembly – Reinstall in this Section.

Figure 4B1 – 50

Rear Final Drive and Drive Shafts Page 4B1-33

Page 4B1-33

2.9 Inner Axle Shaft Seal

LT Section No. – 05-290

Replace

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove drive shaft from side of vehicle which seal is to be replaced, refer to 2.7 Drive Shaft Assembly – Remove

in this Section.

• During drive shaft removal, keep drive

shaft supported so that it does not hang

on one end.

• Drive shaft joint deflection should be kept

to a minimum.

3 Remove inner axle shaft (1) by installing slide

hammer, Tool No. 7374 with three suitabl e size bolts

to axle flange. Use slide hammer to release axle shaft

spring clip.

NOTE

When the axle shaft is removed, a smal l amount

of lubricant may leak from differential carrier.

Figure 4B1 – 51

4 Clean around seal bore and housi ng area to make sure that no foreign matter enters axle shaft needle b earing in

the screw adjuster.

5 Using a suitable scre wdriver (1) and a block of wood

(2), lever seal (3) from screw adjuster bore (4).

NOTE

Take care not to damage the screw adjuster's

aluminium housing (4) with the scre wdriver blad e

(1), as this could cause oil leaks to occur, after a

new oil seal was fitted.

Figure 4B1 – 52

Rear Final Drive and Drive Shafts Page 4B1-34

Page 4B1-34

6 Before installation of a new seal, examine seal surface of inner axle shaft and remove any nicks or burrs. Should

this inspection show that the surface is marked, a new inner axle shaft should b e fitted.

NOTE

• The left hand inner axle shaft is shorter in

length than the right hand shaft.

• If the vehicle is equipped with ABS, the inner

axle shafts are unique for this applicati on.

• Check that the spring clip in end of axle shaft

is not damaged and moves freely in groove.

Replace spring clip if necessary, by

expanding ends of clip and removing from

shaft. Only expand the ends of a new clip

enough to allow installation into shaft groove.

7 Examine seal bore in screw adjuster and remove any nicks or burrs.

8 Lubricate seal lips and outsi de diameter with

Mobilgrease XHP 222 grease (or equivalent). Install

seal using Tool No. AU410, u ntil seal bottoms in bore.

Figure 4B1 – 53

Take care when installing the inner axle shaft

that the securing spring clip or the shaft

splines do not damage the seal lips.

9 Reinstall inner axle sh aft (1), aligni ng splines with

clutch cone (if fitted with a Limited Slip Differential)

and side gear.

10 Lightly hit on end of axle shaft flange (1) with a soft

faced hammer (2) to compress spring clip on shaft into

clutch cone and side gear splines. F ully engage shaft

(1) until clip snaps into side gear groove.

11 Reinstall drive shaft, refer to 2.7 Drive Shaft Assembly,

in this Section.

Figure 4B1 – 54

12 Remove safety stands and lower vehicle.

13 Check and fill differential carrier to correct le vel with specified lubricant.

Refer to 2.2 Checking Differential Carrier Lubricant Level, in this Section.

Rear Final Drive and Drive Shafts Page 4B1-35

Page 4B1-35

2.10 Pinion Oil Seal

LT Section No: 05-290 – 1

ATTENTION

Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

 Pinion flange retaining nut threads.

Replace (Vehicles With a Rear Rubber Coupling)

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Mark the position of the propeller shaft rear coupling to pinion flange, using a felt tipped pen or similar.

3 Remove propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints. This operation may also require

partial exhaust system removal.

4 Lightly centre-punch ali gnment marks (A) on the pinion

flange (1), flange nut (2) and pini on end (3) as an aid

for reassembly.

NOTE

By reassembling to the original position, the

flange run-out will be minimised and the pinion

bearing preload will be maintained.

Figure 4B1 – 55

5 Attach Tool No. DT-47735 to the pinion flange, using

three suitable bolts to hold pinion flange.

NOTE

Use either the rear coupling to pinion flange

retaining bolts with a 25 mm spacer (e.g. flat

washers) installed first or use three bolts M12 x

1.5 x 40, with the thread extending to within 12

mm of the head.

6 Insert a suitable length of pipe (1) over the tang of the

installed tool for leverage, then remove the pinion

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (2).

7 Remove Tool No. DT -47735 from the pinion flange.

Figure 4B1 – 56

Rear Final Drive and Drive Shafts Page 4B1-36

Page 4B1-36

8 Place drain tray beneath differential carrier.

9 Install extractor, Tool No. DT-47736 to the pinion

flange using the same three b olts used to se cure the

flange holding tool, DT-47735 (refer Figure 4B1-57).

10 While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening the

forcing screw in the direction indic ated.

Figure 4B1 – 57

11 Prise pinion oil seal from carrier bore using Tool No.

E308 or a universal seal removin g tool.

Figure 4B1 – 58

12 Lubricate the lips of a new pinion oil seal and the outer

diameter with Mobilgrease XHP 222 or equivalent

grease.

13 Start oil seal into differential carrier housing and drive

seal squarely into position us ing Tool No. E9055. Seal

fits flush to 0.25 mm below carrier housing surface.

14 Ensure that pinion shaft is free from burrs and that

flange oil seal surface is free from damage.

Figure 4B1 – 59

Rear Final Drive and Drive Shafts Page 4B1-37

Page 4B1-37

15 Clean the threads of the pinion shaft and the flange retaining nut, removing any oil, dirt or grease.

16 Coat splines and seal surface of pinion flange with differential gear lubricant, and install flange onto pinion shaft

splines. Ensure that centre-punch marks are aligned.

17 Reinstall holdin g tool DT-47735 to the pinion flange.

18 Apply a thread locking compound such as Loctite 243 or equival ent, to the threads of the pinion flange retaining

nut, then reinstall the nut.

19 Tighten the flange retaining nut until all centre-punch marks align. Then carefully tighten the nut to a pos ition not

more than 5° past the aligned setting.

• The pinion flange is an interference fit on

pinion shaft splines and should only be

pulled into place by tightening the

retaining nut. Do not used force or a

hammer the flange during the installation

process.

• Should the retaining nut be over-tightened

and pre-load exceeded, it will be

necessary to remove the pinion from the

carrier and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load reading.

20 Reinstall prope ller shaft rear coupling to the pinion flange, refer Section 4C1 Propeller Shaft and Universal Joints.

21 If removed previously, reconnect exhaust system, in the reverse to the removal procedure.

Refer to Section 8B Exhaust System, for details.

22 Remove safety stands and lower vehicle.

23 Check lubricant level and top up as necessary. Refer 2.2 Checking Differential Carrier Lubricant Level, in this

Section.

24 Start vehicle and check for exhaust leaks.

Rear Final Drive and Drive Shafts Page 4B1-38

Page 4B1-38

Replace (Vehicles With a Rear Constant Velocity Joint)

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Mark the position of the propeller shaft rear coupling to pinion flange, using a felt tipped pen or similar.

3 Remove propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints. This operation may also require

partial exhaust system removal.

4 Lightly centre-punch ali gnment marks (A) on the pinion

flange, flange nut and pinion end as an aid for

reassembly.

NOTE

By reassembling to the original position, the

flange run-out will be minimised and the pinion

bearing preload will be maintained.

Figure 4B1 – 60

5 Install packing flange DT-47580 into the pinion flange

recess, aligning the holes with those in the pinion

flange.

6 Using two of the propeller shaft constant velocity joint

bolts (2) with flat washers, secure the holding bar, T ool

No. J8614-10 (part of Tool No. J 8614-O1) to the

pinion flange (1). The central recesses in the holding

tool should face inward.

7 While anchoring Tool No. J8614-10, loosen then

remove the pinion flange retaining nut, usin g a

commercially availabl e, 30 mm deep socket and

socket bar (3).

NOTE

A suitable length of pip e installed over the en d of

the socket bar will reduce the effort required to

loosen the pinion flange nut.

Figure 4B1 – 61

Rear Final Drive and Drive Shafts Page 4B1-39

Page 4B1-39

8 Place drain tray beneath differential carrier.

9 With Tool Nos J8614-10 and DT-47580 still installed,

thread the forcing screw, Tool No. J8614-3, in to the

adaptor, Tool No. J8614-2. Install this sub-assembly

into holder, Tool No. J8614-10, then rotate through 45°

to locate in the recesses in J8614-10.

10 While holding J8614-10, use a socket and bar to rotate

the forcing screw J8614-3 in the direction s hown, to

remove the pinion flange.

11 Remove the tools from the pinion flange, then carefull y

set the pinion flange to one side to avoi d damage to

the flanged seal surface.

Figure 4B1 – 62

12 Prise pinion oil seal from carrier bore using Tool No.

E308 or a universal seal removin g tool.

Figure 4B1 – 63

When installing a new pinion oil seal, only

install the seal until it is square and flush

with the machined face of the final drive

housing. If installed too deeply then a

premature oil leak could o ccur.

13 Lubricate the lips and outside diameter of a new pinion

oil seal with Mobilgrease XHP 222 or equivalent

grease. The recess bet ween the lips should be

approximately 50% filled with grease.

NOTE

A light coating of grease is also to be applied to

the dirt lip that contacts the pinion flange slinger.

14 Start oil seal into differential carrier housing and drive

seal squarely into position us ing Tool No. E9055. Figure 4B1 – 64

Rear Final Drive and Drive Shafts Page 4B1-40

Page 4B1-40

15 Ensure that pinion shaft is free from burrs and that flange oil seal surface is free from damage.

16 Clean the threads of the pinion shaft and the flange retaining nut, removing any oil, dirt or grease.

17 Coat splines and seal surface of pinion flange with the recommended final drive lubricant, and install flange onto

pinion shaft splines. Ensure that centre-punch marks made at Step 4, are aligned.

18 Reinstall the packing flan ge T ool No. DT-47580 and holding tool J 8614-10 to the pinion flang e, as detailed in

Steps 5 and 6.

19 Apply a thread locking compound such as Loctite 262 or eq uivalent, to the cleaned threads of the pinion flange

retaining nut, then reinstall the nut.

20 Tighten the flange retaining nut until all centre-punch marks align. Then carefully tighten the nut to a pos ition not

more than 5° past the aligned setting.

• The pinion flange is an interference fit on

pinion shaft splines and should only be

pulled into place by tightening the

retaining nut. During installation, do not,

under any circumstances, use force or

hammer the flange onto the pinion splines.

• Should the retaining nut be over-tightened

and pre-load exceeded, it will be

necessary to remove the pinion from the

carrier and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load setting.

21 Reinstall propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints.

22 If removed previously, reconnect exhaust system, in the reverse to the removal procedure.

Refer to Section 8B Exhaust System, for details.

23 Remove safety stands and lower vehicle.

24 Check lubricant level and top up as necessary. Refer to 2.2 Checking Differential Carrier Lubricant Level, in this

Section.

25 Start vehicle and check for exhaust leaks.

Rear Final Drive and Drive Shafts Page 4B1-41

Page 4B1-41

2.11 Pinion Flange

LT Section 05-290

Replace (Vehicles With a Rear Rubber Coupling)

ATTENTION

The following fasteners MU ST be replaced when performing these operations:

 Drive shaft attaching bolts.

 Pinion flange retaining nut.

Using Old Oil Seal

Resulting from production tolerances in the

length of the pinion flange, it is essential that

the following method be used when installing

a new pinion flange.

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove propeller shaft, refer Section 4C1 Propeller Shaft and Universa l Joints .

3 Remove both drive shafts, refer 2.7 Drive Shafts, in this Section.

4 Check and record pre-load at pini on flange as follows:

a Fit a pulley (1) to pinion flange, using three

suitable bolts and attach a cord around p ulley

and to a spring scale (2).

NOTE

• Use either the rear coupling to pinion flange

retaining bolts with a 25 mm spacer (e.g. flat

washers) installed first or use three bolts M12

x 1.5 x 40, with the thread ext ending to within

12 mm of the head.

• For details of the fabricated pulley, refer to

7 Special Tools at end of this Section.

b Start rotation of pulley and whilst in motion

(approximately 50 – 60 rpm) note and record

reading of spring balance.

This pre-load reading includes pinion bearings,

side bearings, meshing effect of gear set and

pinion oil seal.

To determine pre-load, multipl y readi ng on

spring balance by radius of pulley.

Figure 4B1 – 65

Example: With a pulley diameter of 152 mm, the radius is 76 mm, which equals 0.076 m. With a spring balance reading

of 25 N, the pre-load equals 0.076 m x 25 N = 1.9 N.m.

5 Remove pulley from pinion flange.

Rear Final Drive and Drive Shafts Page 4B1-42

Page 4B1-42

6 Attach Tool No. DT-47735 to the pinion flange, using

the same three bolts used in step 4a, to hold pinion

flange.

7 Insert a suitable length of pipe (1) over the tang of the

installed tool for leverage, then remove the pinion

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (2).

8 Remove Tool No. DT -47735 from the pinion flange.

Figure 4B1 – 66

9 Place drain tray beneath differential carrier.

10 Install extractor, Tool No. DT-47736 to the pinion

flange using the same three b olts used i n steps 4a and

11 While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening the

forcing screw in the direction shown.

Figure 4B1 – 67

12 Ensure that pinion shaft thread is free from burrs, oil, dirt or grease, then coat splines and seal surface of a new

pinion flange with the recommend ed rear axle lubricant.

13 Install the new pinion flange a nd a new retaining nut.

The pinion flange is an interference fit on

pinion shaft splines and should only be pulled

into place by tightening the retaining nut. Do

not used force or a hammer the flange during

the installation process.

Rear Final Drive and Drive Shafts Page 4B1-43

Page 4B1-43

14 Tighten flange retaining nut gradually until pinio n shaft end play is reduced to approxim ately 0.50 mm.

Should the retaining nut be over-tightened

and the pre-load exceeded, it will be

necessary to remove the differential carrier

assembly and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load setting.

15 Attach pulley to the new pinion flange and using a spring balance, check pre-load. Continue tightening nut while

alternatively turning pin io n to seat bearings, until the pre-load figure recorded previously (Step 4b) is rea c hed.

Further increase this original pre-load reading by 0.5 N.m.

NOTE

Rotate pinion an extra 30 – 4 0 turns a nd r e-c heck

the preload to ensure that no change has

occurred.

16 Reinstall drive shafts, refer to 2.7 Drive Shafts, in this Section.

17 Reinstall propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints.

18 If removed previously, reconnect exhaust system, in reverse to the removal procedure.

Refer to Section 8B Exhaust System, for details.

19 Lower vehicle to the ground.

20 Check lubricant level and top up as necessary with the recommended lu bricant,

refer to 2.2 Checking Differential Carrier Lubricant Level, in this Section.

21 Start vehicle and check for exhaust leaks.

Replace (Using New Oil Seal)

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints.

3 Remove both drive shafts, refer to 2.7 Drive Shafts, in this Section.

4 Check and record pre-load at pini on flange as follows:

a Fit a pulley (1) to pinion flange, using three

suitable bolts and attach a cord around p ulley

and to a spring scale (2).

NOTE

• Use either the rear coupling to pinion flange

retaining bolts with a 25 mm spacer (e.g. flat

washers) installed first or use three bolts M12

x 1.5 x 40, with the thread ext ending to within

12 mm of the head.

• For details of the fabricated pulley, refer

7 Special Tools at end of this Section.

b Start rotation of pulley and while in motion

(approximately 50 – 60 rpm), note and record

reading of spring balance.

This pre-load reading includes pinion bearings,

side bearings, meshing effect of gear set and

pinion oil seal.

To determine pre-load, multipl y readi ng on

spring balance by radius of pulley.

Figure 4B1 – 68

Rear Final Drive and Drive Shafts Page 4B1-44

Page 4B1-44

Example: With a pulley diameter of 152 mm, the radius is 76 mm, which equals 0.076 m. With a spring balance reading

of 25 N, the pre-load equals 0.076 m x 25 N = 1.9 N.m.

5 Remove pulley from pinion flange.

6 Attach Tool No. DT-47735 to the pinion flange, using

the same three bolts used in step 4a, to hold pinion

flange.

7 Insert a suitable length of pipe (1) over the tang of the

installed tool for leverage, then loosen the pinion

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (2) until end play

can be felt in the pinion shaft.

8 Check the oil seal and differential side bearing pre-

load using the spring scale and pulley, as detailed in

steps 4a and 4b. Record oil seal and side bearing pre-

load for later use.

9 Remove Tool No. DT -47735 from the pinion flange.

Figure 4B1 – 69

10 Place drain tray beneath differential carrier.

11 Install extractor, Tool No. DT-47736 to the pinion

flange using the same three b olts used insteps 4a and

12 While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening the

forcing screw in the direction shown.

Figure 4B1 – 70

Rear Final Drive and Drive Shafts Page 4B1-45

Page 4B1-45

13 Prise pinion oil seal from carrier bore using Tool No.

E308 or a universal seal removin g tool.

Figure 4B1 – 71

14 Lubricate a new pinion oil seal lips and the outer

diameter with Mobilgrease XHP 222 grease or

equivalent.

15 Start oil seal into differential carrier housing and drive

seal squarely into position us ing Tool No. E9055. Seal

fits flush to 0.25 mm below carrier housing surface.

16 Ensure that pinion shaft is free from burrs, then clean

the threads of the pinion shaft, removing any oil, dirt or

grease.

17 Coat splines and seal surface of pinion flange with

differential gear lubricant, then reinstall flange to the

pinion shaft splines.

18 Install a new flange retaining nut, then tighten to draw

the pinion flange onto the pinion shaft spli nes.

The new pinion flange will be an interference

fit on pinion shaft splines and should only be

pulled into place by tightening the retaining

nut. Do not used force or a hammer the

flange during the installation process.

Figure 4B1 – 72

19 Continue to tighten the flange retaining nut gradually until pinion shaft end play is reduced to approximately 0.5

mm.

Should the retaining nut be over-tightened

and the pre-load exceeded, it will be

necessary to remove the differential carrier

assembly and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load setting.

20 Check new oil seal and differential assemb ly pre-load using sprin g balance as previously outlin ed in steps 4a and

4b. Record pre-load for reassembly refer ence.

21. The pre-load reading for differential assembly obtained in step 8, is subtracted from pre-load reading obtained in

step 20. The difference bet ween these fi gures represents extra lip tension of new seal expressed as a N.m pre-

load figure. The difference be tween the pre-load readings obtained in steps 8 and 20 must be added to pre-load

reading obtained in step 4b to obtain a total pre-load reading.

Rear Final Drive and Drive Shafts Page 4B1-46

Page 4B1-46

Theoretical Example

Step 20 New oil seal and side

bearing preload setting. 1.47 N.m

Step 8 Old oil seal and side

bearing preload reading. 1.02 N.m

Subtract Step 8 from Step 20 0.45 N.m

Step 4b Complete differential

assembly preload

reading. 1.47 N.m

The preload readi ng combination will be

the sum of:-

1.47 N.m

plus

0.45 N.m

Which gives a total preload reading of:- 1.92 N.m

Should the retaining nut be over-tightened

and the pre-load exceeded, it will be

necessary to remove the differential carrier

assembly and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load setting.

22 Continue tightening retaining nut while alternately turning pinion to seat bearings until total pre-load figur e obtained

in step 21 is achieved, then i ncrease this pre-load reading by 0.11 to 0.34 N.m. Further rotate pinion an extra 30 –

40 turns and recheck pre-load to ensure that no change has occurred.

NOTE

It must be realised that the pre-load readings in

the example are only theoretical. In practice, the

figures could differ greatly, so the readings

obtained when performing the actual operations,

are the ones to use.

23 Reinstall drive shafts, refer to 2.7 Drive Shafts, in this Section.

24 Reinstall propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints.

25 If removed previously, reconnect exhaust system, in the reverse to the removal procedure.

Refer to Section 8B Exhaust System, for details.

26 Lower vehicle to the ground.

27 Check lubricant level and top up as necessary, refer to 2.2 Checking Differential Carrier Lubricant Level.

28 Start vehicle and check for exhaust leaks.

Rear Final Drive and Drive Shafts Page 4B1-47

Page 4B1-47

Replace (Vehicles With a Rear Constant Velocity Joint)

LT Section No. – 05-290

ATTENTION

The following fasteners MU ST be replaced when performing these operations:

 Drive shaft attachin g bolts.

Using Old Oil Seal

Due to production tolerances in the length of

the pinion flange, it is essential that the

following method be used when installing a

new pinion flange.

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove propeller shaft, refer 2.1 Propeller Shaft, in Section 4C1 Rear Propeller Shaft & Universal Joints.

3 Remove both driveshafts, refer 2.7 Driveshafts in this Section.

4 Check and record pre-load at pini on flange as follows:

a Fit a pulley (1) to pinion fla nge, using two

M8 x 1.25 bolts and attach a cord around pul ley

and to a spring scale (2).

NOTE

For details of the fabricated pulley, refer to

7 Special Tools at end of this Section.

b Start rotation of pulley and whilst in motion

(approximately 50 – 60 rpm) note and record

reading of spring balance.

NOTE

• This pre-load reading includes pinion

bearings, side bearings, meshing effect of

gear set and pinion oil seal.

• To determine pre-load, multiply reading on

spring balance by radius of pulley.

Example: With a pulley diameter of 152 mm, the radius is

76 mm, = 0.076 m. With a spring balance reading of 25 N,

the pre-load = 0.076 m x 25 N = 1.9 N.m.

5 Remove pulley from pinion flange.

Figure 4B1 – 73

Rear Final Drive and Drive Shafts Page 4B1-48

Page 4B1-48

6 Install packing flange, T ool No. DT -47580 into the

pinion flange recess, aligning the holes with those in

the pinion flange.

7 Using two of the propeller shaft constant velocity joint

bolts (2), with flat washers, secure the holding bar,

Tool No. J8614-10 (part of Tool No. J 8614- O1) to the

pinion flange (1). The central recesses in the holding

tool should face inward.

8 While anchoring Tool No. J8614-10, loosen the pinion

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (3), until end play

can be felt in the pinion shaft.

NOTE

A suitable length of pip e installed over the en d of

the socket bar (3) will reduce the effort required

to loosen the pinion flange nut.

9 Check the oil seal and differential side bearing pre-

load using the spring scale and pulley, as detailed in

steps 4a and 4b. Record oil seal and side bearing pre-

load for later use.

Figure 4B1 – 74

10 Place drain tray beneath differential carrier.

11 With Tool Nos J8614-10 and DT-47580 still installed,

thread the forcing screw, Tool No. J8614-3, in to the

adaptor, Tool No. J8614-2. Install this sub-assembly

into holding bar, Tool No. J8614-10, then rotate

through 45° to locate in the recesses in J8614-10.

12 While holding J8614-10, use a socket and bar to rotate

the forcing screw J8614-3 in the direction s hown, to

remove the pinion flange.

13 Remove the tools from the pinion flange, then carefull y

set the pinion flange to one side to avoi d damage to

the flanged seal surface.

Figure 4B1 – 75

14 Ensure that pinion shaft thread is free from thread sealant, burrs, oil, dirt or grease, then coat splines and seal

surface of a new pinion flange with the recommend ed final drive lubricant.

15 Install the new pinion flange a nd a new retaining nut.

The new pinion flange will be an interference

fit on the pinion shaft splines and should only

be pulled into place by tightening the

retaining nut. During installation, do not,

under any circumstances use force or

hammer the flange onto the pinion splines.

Rear Final Drive and Drive Shafts Page 4B1-49

Page 4B1-49

16 Tighten flange retaining nut gradually until pinio n shaft end play is reduced to approxim ately 0.50 mm.

17 Attach pulley to the new pinion flange and using spring balance, check pre-load. Continue tightening nut while

alternatively turning pin io n to seat bearings, until the pre-load figure recorded previously (Step 4b) is rea c hed.

Further increase this original pre-load reading by 0.5 N.m.

18 Rotate the pinion an extra 30 – 40 turns a nd re-check the preload to ensure that no change has occurred.

Should the retaining nut be over-tightened

and the pre-load exceeded, it will be

necessary to remove the differential carrier

assembly and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load setting.

19 Reinstall driveshafts, refer to 2.7 Driveshaft Assembly in this Section.

20 Reinstall propeller shaft, refer to Section 4C1 Rear Propell er Shaft & Universal Joints.

21 If removed previously, reconnect exhaust system, in reverse to the removal procedure.

Refer to Section 8B Exhaust System, for details.

22 Lower vehicle to the ground.

23 Check lubricant level and top up as necessary with the recommended lu bricant,

refer to 2.2 Checking Differential Carrier Lubricant Level, in this Section.

24 Start vehicle and check for exhaust leaks.

Using New Oil Seal

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove propeller shaft, refer to Section 4C1 Rear Propeller Shaft & Universal Joints.

3 Remove both driveshafts, refer to 2.7 Driveshaft Assembly in this Section.

4 Check and record pre-load at pini on flange as follows:

a Fit a pulley (1) to pinion fla nge, using two

M8 x 1.25 bolts and attach a cord around pul ley

and to a spring balance (2).

NOTE

For fabricated pulley details, refer to

7 Special Tools at end of this Section.

b Start rotation of pulley and whilst in motion

(approximately 50 – 60 rpm), note and record

the spring balance reading.

NOTES

• This pre-load reading includes pinion

bearings, side bearings, meshing effect of

gear set and pinion oil seal.

• To determine pre-load, multiply reading on

spring balance by radius of pulley. Figure 4B1 – 76

Example: With a pulley diameter of 152 mm, the radius is 76 mm which equals 0.076 m. With a spring bal ance reading

of 25 N, the pre-load equals 0.076 m x 26 N = 1.9 N.m.

5 Remove pulley from pinion flange.

Rear Final Drive and Drive Shafts Page 4B1-50

Page 4B1-50

6 Install packing flange, T ool No. DT -47580 into the

pinion flange recess, aligning the holes with those in

the pinion flange.

7 Using two of the propeller shaft constant velocity joint

bolts (2), with flat washers, secure the holding bar,

Tool No. J8614-10 (part of Tool No. J 8614- O1) to the

pinion flange (1). The central recesses in the holding

tool should face inward.

8 While anchoring Tool No. J8614-10, loosen the pinion

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (3), until end play

can be felt in the pinion shaft.

NOTE

A suitable length of pip e installed over the en d of

the socket bar (3) will reduce the effort required

to loosen the pinion flange nut.

9 Check the oil seal and differential side bearing pre-

load using the spring scale and pulley, as detailed in

steps 4a and 4b. Record oil seal and side bearing pre-

load for later use.

Figure 4B1 – 77

10 Place drain tray beneath differential carrier.

11 With Tool Nos J8614-10 and DT-47580 still installed,

thread the forcing screw, Tool No. J8614-3, in to the

adaptor, Tool No. J8614-2. Install this sub-assembly

into holder, Tool No. J8614-10, then rotate through 45°

to locate in the recesses in J8614-10.

12 While holding J8614-10, use a socket and bar to rotate

the forcing screw J8614-3 in the direction s hown, to

remove the pinion flange.

13 Remove the tools from the pinion flange, then carefull y

set the pinion flange to one side.

Figure 4B1 – 78

14 Prise pinion oil seal from carrier bore using Tool No.

E308 or a commercially available, universal seal

removing tool.

Figure 4B1 – 79

Rear Final Drive and Drive Shafts Page 4B1-51

Page 4B1-51

When installing a new pinion oil seal, only

install the seal until it is flush with the

machined face of the final drive housing. If

installed too deeply then a premature oil leak

could occur.

15 Lubricate the lips and outside diameter of a new pinion

oil seal with Mobilgrease XHP 222 grease or

equivalent. The recess between the lips should be

approximately 50% filled with grease.

NOTE

A light coating of grease is also to be applied to

the dirt lip that contacts the pinion flange slinger.

16 Start oil seal into differential carrier housing and drive

seal squarely into position using Tool No. E9055. Figure 4B1 – 80

17 Ensure that pinion shaft is free from burrs, then clean the threads of the pinion shaft, removing any thread sealant,

oil, dirt or grease.

18 Coat splines and seal surface of pinion flange with the recommended final drive lubricant, then reinstall flange to

the pinion shaft splines.

19 Install a new flange retaining nut, then tighten to draw the pinion flange onto the pinion shaft splines.

The new pinion flange will be an interference

fit on the pinion shaft splines and should only

be pulled into place by tightening the

retaining nut. During installation Do not,

under any circumstances use force or

hammer the flange onto the pinion splines.

20 Continue to tighten the flange retaining nut gradually until pinion shaft end play is reduced to approximately

0.5 mm.

21 Check new oil seal and differential assemb ly pre-load using sprin g balance as previously outlin ed in steps 4a and

4b. Record pre-load for reassembly refer ence.

Rear Final Drive and Drive Shafts Page 4B1-52

Page 4B1-52

22 The pre-load reading for the final drive asse mbly obtained in step 9, is subtracted from the pre-load reading

obtained in step 21. The difference b etween these figures represents extra lip tens ion of new seal expressed as a

N.m pre-load figure. The difference between the pre-load readings obtained in steps 9 and 21 must be added to

pre-load reading obtained in step 4b to obtain a total pre-load reading.

Theoretical Example

Step 21 New oil seal and side

bearing pre-loa d setting 1.47 N.m

Step 9 Old seal and side bearing

pre-load reading 1.02 N.m

Subtract Step 9 from Step 21 0.45 N.m

Step 4b Complete differential

assembly pre-load

reading 1.47 N.m

The pre-load reading combination will

be the sum of:-

1.47 N.m

plus

0.45 N.m

Which gives a total pre-load reading of:- 1.92 N.m

23 Continue tightening retaining nut while alternately turning pinion to seat bearings until total pre-load figur e obtained

in step 22 is achieved, then i ncrease this pre-load readin g by 0.11 – 0.34 N.m. Further rotate pinion an extra

30 – 40 turns and recheck pre-load to ensure that no change has occurred .

Should the retaining nut be over-tightened

and the pre-load exceeded, it will be

necessary to remove the differential carrier

assembly and install a new collapsible

spacer. Under no circumstances must the

retaining nut be backed off to decrease the

pre-load setting.

NOTE

It must be realised that the pre-load readings in

the example are only theoretical. In practice, the

figures could differ greatly, so the readings

obtained when performing the actual operations,

are the ones to use.

24 Reinstall drive shafts, refer to 2.7 Driveshaft Assembly in this Section.

25 Reinstall propeller shaft, refer to Section 4C1 Rear Propell er Shaft & Universal Joints.

26 If removed previously, reconnect exhaust system, in the reverse to the removal procedure.

Refer to Section 8B Exhaust System, for details.

27 Remove safety stands and lower vehicle.

28 Check lubricant level and top up as necessary, refer to 2.2 Checking Differential Carrier Lubricant Level, in this

Section.

29 Start vehicle and check for exhaust leaks.

Rear Final Drive and Drive Shafts Page 4B1-53

Page 4B1-53

3 Major Service Operations

3.1 Outer Rear Wheel Driveshaft Flange

Outer Rear Wheel Driveshaft Assembly

and/or Wheel Bearing

LT Section No: 05-290

ATTENTION

The following fasteners MU ST be replaced when performing these operations:

 Collar nut to outer rear wheel driveshaft assembly

 Drive shaft constant velocity joint attaching bolts.

 Lower rear disc brake shield to trailing arm bolts

Vehicle must be at curb weight before final tightening.

zLower shock absorber mounting bolt.

NOTE

• The following pr ocedure inv olv es the removal

of the outer rear wheel driveshaft flange,

outer rear wheel driveshaft and/or wheel

bearing with the trailing arm installed in the

vehicle. A similar procedure is included in

Section 4A1 Independent Coil Spring Rear

Suspension, when the trailing arm is

removed from the vehicle.

• This 'on-vehicle' procedure is not suitable for

the AWD Wagon, as the revised design of

the rear trailing arm on this vehicle prevents

the use of the stand-off supports required.

Refer to Section 4A1 Independent Coil

Spring Rear Suspension, for the necessary

procedure.

• The rear wheel bearing should only be

removed if it is faulty, or if the outer rear

wheel driveshaft assembly is to be removed. Figure 4B1 – 81

Legend

1 Collar Nut Lock Plate

2 Collar Nut

3 Outer Rear Wheel Driveshaft Flange

4 Trailing Arm

5 Brake Backing Plate

6 Brake Disc

7 Brake Caliper

8 Rear Wheel Bearing

9 Outer Rear Wheel Driveshaft Assembly

10 Rear Wheel Bearing Retaining Ring

Rear Final Drive and Drive Shafts Page 4B1-54

Page 4B1-54

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 On the side of the vehicle where the trailing arm is to be removed, remov e the wheel trim or wheel nut covers, mark

relationship of road wheel to hub (e.g. end of wheel stud), with a felt tipped pen or similar. Loosen then remove

road wheel attaching nuts. Remove the roa d wheel.

3 Remove brake hose retaining clip (1) from brake

backing plate bracket (2). Disconnect rear caliper

brake hose (3) from brake pipe (4) and disconnect

pipe from backing plate bracket (2).

4 Plug open ends of brake pipe (4) and hose (3) to

prevent fluid loss and foreign matter entry.

Figure 4B1 – 82

If the brake pipe to hose is not disconnected,

the brake caliper must be secured to the

vehicle underbody. The caliper is not to hang

by the brake hose.

5 Remove brake caliper anchor plate to trailing arm

attaching bolts (1) and remove caliper (2) from disc.

6 Remove brake disc from the wheel bearing hub.

NOTE

While the brake disc to hub location is m arked in

production, ensure that the disc to hub position

is carefully marked (e.g. disc to end of wheel

stud), with a felt tipped pen or similar. This is

necessary to overcome the possibility of

inducing a brake shudder condition after

reassembly.

Figure 4B1 – 83

7 If the park brake shoe adjustment needs to be

released to allow disc removal, adopt the following

method:

a Remove one of the access hole plugs (1) from

one of the access holes provided in the disc.

b Using a suitable lever such as a screwdriver,

loosen the park brake shoe screw adjuster, until

the disc is freed.

c After disc removal, reinstall the access hole plug

to prevent loss.

Figure 4B1 – 84

Rear Final Drive and Drive Shafts Page 4B1-55

Page 4B1-55

8 Position floor jack with a block of wood under the trailing arm (2). Raise jack slightly to take spring load off trailing

arm.

9 Disconnect rear shock absorber lower mounting bolt (1) from trailing arm (2), and pull lower end of shock absorber

(3) from trailing arm. Leave the supporting ja ck and wooden block in position.

NOTE

View ‘A’ in Figure 4B1-85 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 85

10 Install holding bar, T ool No. KM 468 over the wheel

studs to hold outer rear wheel driveshaft assembly

from rotating.

11 Loosen then remove the six drive shaft (1) constant

velocity joint to outer rear wheel driveshaft flange

attaching bolts (2) and plates, using an 8 mm Allen

key socket and suitable socket equipment (3).

12 Discard the removed bolts as they must be repl aced

on reassembly.

Figure 4B1 – 86

Rear Final Drive and Drive Shafts Page 4B1-56

Page 4B1-56

Bruising to the inside of the drive shaft

constant velocity joint boots will occur if the

trailing arm is lowered. This will lead to

premature failure of the boot and eventual

failure of the joint if left unchecked.

13 Separate drive shaft from flange and lift upward. While

keeping the outer constant velocit y joint (1) in the

same plane as the driveshaft, use a piece of wire (2)

and tie up the drive shaft assembly to lower end of

shock absorber upper mounting.

14. The supporting jack may no w be lowered and the

wooden block removed.

Figure 4B1 – 87

15 Remove park brake shoe b y g rasping each end as

shown. Push up on one end of the shoe, dislodging

the end from the actuator pin and the shoe from the

retaining clip.

Figure 4B1 – 88

16 Using a screwing motion, rotate the park brake shoe

around the outer rear wheel driveshaft flange to

remove it from the vehicle.

17 Remove the park brake shoe spring retainer by prisi ng

from the rear disc shield, with a screwdriver or similar

lever.

18 Using suitable socket equipment, loosen then remove

the two lower bolts securing the park brak e adjuster

and brake backing plate to th e trailing arm. Discard the

removed bolts.

19 Using Tool No. AU416 and suitable socket equipment,

loosen then remove the two upper brake backing plate

to the trailing arm, Torx bit headed bolts. Figure 4B1 – 89

Rear Final Drive and Drive Shafts Page 4B1-57

Page 4B1-57

20 Secure flange holding tool, KM620-1A and outer rear

wheel driveshaft flange ring tool KM62 0-2 to outer rear

wheel driveshaft flange (1) with three of the removed

drive shaft constant velocity joint to outer rear wheel

driveshaft flange attaching bolts (2).

NOTE

Align holes marked ‘B' on the flange holding too l

KM620-1A and KM620-2 with holes in the outer

rear wheel driveshaft flange before installing and

tightening bolts.

Figure 4B1 – 90

21 Install a suitable length and diameter steel tube over

handle of KM620-1A to stop it from rotating, then use

suitable socket equipment (1) to loosen and remove

the collar nut and lock plate.

22 Discard the removed collar nut and lock plate, as

these parts must be replaced on reass embl y.

Figure 4B1 – 91

23 Lubricate the threads of forcing screw KM620-3, then

install to adaptor KM620-4-A. Apply grease to ball end

of plunger, Tool No. KM620-5 B, then install that, into

the end of forcing screw KM620-3.

24 Install the whole sub-assembly through the central

opening of flange holding too l KM620-1-A. Secure the

adaptor KM620-4A to the flange holding tool KM620-

1A, using three suitable bolts (1).

NOTE

Adjust the position of the forcing scre w KM620-3

in the adaptor KM620-4A, to allow adaptor to be

in full contact with the flange holding tool

KM620-1A. Figure 4B1 – 92

Rear Final Drive and Drive Shafts Page 4B1-58

Page 4B1-58

25 While holding KM620-1A from rotating, turn the screw

KM620-3, forcing the flange free from the outer rear

wheel driveshaft.

26 Separate tool components from flange once it has

been removed.

Figure 4B1 – 93

27 Before removing the outer rear wheel drives haft

assembly and rear wheel bearing from the trailing arm,

use a commercially available M10 x 1.25 b ottoming

tap and clean the four backing plate to trailing arm bolt

threads, using a suitable lubricant and working from

the outer rear wheel driveshaft assembly side.

This step is necessary to clear any dried mud,

dirt etc, from the exposed portion of the threads

on the inboard side of the trailing arm. Also, the

deepest thread (position ‘C’) may not be

completely formed through to the inbo ard side.

28 Install two supports KM620-7A in positions ‘A’ and two

KM620-7AUS to ‘B’ and ‘C’ in the trailing arm, as

indicated.

29 As a guide, the two longest supports (KM620 -7A) are

to be installed at the brake caliper mounting side

(position ‘A’). The longer of KM620-7AUS supports is

installed at position ‘B’ and th e shorter is installed at

position ‘C’.

30 After installing all four supports in the correct positions,

tighten with a set spanner.

Figure 4B1 – 94

31 Install flange holding tool KM620-1A over the four

supports, KM620-7A (2 places) and KM62 0-7AUS (2

places), install four suitable nuts (1) and tig hten to

secure.

32 Pre-assemble lubricated forcing screw KM620-3 to

adaptor KM620-4A. Apply grease to b all end of

plunger KM620-5B, then install that, into the end of

forcing screw KM620-3.

33 Install this sub-assembly through the central opening

of holding tool KM620-1A. Secure the adaptor KM620-

4A to the flange holding tool KM620-1A, using three

suitable bolts (2).

NOTE

Adjust the position of the forcing scre w KM620-3

into the adaptor KM620-4A, to allow full contact

of the adaptor to the flange holding tool KM620-

1A.

Figure 4B1 – 95

Rear Final Drive and Drive Shafts Page 4B1-59

Page 4B1-59

34 Insert a suitable length of tube over the handle of

holding tool KM620-1A to stop it from rotating and turn

the forcing screw KM620-3 to press outer rear wheel

driveshaft from rear wheel bearing.

35 When the outer rear wheel driveshaft has been

removed, remove nuts (1) holding KM620-1 A

assembly to the distance pieces, KM620-7A and

KM620-7-AUS. Remove KM620-1A, an d remove

KM620-5B from the end of KM620-3.

36 Unscrew the forcing screw (KM620-3), as this same

arrangement is used to press the rear wheel bearing

from the trailing arm.

NOTE

The rear wheel bearing inner cone will separate

from the bearing assembly and be retained on

the outer rear wheel driveshaft assembly.

37 Remove the brake backing plate and park brake

assembly from the trailing arm and set to one side. Figure 4B1 – 96

NOTE

The next step is not required if the outer rear

wheel driveshaft is to be replaced.

38 If the outer rear wheel driveshaft assembly (1) is to be

reinstalled, then the outer half of the inner rear wheel

bearing cone (2) will nee d to be removed from the

outer rear wheel driveshaft assembly (1).

a Install press plates J22912-0 1 over the bearing

cone (2) and tighten the press plate bo lts to grip

the bearing cone.

b Press the outer rear wheel driveshaft assembl y

(1) from the bearing cone (2) and discard

bearing cone.

NOTE

A new outer rear wheel driveshaft assembly is

supplied with wheel studs already installed. Figure 4B1 – 97

39 Remove wheel bearing retaini ng ring (1) from trailing

arm (2), using suitable circlip pliers (3).

Figure 4B1 – 98

Rear Final Drive and Drive Shafts Page 4B1-60

Page 4B1-60

40 With the tool components set up as sho wn, install re ar

axle bearing removing plate KM 620-6 to rear of the

axle bearing. Reposition the forcing screw KM620-3 to

hold the removing plate KM620-6 in place.

41 Insert a suitable length of tube over the handle of

holding tool KM620-1A to stop it from rotating, then

turn the forcing screw KM620-3 to press the wheel

bearing from the trailing arm.

42 If installing a replacement trailing arm without bushes,

install new bushes. Refer to 2.6 T r ailing Arm Bushes

in Section 4A1 Rear Suspension.

Figure 4B1 – 99

Reinstall

To Install a New Bearing

1 Ensure that bearing bore of trailing arm is cl ean and free of any foreign matter.

2 Coat outside diameter of ne w wheel bearing and bore of trailing arm with an EP grease with molybdenum

disulphide, such as Shell Retinax HDX2 grease, BP Energrease LMS-EP 23, or equ ivalent.

3 Remove bolts securing adaptor KM620-4-A to the

holding tool KM620-1A, then remove the adaptor and

forcing screw KM620-3 from the holding tool KM620-

1A.

4 Lubricate the thrust ball bearing race (1) (part of

KM620-A) with an EP grease with molybde num

disulphide, such as Shell Retinax HDX2 grease, BP

Energrease LMS-EP 23, or equivalent., then assemble

the bearing onto the flanged end of adaptor KM620-

4A.

5 Reinstall the forcing screw and adaptor/bearing

assembly to the flange holding tool KM62 0-1A. Do not

reinstall the adaptor (KM620-4A) to hold ing tool

(KM620-1A) attaching bolts.

6 Install bearing installer KM620-8A into a new bearing

(2) and install both into the trailing arm (3).

Figure 4B1 – 100

7 Join the forcing screw (KM620-3), and bearing installer (KM620-8A) by engaging the screw thread of the forcing

screw (KM620-3) with installer (KM620-8A) and tightening the forcing screw to engage at least eight full threads.

8 While holding the forcing screw (KM620-3) from turning by using suitable socket equipment (4), rotate the adaptor

KM620-4A in a clockwise direction, usin g a suitable 40 mm wrench to draw the new bearing (2) fully into position.

9 When the bearing is fully installed, separate installer KM620-8A from the forcing screw KM620-3, then remove the

installer and forcing screw (KM620-3), adaptor (KM620-4A) and bearing, from the hol ding tool (KM620-1A). Leave

remaining tools installed.

10 Using suitable circlip pliers, install a new bearing retaining ring into trailing arm, ensuring that the ring is seated

correctly.

11 Install rear disc brake shield to trailing arm but do not

install fasteners (‘1’ and ‘2’) at this time, as the

supports, KM620-7A and KM620-7-AUS could not be

fully installed in the threaded holes on the opposite

side.

Figure 4B1 – 101

Rear Final Drive and Drive Shafts Page 4B1-61

Page 4B1-61

To Reinstall Outer Rear Wheel Drive Shaft

1 Remove KM620-1A from distance pieces, KM620-7A and KM620-7AUS.

2 Install sleeve KM620-9A over KM620-3, with the

stepped shoulder facing away from the outer rear

wheel driveshaft bearing.

3 Reinstall KM620-1A to KM620 -7A and KM620-7AUS,

tightening the attaching nuts.

4 Screw the threaded end of the outer rear wheel

driveshaft into KM620-3, engaging the full thread

depth.

5 While holding KM620-3 from turning, rotate KM620-4A

to draw outer rear wheel driveshaft into wheel bearing.

6 Unscrew forcing screw KM620-3 from outer rear wheel

driveshaft, then remove the nuts holding tool KM620-

1A to the distance pieces KM620-7A and KM620-

7AUS.

7 Remove the distance pieces KM620-7A and KM620-

7AUS from the trailing arm.

Figure 4B1 – 102

8 Assemble KM620-2 and KM620-1A to outer rear

wheel driveshaft flange using three drive shaft

constant velocity joint to flange bolts.

9 Lubricate outer rear wheel dri veshaft flange splines

and outer rear wheel drivesha ft threads with the

recommended differential carrier lubricant.

10 With KM620-4A, thrust ball bearing race (2) and

KM620-3 assembled to KM620-1A, screw the internal

thread of KM620-3 onto the outer rear wheel

driveshaft assembly.

Figure 4B1 – 103

11 While holding the forcing screw (KM620-3) from

turning with suitable socket equipment (1), use a

suitable 40 mm wrench to rotate the adaptor KM620-

4A in the direction shown, to install the outer rear

wheel driveshaft flange onto outer rear wheel

driveshaft.

12 Unscrew KM620-3 from the outer rear wheel

driveshaft, then remove it and adaptor KM620-4A from

the holding tool KM620-1A. Le ave the h olding tool

KM620-1A and outer rear wheel driveshaft flange ring

tool KM620-2 installed to the outer rear wheel

driveshaft flange.

Figure 4B1 – 104

Rear Final Drive and Drive Shafts Page 4B1-62

Page 4B1-62

13 Install NEW collar nut to the outer rear wheel

driveshaft assembly and, using a suitab le length and

sized pipe over the handle of KM620-1A to hold outer

rear wheel driveshaft assembl y from turning, tighten

collar nut to the correct torque specification.

Collar nut to outer rear wheel drive

shaft assembly torque specification...................300 N.m

14 Remove the holding tool KM620-1A and outer rear

wheel driveshaft flange ring tool KM62 0-2 from the

outer rear wheel driveshaft flange.

Figure 4B1 – 105

15 Using a 1.25 inch socket (1), 150 mm socket bar (2)

and a soft faced hammer, install new lock plate over

collar nut.

Figure 4B1 – 106

16 Assemble driveshaft (1) outer constant velocity joint to

outer rear wheel driveshaft flange, alig ning bolt holes.

17 Reinstall six NEW attaching bolts (2) with plates and

tighten bolts to the correct torque specification, using

suitable socket equipment (3).

 Drive shaft constant velocity

joint bolt torque specification.......................50 N.m, then

90° turn angle

Figure 4B1 – 107

Rear Final Drive and Drive Shafts Page 4B1-63

Page 4B1-63

The lower, rear disc brake shield to trailing

arm attaching bolts must be replaced on

reassembly.

18 Reinstall the four brake backing plate to trailing arm

bolts (‘1’ and ‘2’) and tighten to the correct torque

specification.

Upper rear disc brake shield to

trailing arm bolt torque specification.....................75 N.m

 Lower rear disc brake shield to

trailing arm bolt torque specification.....................85 N.m

NOTE

The upper Torx hea ded bolts have washers with

cut-outs that are to be installed with the cut-out

edge facing around the trailing arm hub, outer

surface.

Figure 4B1 – 108

19 Reinstall brake disc (1) to outer rear wheel driveshaft,

aligning the marks made before remova l.

NOTE

If the outer rear wheel driveshaft has been

replaced, then runout checks must be carried out

on the outer rear wheel driveshaft flang e and the

installed brake disc (1). Refer to 2.4 Trailing Arm

Outer Rear Wheel Drive Shaft Assembly, in this

Section for important information re gar ding thes e

checks.

20 Reinstall the brake caliper (3) to the trailing arm,

reinstall brake caliper anchor plate to trailing arm

attaching bolts (2 and tighten to the correct torque

specification.

Brake caliper anchor plate

to trailing arm attaching

bolt torque specification.......................................85 N.m

Figure 4B1 – 109

21 After reconnecting the brake li ne to the caliper hose and inst alling the brake hose retaining clip,

bleed the rear brakes and check for leaks. For the recommended procedure,

refer to Section 5A Service and Park Braking Systems.

22 Support the trailing arm with a floor jack and wooden block, sufficient to enable the shock absor ber to be

reinstalled.

23 Reinstall shock absorb er (3) to traili ng arm (2), install the lower mounting bolt (1) but do not torque to specification

at this stage.

Rear Final Drive and Drive Shafts Page 4B1-64

Page 4B1-64

NOTE

View ‘A’ in Figure 4B1-110 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 110

24 Install road wheel, aligning marks made before removal and reinstall attaching nuts.

25 Lower vehicle to the ground and bounce the rear of the vehicle several times to settle the suspension components.

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

26 Tighten the lower shock absorber bolt to the correct torque specification.

z Shock absorber lower mounting

bolt torque specification.....................................115 N.m

27 Tighten road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern.

Refer to Important Service Requirements in 2.1 General Informatio n, in this Section for more details.

Road wheel attaching nut

torque specification..................................110 – 140 N.m

28 Refit wheel cover/wheel nut decorative caps.

Rear Final Drive and Drive Shafts Page 4B1-65

Page 4B1-65

3.2 Final Drive Assembly

LT Section 05-290 – 1

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Final drive assembly to crossmember attaching bolts.

 Rear mount to differential carrier rear cover attaching bolts.

 Rear mount to vehicle underbody attaching bolts.

 Rear drive shaft constant velocity joint attaching bolts.

 Rear crossmember front mounting bolt

 Rear crossmember front mounting brace to underbody bolt.

The following fasteners MUST be at curb weight before final tightening:

 Rear shock absorber to trailing arm bolt.

Whenever any component that forms

part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that

the complete ABS system be checked; refer

ABS Function Check, in Section 5B ABS &

ABS/TC & Electronic Brake Assist (EBA).

Before disturbing the rear suspension

crossmember mounting bolts, an alignment

procedure is required on reinstallation and a

special tool is required for this purpose. If this

tool is not available, then the crossmember

cannot be correctly aligned and steering

and/or handling abnormalities will result.

NOTE

For this service operation, new intermediate

muffler support retainers must be used on

reassembly.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove wheel covers (steel wheels) or wheel nut caps (all oy wheels).

3 Mark relationship of road wheels to hubs (e.g. end of wheel stud), with a felt tipped pen or similar. Loosen, then

remove the road wheel attaching nuts, working in a 'star' pattern. Refer to Important Service Requirements, in

2.1 General Information, in this Section.

4 Remove the road wheel.

5 To provide access to the propeller shaft fasteners, it is recommended that the exhaust system is removed, from the

rear of the catalytic converters, rearward. Refer to Section 8B Exhaust System.

6 Remove propeller shaft, refer to Section 4C1 Propeller Shaft and Universal Joints.

Rear Final Drive and Drive Shafts Page 4B1-66

Page 4B1-66

7 Disconnect both park brake cabl es from the equaliser bracket.

Refer to Section 5A Service and Park Braking System.

8 Disconnect brake pipe (3) from brake hose (4) at

trailing arm bracket (2) and remove the brake hose

retaining clip (1).

9 Plug the open ends of both pipes and hos es to prevent

unnecessary fluid loss and/or dirt entry.

10 Repeat for the other side.

Figure 4B1 – 111

11 Pull out differential carrier breather hose (1) from

vehicle underbody crossmember hole (2).

Figure 4B1 – 112

12 If vehicle is fitted with ABS, disengage both the sensor

lead connectors (3) from the underbody retaining clips

(4) then separate the sensor connectors from the body

harness connectors by levering with a screwdriver

Figure 4B1 – 113

Rear Final Drive and Drive Shafts Page 4B1-67

Page 4B1-67

13 Using a scriber, mark rear mount (1) to vehicle under

body location (A). This will assist in rear crossmember

alignment on reinstallation.

14 Support weight of differential carrier with floor jack.

Figure 4B1 – 114

15 Remove rear mount (1) to vehicle underbody attaching bolts (2) and disca r d removed bolts. If an AWD Wagon, also

remove the spacer block (3).

NOTE

View 'A' in Figure 4B1-115 shows the

arrangement for all independent rear suspension

models, except for the AWD Wagon, which is

shown in 'B'.

Figure 4B1 – 115

Bruising to the inside of the drive shaft

constant velocity joint boots will occur if the

shock absorber is disconnected from the

trailing arm before the rear of the differential

carrier and crossmember assembly has been

lowered by at least 60 mm. Bruising of the

boot will lead to premature failure of the boot

and eventual failure of the joint, if left

unchecked.

Rear Final Drive and Drive Shafts Page 4B1-68

Page 4B1-68

16 Lower differential carrier and rear crossmem ber assembly by at least 60 mm.

If automatic level ride suspension is fitted to

the vehicle, there are specific procedures

relating to the system pressure and the

removal of the rear shock absorbers. Refer to

Section 4A1 Independent Coil Spring Rear

Suspension.

17 Position floor jack with a block of wood under trailing arm. Raise jack slightly to take spring load off trailing arm.

18 Disconnect rear shock absorber lower mounting bolt (1) from trailing arm (2), and pull lower end of shock absorber

(3) from trailing arm.

NOTE

View ‘A’ in Figure 4B1-116 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1-116

19 Remove rear springs and insulators from veh icle

underbody and trailing arms.

20. Raise differential carrier and rear crossmember on

floor jack until rear mount contacts underbody.

Figure 4B1 – 117

21 If replacing differential carrier assembly, rear cover or

rear mount, loosen and remove rear mount to rear

cover attaching bolts (1), remove rear mount (2) and

discard attaching bolts (1). Discard the removed bolts.

Figure 4B1 – 118

Rear Final Drive and Drive Shafts Page 4B1-69

Page 4B1-69

22 Use a floor jack and block of wood to suppor t differential carrier and crossmember assembly.

23 Remove brace to underbody bolts (1) (3 places) and crossmember to vehicle underbody attaching bolt (2) from

each side.

24 Remove the braces (3) from the vehicle.

25 With an assistant supporting front end of rear crossmember, lower assembly on jack an d remove from beneath

vehicle.

26 If the vehicle is fitted with isolating rubbers o r snubber bushes (4) located on top of each rear crossmember front

bush, remove and set to one side.

NOTE

View ‘A’ in Figure 4B1 – 119 shows the isolating

rubber fitted to GEN III V8 and manual

transmission, while view ‘B’ shows the AWD

Wagon arrangement.

Figure 4B1 – 119

27 Using an 8 mm Allen key sock et, remove drive shaft

inner constant velocity joint (1) to inner axle shaft (2)

attaching bolts (3) and plates (4). Discard all removed

bolts as they must be replaced on reassembly.

Support drive shafts with suitable tie wire so

they do not hang down on one end. Drive

shaft joint deflection should b e kept to within

the angular movement of an installed drive

shaft.

28 Disconnect joints from inner axle shafts. Figure 4B1 – 120

Rear Final Drive and Drive Shafts Page 4B1-70

Page 4B1-70

29 Remove differential carrier (3) to rear crossmember (2)

attaching bolts (1), remove rear crossmember

assembly from differential carrier and discar d

attaching bolts(1).

30 If not carried out in Step 21, remove rear mount to rear

cover attaching bolts, remove mount and disc ard

attaching bolts.

Figure 4B1 – 121

Reinstall

Installation is the reverse of removal procedure e xcept for the following items:

1 If necessary, reinstall rear mount (1) to rear cover

using NEW bolts but leave bolts finger tight at this

stage.

2 Line up mounting holes in final drive assembly (2) and

rear crossmember (3). Install NEW attaching bolts (4)

(four places) and tighten to the correct torque

specification.

 Final drive assembly to crossmember

attaching bolt torque specification...............90 N.m, plus

40° turn angle

Figure 4B1 – 122

3 Inspect drive shaft constant velocity joint boots for

damage, replacing as necessary.

4 Install NEW drive shaft inner constant velocity joint

bolts and locking plates to secure the inner constant

velocity joint to the inner axle shaft and tighten to the

correct torque specification.

 Drive shaft constant velocity joint

bolt torque specification..............................50 N.m, plus

90° turn angle

Figure 4B1 – 123

Rear Final Drive and Drive Shafts Page 4B1-71

Page 4B1-71

5 With the help of t wo assistants, place the differential carrier and rear crossmember assembly onto a floor jack.

• When raising the assembly, take care that

the rear mount does not foul on the fuel

tank or fuel hoses.

• During this operation, ensure that trailing

arms are also supported on safety stands,

to keep the drive shafts as near to

horizontal as possible. Otherwise, bruising

to the insides of the co nstant velocity joint

boots will result, leading to boots splitting

and eventually joint failure, if left

unchecked.

6 Position assembly under vehic le, raise with the jack and, with the aid of the assistants, guide the crossmember

front mounting points into position.

7 If the vehicle is fitted with an isolating rubber (' 4' in view A) or snubber bush ('4' in view B) on each side, they must

be fitted at the top of each crossmember front bush as shown, before raisin g the assembly into place.

NOTE

View 'A' in Figure 4B1-123 shows the

arrangement for the GEN III V8 engine and

manual transmission models, while view ‘B’

shows the snubber bushes fitted to AWD wagon

models.

Figure 4B1 – 124

8 Install crossmember front mounting braces (3), attaching bolts (‘1’ – three p laces each side) and rear

crossmember, front mounting bolt (2) but do not fully tighten any of these bolts at this stage.

Rear Final Drive and Drive Shafts Page 4B1-72

Page 4B1-72

Ensure that mount does not twist during the

bolt tightening process, as the mount to

vehicle underbody mating surface should be

parallel to the rear crossmember, to within 1

mm (‘X’).

9 Lower rear of the final drive assembly to gain access

to the rear mount to cover attaching bolts. Tighten

attaching bolts to the correct torque specificat ion.

 Rear mount to rear cover

bolt torque specification.......................................95 N.m

NOTE

Use a spirit level on rear mount to underbody

surface and top surface of crossmember to

ensure that both surfaces are parallel.

Dimension ‘A’ is to be 56.7 mm.

Figure 4B1 – 125

10 Lower differential carrier and rear crossmember

assembly on floor jack and safety stands. Install rear

springs (1) and the two insulators, (2 and 3).

NOTE

During this operation, the differential carrier and

rear crossmember assembly rear mount mus t be

lowered at least 60 mm from the vehicle

underbody. Otherwise damage to the drive shaft

constant velocity joint boots will occur.

Figure 4B1 – 126

11 Reinstall shock absorber to trailing arm, fit washer to the lower mounting bolt, install bolt but do not fully tighten at

this time, as the vehicle must be at curb weight before final tightening is undertaken.

NOTE

View ‘A’ in Figure 4B1-127 shows the sedan and

coupe lower shock absorber mounting, while view

‘B’ shows the station wagon and utility

arrangement.

Figure 4B1 – 127

Rear Final Drive and Drive Shafts Page 4B1-73

Page 4B1-73

12 Raise assembly until rear mount contacts vehicle underbody.

13 Align rear mount (1) with marks on underbody, made on disassembly, then loosely install new attaching bolts (2)

but do not fully tighten at this stage.

NOTE

View 'A' in Figure 4B1-128 shows the

arrangement for all independent rear suspension

models, except for the AWD Wagon, which is

shown in 'B', with the spacer (3) included.

Figure 4B1 – 128

Failure to correctly align the rear

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

14 The rear crossmember MUST now be aligned to the vehicle centreline, using the special tool and procedure as

detailed in Sect ion 1A2 Body Dimensions.

15 Tighten all crossmember mou nting faste ners to the correct torque specifica t ion.

 Rear mount to vehicle underbody

attaching bolt torque specification...............35 N.m, plus

60° turn angle

 Crossmember front mounting

bolt torque specification............................125 N.m, plus

35 ° turn angle

 Crossmember front mounting

brace bolt torque specification .............................75 N.m

Rear Final Drive and Drive Shafts Page 4B1-74

Page 4B1-74

16 Install differential carrier breather hose into vehicle

underbody crossmember hole. Ensure that end of

hose is pushed into hole approximately 25 mm.

Figure 4B1 – 129

17 If equipped with ABS, reconnect wheel sensor wiring

harness connectors (3). Reinstall into the retaining

clips (4).

18 Reinstall park brake inner cables to the fron t retainer,

install and secure outer cable s in the underbody

retainers, then install the outer cable retaining bracket

bolt to the vehicle underbody.

19 Check and fill differential carrier to correct le vel with

specified lubricant, refer to 2.2 Checki ng Differential

Carrier Lubricant Level, in this Section.

20 Check park brake adjustment and bleed brake

hydraulic system, refer to Section 5A Service and Park

Braking System.

21 Reinstall propeller shaft. Refer to Section 4C1

Propeller Shaft and Universal Joints.

22 Reinstall exhaust s ystem,

refer to Section 8B Exhaust System. Figure 4B1 – 130

23 Reinstall road wheels, aligning the marks made prior to removal and secure with attaching nuts.

24 Lower vehicle to the ground.

25 Bounce the rear of the vehicle several times to settle suspension then, tighten road wheel attaching nuts to correct

torque specification, working in a ‘star’ pattern; refer to Important Service Requ irements, in 2.1 General Information,

in this Section.

Road wheel attaching

nut torque specification............................110 – 140 N.m

26 Refit wheel cover/wheel nut decorative caps.

27 Lower vehicle to the ground and, with the vehicle weight on a;; four wheels, tighten the lower shock absorber l ower

mounting bolts to the correct toque specificat ion.

z Shock absorber lower mounting

bolt torque specification.....................................115 N.m

28 Start vehicle and check for exhaust leaks. Repair as nec essary.

Rear Final Drive and Drive Shafts Page 4B1-75

Page 4B1-75

3.3 Removed Final Drive Assembly

ATTENTION

The following fasteners MU ST be replaced when performing these operations:

 Final drive ring gear attaching bolts.

NOTE

Apart from the fact that the appearance of the

pinion flange and the drive pinion is different, the

unit repair for the removed final drive assem bly is

the same as described here, for the 3.46:1 ratio

assembly without LSD.

Figure 4B1-131

Rear Final Drive and Drive Shafts Page 4B1-76

Page 4B1-76

Legend

'A' Standard Differential

'B' Limited Slip Differential

1 Nut – Pinion flange retaining

2 Flange Asm – Differential pinion

3 Seal – Rear axle pinion oil

4 Bearing Asm – Pinion front

5 Collapsible Spacer – Pinion bearing

6 Shim – Pinion position adjusting

7 Breather Asm – Rear axle

8 Bearing Asm – Pinion Rear

9 Ring Gear and Pinion

10 Bearing Asm – Differential side

11 Screw – Differential side bearing

adjusting

12 Bearing Asm – Inner axle shaft

13 Seal – Inner axle shaft

14 O-ring – Screw adjuster

15 Shaft – Inner axle

16 Clip – Inner axle shaft

17 Screw Plug & Washer – Filler

18 Bolt – Rear cover attaching

19 Cover – Rear axle housing

20 Plug – Drain

21 Plate – Lock

22 Case – Differential

23 Shaft – Differential pinion gear - long

24 Lock Pin – Differential pinion shaft

25 Washer – Differential pinion gear

thrust

26 Gear – Differential pinion

27 Gear – Differential side

28 Washer – Differential side gear thrust

29 Shaft – Differential pinion gear - short

30 Block – Thrust

31 Gear and Cone Assembly – Differential

Side

32 Plate – Thrust spring (LSD only)

33 Spring – Differential pre-load - outer

34 Spring – Differential pre-load -middle

35 Spring – Differential pre-load -inner

36 Shaft – Cross (LSD)

37 Bolt – Ring gear to case

38 Pin – Dowel

39 Bolt – Case cap to cover

40 Housing – Carrier

41 Tag – Lubrication

Disassemble

NOTE

The disassembly operation is the same for all

assemblies, except where indi cated.

1 Remove differential carrier assembly. Refer to 3.2 Final Drive Assembly, in this Section.

2 Secure holding tool, Tool No. KM-480 or a fabricate d

copy (refer 7 Special Tools, in this Section for details) ,

to the differential carrier using two of the discarded

differential carrier to rear crossmember attachin g bolts.

3 Install holding tool into be nch mounted fixture base,

Tool No. J-3289-20.

Figure 4B1 – 132

Rear Final Drive and Drive Shafts Page 4B1-77

Page 4B1-77

4 Remove rear cover to differential carrier attaching

bolts and screw adjuster lock plates.

5 Using a soft faced hammer, tap rear cover at rear

mount area to break rear cover to differential carrier

seal.

6 Remove rear cover, rotate the assembly and drain

residual differential lubricant into a suitable container.

Figure 4B1 – 133

7 Before removing differential case assembly and drive pinion from differential carrier, the follo wing inspection

procedures should be adopted. These inspections can help to isolate the cause of final drive assembly noise a nd

determine corrections needed.

a Visually inspect the moving parts for chipped or scuffed surfaces.

b Check the torque of the ring gear bolts and t he pinion flange nut.

NOTE

Ring gear bolts have a left hand threa d.

c Mount a dial indicator to read from the rear face

of the ring gear, then rotate the differential case

through several turns to measure ring gear run-

out.

Ring gear face

run-out specification................0.13 mm maximum

d Leave the dial indic ator set up and push the ring

gear hard one way, then hard the opp osite way

to measure side play. There should b e no sid e

play present.

e Check to ensure that there is no pinion end play.

If end play is evident, then special attention

should be made to the bearing insp ection

process, after disassembly.

Figure 4B1 – 134

Rear Final Drive and Drive Shafts Page 4B1-78

Page 4B1-78

f Set up the dial indicator to measure ring gear

backlash at three equally spaced positions

Backlash specification

(At the tightest point)..................... 0.10 – 0.18 mm

g If no obvious faults are found, check the gear

tooth contact pattern. Refer to Ring Gear and

Pinion Contact Pattern in this Section, for

diagnostic assistance.

Figure 4B1 – 135

8 Remove inner axle shafts (1) by installing slide

hammer, Tool No. 7374 and three suitable size bolts

to each axle flange. Use the slide hammer to release

axle shaft spring clips.

NOTE

The left hand inner axle shaft is shorter in length

than the right hand shaft.

Figure 4B1 – 136

9 If new screw adjuster seals are to be installed, use a

suitable screwdriver and a block of wood to lever out

seals from screw adjusters.

NOTE

Take care not to damage the screw adjuster's

aluminium housing with the screwdriver blade,

as this could cause oil leaks to occur, after a

new oil seal is fitted.

Figure 4B1 – 137

Rear Final Drive and Drive Shafts Page 4B1-79

Page 4B1-79

10 Remove screw adjusters from housing using Tool No.

205-463 (also released as AU407).

11 Remove differential case assembly from carrier

housing.

Figure 4B1 – 138

12 To remove side bearing cups from screw adjusters,

install screw adjusters, reversed, into differentia l

carrier.

13 Install adaptor, Tool No. AU412 onto screw adjuster.

Using puller, Tool No. 1150, and forcing screw Tool

No. E6661S, pull side bearing cups from screw

adjusters and discard.

NOTE

Side bearing cups ar e only to be removed if side

bearing assemblies are to be replaced.

Figure 4B1 – 139

For AWD Wagon Models

14 Install packing flange, T ool No. DT -47580 into the

pinion flange recess, aligning the holes with those in

the pinion flange.

15 Using two of the propeller shaft constant velocity joint

bolts (2), with flat washers, secure the holding bar,

Tool No. J8614-10 (part of Tool No. J 8614- O1) to the

pinion flange (1). The central recesses in the holding

tool should face inward.

16 While holding Tool No. J8614-10, loosen the remove

the pinion flange retaining nut, using a commercially

available, 30 mm deep socket and socket bar (3).

Figure 4B1 – 140

Rear Final Drive and Drive Shafts Page 4B1-80

Page 4B1-80

17 With Tool Nos J8614-10 and DT-47580 still installed,

thread the forcing screw, Tool No. J8614-3, in to the

adaptor, Tool No. J8614-2. Install this sub-assembly

into holding bar, Tool No. J8614-10, then rotate

through 45° to locate in the recesses in J8614-10.

18 While holding J8614-10, use a socket and bar to rotate

the forcing screw J8614-3 in the direction s hown, to

remove the pinion flange.

19 Remove the tools from the pinion flange, then carefull y

set the flange to one side to avoid damage to the

flanged seal surface.

Figure 4B1 – 141

For RWD VZ Models

20 Install Tool No. DT-47735 to the pi nion flange using

three suitable bolts.

NOTE

Use either the rear coupling to pinion flange

retaining bolts with a 25 mm spacer (e.g. flat

washers) installed first or use three bolts M12 x

1.5 x 40, with the thread extending to within 12

mm of the head.

21 While holding DT-47735 with a suitable length of pipe

(1) over the tang, loosen then remove the pinion

flange retaining nut, using a commercia lly available,

30 mm deep socket and bar (2).

22 Remove flange holding tool DT-47735 from pinion

flange. Figure 4B1 – 142

23 Install extractor, Tool No. KM 628-A to the pinio n

flange, using the same arrangement used in step 20.

24 While holding KM 628-A with a set spanner (1), use

suitable socket equipment (2) to withdraw the pinion

flange by tightening the forcing scre w in the direction

indicated.

25 Remove extractor. Tool No. KM628-A from pinion

flange, then carefully set the flange to one side to

avoid damage to the flanged seal surface.

Figure 4B1 – 143

Rear Final Drive and Drive Shafts Page 4B1-81

Page 4B1-81

All VZ Models with IRS

26 Pry pinion oil seal out of carrier bore using Tool No.

E308 or a suitable seal extraction tool.

Figure 4B1 – 144

27 Remove pinion (1) by tapping on front end with a soft

faced hammer (2) to withdraw it through rear of carrier.

Remove pinion front bearing from carrier bore.

Remove and discard pinion bearing spacer.

Figure 4B1 – 145

28 If pinion bearings are to be replaced, remove bearing

cups using Tool No. E9293.

• View ‘A’ shows the tool arrangement to

remove the front (outer) pinion bearing cup,

while view ‘B’ shows the arrangement to

remove the rear (inner) bearing cup.

• When removing the rear (inner) pinion

bearing cup from all but 3.08:1 ratio

assemblies, the adaptor 'B' to be used with

E9293, is DT-47695.

• As the installation Tool No. E9271 (refer

Figure 4B1-147) relies on an installed

bearing cup for alignment, it is essential that

only one bearing cup is replaced at the one

time.

Figure 4B1 – 146

Rear Final Drive and Drive Shafts Page 4B1-82

Page 4B1-82

29 To install a new, rear (inner) pini on bearing cup (1),

use installer Tool No. E9271 with adaptor E9271/B, as

shown. The same arrangement is used to install a new

front (outer) pinion bearing cup, using ad aptor

E9271/A (or 205-552-1).

NOTE

When installing the rear (inner) pinion bearing

cup to all but 3.08:1 assemblies, the adaptor to

be used with E9271, is 205-552-2.

Figure 4B1 – 147

30 To remove rear (inner) bearing from the pinion,

remove legs from the ring of Tool No. E1673MT.

31 Place ring of Tool No. E1673MT on suitable press

plates. Install pinion and adap tors E1673A15 (3.08:1

assembly) or E1673S15 (all other assemblies) into the

ring.

32 Press pinion from bearing.

NOTE

With the larger pinion head size on all but the

3.08:1 assemblies, the ring must be placed over

the bearing first, then the adaptors manoeuvred

into place under the bearing cone.

33 Discard the removed bearing.

Figure 4B1 – 148

Rear Final Drive and Drive Shafts Page 4B1-83

Page 4B1-83

Differential Case

The following procedures describe the standard type differential case assembly. For Limited Slip Differential case

assembly, refer to 3.4 Limited Slip Differential, in this Section.

NOTE

The 3.08:1 differential is unique and is not

interchangeable with other ratio assemblies. The

general overhaul procedures however, remain

the same for all types.

The unique co mponents for the 3.08:1 differential

are; differential case, differential pinions, side

gears and thrust block.

1 Before disassembling the differential case, inspect differential side bearings for any signs of damage.

NOTE

The side beari ngs can be manufactured by either

one of two manufacturers; Timken or Koyo. When

replacing the differential side bearings, the two

bearings and cups must be of the same brand.

The pinion bearings may be of a different

manufacture but again, they must be a matched

pair. The reason for matched pairs of bearings is

that a different preload specification is required

for each brand.

2 If removing the side bearings from the differential

case, use Tool No. E1673MT, adaptors E1673N15

and stepped plug E1673B 16, as shown.

3 Discard the removed side bearin gs.

NOTE

To remove side bearing cups, refer to

Final Drive Assembly – Disassemble, Step 12.

Figure 4B1 – 149

4 Grip the differential case in a vice fitted with soft ja ws.

5 Remove ring gear (1) attaching bolts (2).

NOTE

Ring gear attaching bolts (2) use a left hand

thread and are identified by an 'L' on the bolt

head.

6 Remove differential case from vice.

Figure 4B1 – 150

Rear Final Drive and Drive Shafts Page 4B1-84

Page 4B1-84

7 Using a soft faced hammer (1), remove ring gear (2)

from differential case (3) by hitting do wn on ring ge ar.

Support ring gear during this operation so that it does

not strike bench top as it comes free of case.

NOTE

Do not use a screwdriver to prise between ring

gear and case.

Figure 4B1 – 151

8 Drive out differential pinion gear long shaft a nd short

shafts retaining pins (1) from differential case, using a

suitable size pin punch an d hammer.

Figure 4B1 – 152

9 Re-mount the differential case in vice with soft jaws.

Using a brass drift (1) and hammer, drive out pinio n

long shaft (2) from differential case.

Figure 4B1 – 153

10 Remove differential case (3) from vice. Using a brass

drift (1) and hammer (2), separate two differential case

halves by driving against thrust block.

NOTE

Do not use a screwdriver to prise the differential

case halves apart.

Figure 4B1 – 154

Rear Final Drive and Drive Shafts Page 4B1-85

Page 4B1-85

11 Using a brass drift (1) and hammer, drive out pinio n

gear short shafts (2) from differential case.

Figure 4B1 – 155

12 Lift out pinion gears (1), thrust washers and thrust

block (2) from differential case.

13 Remove differential side gears and thrust washers

from differential case halves.

NOTE

• When removing the thrust block from all but

the 3.08:1 ratio differential, note that the

pinion shafts are angled at 96° and not 90°

as is more usual.

• Keep the gears with their respective thrust

washers in pairs so they can be reinstalle d in

their original position. Figure 4B1 – 156

Inspect

All components should be thoroughly cleaned and dried, then inspected.

Differential Case

Check case for general soundness an d pay particular attention to the following points;

1 If differential case side bearings have been removed, check case journals for damage and that bearin g seating

surfaces are free from dirt and burrs.

2 The ring gear spigot and mounting face should be clean and free from dirt and burrs.

3 The mating surfaces for differential case halves should be clean and free from burrs.

4 The thrust surfaces for differential side gears and pinions should be examined for excessive wear.

5 The differential side gear journal bores should be clean and free from scoring.

6 The case bores for differential pinion gear shafts should be checked for ovality.

Differential Side Gears and Pinion Gears

1 Examine all gear teeth for cracks and hard contact marks.

2 The differential side gear spli nes should be checked for excessive wear. Wear on splines can contribute to

excessive driveline backlash.

3 Check differential side gear journals and back faces for scoring.

4 Check fit of differential side gears in differential case cap and cover. Wear on side gear hubs or in the case bores

can cause a "clunking" noise i n rear a xl e assembly when vehicle is driven at low speeds.

5 Inspect differential pinion bores and thrust surfaces for scoring. Also check differential pinion ge ar shafts are not

bent and that surfaces where pinions run are not worn or scored.

6 Check thrust washers. They should be free from cracks, nicks and burrs. Excessive wear of thrust washers or

pinion gear thrust surfaces can also contribute to excessive driveline backlash.

7 Check thrust block pinion gear shaft bores for ovality.

Rear Final Drive and Drive Shafts Page 4B1-86

Page 4B1-86

Ring Gear and Pinion

1 Inspect gear teeth for scoring or damage. Scoring of gear teeth is usua lly caused by excessive shock loading, use

of incorrect lubricant or insufficient "run in" before towing a heavy loa d. (Refer to the appropriate Owner's

Handbook). Scored gears must be replac ed.

2 The ring gear bore and back face should be clean and free from burrs.

3 The rear bearing seating surface on the pinion shoul d be clean and free from burrs.

4 Inspect pinion splines and flange splines for evidence of wear.

5 Inspect thread and bearing journals of pinion for

damage.

6 If on reassembly, a new gear set is to be installed,

ensure that the same matching number appe ars on

both the pinion and ring gear, as shown by ‘A’. The

pinion installation marking figure is indicated by ‘B’.

7 On ring gear bolts, clean the serrations under each

bolt flange.

Figure 4B1 – 157

Bearings

1 Bearing cups should have an even wear pattern and must be free from flaking or pitting. Ensure that seating

surfaces are clean and free from burrs or raised metal.

2 The bearing assembli es should feel smooth when turned in their cups.

3 The assembly should be free from loose particles.

4 No cracks should be present in roller cages, and bores should sho w no evidence of flaking or pitting.

NOTE

Refer to 4.4 Final Drive Bearing Diagn osis, in this

Section, for identification of bearing failures.

Differential Carrier

1 Check casting all over for general soundness.

2 Examine oil passages a nd ensure they are free from obstructions and loose particles.

3 The bore for the pinion oil seal should be free from burrs.

4 Inspect rear cover face and bolt holes for damage.

5 Check rear cover seating surface for scoring or other damage.

Rear Final Drive and Drive Shafts Page 4B1-87

Page 4B1-87

Screw Adjusters and Inner Axle Shafts

1 Inspect inner axle shaft needle bearings i nsi de screw adjusters for wear or damage.

2 If inner axle shaft needle bearings are to be replaced, reinstall screw adjusters into differential carrier and remove

inner axle shaft seals. Refer to Step 9 of Final Drive Assembly – Disassem ble.

3 Remove screw adjusters (2) from carrier and position

each onto a block of wood (3).

4 Using a 1.25 inch socket (1) and bar or a 73 mm

diameter tube, press the bearing from each of the

screw adjusters (2).

5 Remove and discard O-rings f rom screw adjusters.

6 Examine adjuster seal bores for burrs, nicks or other

damage. Examine oil pass ages and ensure t hey are

free from obstructions and loose particles.

7 Check that the adjuster thread and be aring bores are

clean and free from burrs or other damage.

Figure 4B1 – 158

Side bearing cups must be installed into

screw adjusters before installing needle

bearings. This is to ensure that needle

bearings are located correctly into screw

adjuster bores.

NOTE

To install side bearing cups, refer to Step 1,

Differential Case Side Bearin g Pre-Load Setting,

in this Section.

8 To install new screw adjuster needle bearings, place

screw adjuster (2) over fixture, Tool No. AU409 and

press needle bearing (1) into adjuster (2) using Tool

No. AU411. Repeat procedure for the remaining screw

adjuster. Figure 4B1 – 159

9 Examine seal surface of inner axle shafts and carefully remove any nicks or burrs. If this surface is irreparable on

either axle shaft, a new axle shaft must be fitted.

10 Check that the spring clip in end of each inner axle shaft is undamaged and moves freely in each groove. Replace

spring clips if necessary, by expanding ends of each clip and removing from inner axle shafts. Only expand the

ends of new clips sufficiently to allow installation into a xle shaft grooves.

Rear Cover

1 Clean sealant from rear cover sealing surface.

2 Inspect rear cover for cracks or damaged sealing surface.

3 Ensure breather passage is clea n and free of obstructions.

Rear Final Drive and Drive Shafts Page 4B1-88

Page 4B1-88

Reassemble

Differential Case

1 Lubricate all differential gears, bearings, thrust

washers and differential pinion gear shafts with the

recommended rear axle lubric ant before assembly.

2 Position differential side gears (1) with their thrust

washers (2) into differential case halves (3).

Figure 4B1 – 160

3 Using a soft faced hammer, reinstall pinio n gear short

shafts (1) and long shaft (2) into differential case, just

enough to allow a pinion gear thrust washer to sit on

the end of each shaft.

NOTE

Check that the retaining pin holes in the

differential case and pinion gear shafts are

aligned and that the chamfered edge of the

holes in each shaft facing up.

Figure 4B1 – 161

4 Install one of the pinion gear t hrust washers over

inside end of one of the short shafts.

5 Position appropriate pinion gear (1) next to thrust

washer and tap in short shaft (2) until it comes throug h

centre of the gear (1).

6 Carry out steps 4 and 5 for second pinion gear short

shaft.

Figure 4B1 – 162

7 Reinstall thrust block (1) between two installed pinion

gears. Knock the two pinion gear short shafts into

position, ensuring that retaining pin holes in the shafts

line up with holes in differentia l case.

Figure 4B1 – 163

Rear Final Drive and Drive Shafts Page 4B1-89

Page 4B1-89

8 Install pinion gear thrust washer and gear to long shaft

(1). Tap long shaft (1) through gear and thrust block.

Figure 4B1 – 164

9 Reinstall remaining pinion gear and thrust washer. T ap

long shaft through pinion gear, ensuring that thrust

washer aligns with cross shaft and the retaining pin

hole in the shaft aligns with hole in differenti al case.

Figure 4B1 – 165

10 Install pinion gear long shaft and sh ort shaft retaining

pins. Ensure that ends of retaining pins (1) protrude 6

mm from differential case cap to cover mating surface.

This is needed to provide a positive location for the

differential case cover to case cap.

Figure 4B1 – 166

11 Holding differential side gear (1) in position with a

finger through differential case cover bor e as shown,

push the two differential case halves together, locating

on the three protruding retaining pins.

Figure 4B1 – 167

Rear Final Drive and Drive Shafts Page 4B1-90

Page 4B1-90

NOTE

For ease of assembly, it may be necessary to

heat the ring gear on a hot plate until it is hot to

the hand, prior to installing onto the differential

case cap.

A flame must never be used to heat the ring

gear.

NOTE

Use left hand threaded guide pins (3) to pilot the

ring gear over the differential case spi got.

12 Place ring gear (1) into position on differential case

cap (2) and install ring gear attaching bolts.

Figure 4B1 – 168

13 Install and gradually tighten NEW ring gear attaching bolts evenly, unti l gear face is flush with differential case

spigot. Tighten all bolts to the correct torque specific ation.

Final drive ring gear bolt

torque specification............................................140 N.m

NOTE

Ring gear attaching bolts use a left hand thread

and are identified by an 'L' on the bolt head.

14 If installing new side bearings (1), use Tool No. E9277

to press new side bearings onto differential case

journals.

NOTE

Check that both nearing assemblies are of the

same manufacture – Timken or Ko yo.

Figure 4B1 – 169

Rear Final Drive and Drive Shafts Page 4B1-91

Page 4B1-91

Differential Case Side Bearing Pre-Load Setting

1 If removed during disassembly, press new bearing

cups into screw adjusters firmly to the shoulder by

positioning screw adjuster onto Tool No. AU409 and

using Tool No. AU411 to pres s new cup into place.

Repeat procedure for remaini ng screw adjuster.

NOTE

• Ensure that bearing side and cup matching is

maintained and that the pair of bearing

assemblies are of the same manufacture –

either Timken or Koyo.

• The screw adjuster used on all but th e 3.08:1

unit is 1.9 mm deeper than the one used for

3.08:1 ratio unit. The deeper screw adjuster

can be identified by a groove on the inner

edge.

2 Install new O-rings to screw adjusters and apply a

lubricant such as rubber grease to each.

3 While supporting the differential case in the carrier, fit

screw adjusters to both sides of carrier. Continue

tightening adjusters until case assembly is supported

by side bearings.

Figure 4B1 – 170

4 Rotate differential case several times to ensure that

side bearings are correctly seated.

5 Wrap a piece of string aroun d differential case flange

and check side bearing pre-load by pulling on end of

string with a spring balance (1). Spring balance

reading must be within specification.

6 Tighten or loosen one of the scre w adjusters until the

correct pre-load is obtained.

Side Bearing Preload Specification

New Bearings Timken Koyo

15 – 35 N 8 – 24 N

Used Bearings Timken Koyo

8 – 18 N 5 - 13 N

Figure 4B1 – 171

7 Using Tool No. 205-4 63 (or AU407) and a torque

wrench, measure tightening torque of each screw

adjuster (usually within the range of 50 – 6 0 N.m) and

record.

NOTE

These torque readings will be used to set

bearing pre-loa d on fina l assembly.

8 Using Tool No. AU407, loosen and remove screw

adjusters, remove differential case assembly.

Figure 4B1 – 172

Rear Final Drive and Drive Shafts Page 4B1-92

Page 4B1-92

Hypoid Pinion Positioning Shim Selection

The pinion posit ioning shim is located between pinion rear (inner) bearing c up and carrier housing.

If the ring gear and pinion or the pinion rear bearing assembly are replace d, pinion depth must be rechecked with pinion

setting gauge, Tool No. DT-47737 (or previously released E9300A, plus dumm y pinion spacer, DT-47696 and arb our

AU408).

NOTE

The pinion setting gauge DT-47737 includes

these items:

Dummy pinion.......................................3C10E/11

Pad .......................................................3C10E/13

Sleeve...................................................3C10E/14

Dummy pinion spacer...........................DT-47696

Forcing nut.................................................6651/1

Arbour........................................................AU408

The gauge and arbour pr ovide a nominal or 'zero' pinion as a gauging reference.

NOTES

• If a new gear set is to be installed, check that

the same matching number (‘A’) appears on

both the pinion and the ring gear, with either

white or yellow marker.

• The pinion installation marking figure is

indicated by ‘B’, again with either white or

yellow marker.

• The final drive pinion fitted to the 3.08:1 ratio

assemblies, has a different mounting

distance to other ratios (94.49 mm and

102.50 mm respectively). Also, as 3.08:1

ratio, final drive assemblies have a different

rear (inner) pinion bearing, gear set sizes,

differential case assemblies and screw

adjusters, none of these parts are to be

mixed.

Figure 4B1 – 173

1 Inspect pinion bearing cups/c ones for nicks and burrs. Replace if damaged.

2 Lubricate pinion front and re ar bearings with the recommended differential carrier lubricant. Do not use eng ine or

other oils, as a misleading rotating torque can be obtained.

NOTE

Make sure that both pinion bearings used on the

dummy pinion to determine the pinion positio ning

shim thickness, are those t hat will be used on the

final reassembly.

MY 2005 VZ Series Vehicles with the 3.08:1 Ratio Axle Assembly

3 Install the rear bearing onto dumm y pinion, Tool No. DT-47737 (or E930 0A).

Rear Final Drive and Drive Shafts Page 4B1-93

Page 4B1-93

MY 2005 VZ Series Vehicles with Other Ratio Axle Assemblies

4 Install the spacer, Tool No. DT-47696, to the dummy pinion, supplied as part of DT-47737 (or E9300A), then install

the rear (inner) pinion bear ing onto the dummy pinion.

5 Install dummy pinion and rear (inner) bearing into carrier ho usin g. F it front (outer) bearing to dummy pinion, then

install the dummy pinion sleeve (3C10E/14) and nut (6651/1).

NOTE

Both bearings are to be thos e that will be used in

the final assembly and both must be lubricated

with the recommended lubricant for that

assembly.

6 Tighten nut on end of dummy pinion, using a

commercially availabl e, dial type torque wrench (1),

until the specified rotational torque is obtaine d.

Dummy Pinion Rotational Torq u e Sp ecification

New Bearings (No Pinion Oil Seal Installed)

Timken Koyo

1.4 – 2.0 N.m 1.5 – 1.9 N.m

Used Bearings (No Pinion Oil Seal Installed)

Timken Koyo

0.7 – 1.2 N.m 0.7 – 1.2 N.m

7 Rotate dummy pinion back and forth during tightening

to ensure that bearings settle in their cups.

Figure 4B1 – 174

NOTES

• Once the specified preload is reached,

remove the gauge pad (3C10E/13) from the

rear of the dummy pinion to allow continuous

rotation of the pinion during the preload

tightening process. Rotate the pinion

approximately 50 turns in each direction, the n

re-check the bearing preload, readjusting as

required, to achieve the specified figure.

When the required preload is reached,

reinstall the gauge pad and secure with the

screw provided.

• Pinion bearing pre-load is very important

because it retains the pinion in its correct

relationship to the ring gear.

• Bearings that are installed with insufficient or

no pre-load will, after a comparatively short

period of running, develop end play. This

causes noisy operation on overrun and could

be responsible for scuffing of ring gear and

pinion teeth.

• Bearings that have too much pre-load, may

become pitted or flaked and result in

premature failure. It is therefore essential to

ensure that bearings are pre-loaded to

specified torque specification.

Rear Final Drive and Drive Shafts Page 4B1-94

Page 4B1-94

8 Position arbour Tool No. AU408 in carrier assembly

and install screw adjusters with side bearing cups.

Adjust screw adjusters to lightly clamp arbour, using

Tool No. 205-463 (or AU407).

NOTE

Ensure that arbour is free of any burrs that may

damage bearing cups.

Figure 4B1 – 175

9 Check clearance between arbour (Tool No. AU408)

and head of dummy pinion with a feeler gauge (1).

Record this dimension.

Figure 4B1 – 176

10 On the end of the pinion, a drive pinion installation

marking figure (1) is applied with either a white or

yellow marker. A zero marking ('0') indicates that shim

size equal to the dimension measur ed in Step 9 is the

correct size for this carrier/pinion combination.

A positive marking, e.g. +3, means that a thickness

measurement equivalent to this numerical marking

must be subtracted from shim size measured in Step

9. Refer to the following chart for specific details.

A negative marking, e.g. –3, means that a thickn ess

measurement equivalent to this numerical marking

must be added to the shim size measured in Step 9.

Refer to the following chart for specific details. Figure 4B1 – 177

Rear Final Drive and Drive Shafts Page 4B1-95

Page 4B1-95

Pinion

Marking Shim Thickness

Required

– 4 Add 0.100 mm to the Step 9 measurement

– 3 Add 0.075 mm to the Step 9 measurement.

– 2 Add 0.050 mm to the Step 9 measurement.

– 1 Add 0.025 mm to the Step 9 measurement.

0 Size as measured in Step 9.

+ 1 Subtract 0.025 mm from the Step 9 measurement.

+ 2 Subtract 0.050 mm from the Step 9 measurement

+ 3 Subtract 0.075 mm from the Step 9 measurement.

+ 4 Subtract 0.100 mm from the Step 9 measurement

Pinion positioning shims are serviced in thicknesses of 0.2 mm

to 0.75 mm in 0.025 mm increments. They are also dimensioned

differently, depending on the pinion bearing used.

11 Remove dummy pinion and arbour from carrier assembly.

Pinion Installation

1 Select pinion positioning shim stack as determined in

the Hypoid Pinion Positioning Shim Selection

procedure, in this Section.

2 Remove pinion rear (inner) bearing cup, using Tool

No. E9293, using adaptor Tool No. E9293-2 (for the

3.08:1 unit) or DT-47695 (for all other ratio units).

Figure 4B1 – 178

3 Install pinion positioning shim /s (1) into pinion rear

bearing cup bore (2).

Figure 4B1 – 179

Rear Final Drive and Drive Shafts Page 4B1-96

Page 4B1-96

4 Reinstall pinion rear (inner) bearing cup (1) using Tool

No. E9271 and adaptor E9271/B or 205-552-2. Ensure

that cup is seated squarely in bore.

NOTE

When installing the inner pinion bearing cup to

all assemblies except the 3.08:1 ratio unit, the

adaptor to be used with E9271, is 205-552-2.

Figure 4B1 – 180

5 Press rear bearing inner race aga inst the shoulder of

the pinion, using Tool No. E3C10AE R.

NOTES

• To avoid possible damage to the pinion gear

teeth when pressing the bearing on, ensure

that the press plates are perfectly flat, free of

burrs and foreign matter prior to installing the

rear bearing.

• Locate bearing inner race squarely on the

pinion and press only on inner race surface.

• Only lubricate the bearing with the

recommended differential carrier lubricant.

Figure 4B1 – 181

6 Place the pinion in the carrier.

7 Lubricate pinion front bearing with the recommended differential carrier lubr icant and assemble the collapsible

pinion bearing spacer and front bearing onto pinion, while supporting pinio n head.

For VZ AWD Models

8 Install packing flange, T ool No. DT -47580 into the

pinion flange recess, aligning the holes with those in

the pinion flange.

9 Using two of the propeller shaft constant velocity joint

bolts (2), with flat washers, secure the holding bar,

Tool No. J8614-10 (part of Tool No. J 8614- O1) to the

pinion flange (1). The central recesses in the holding

tool should face inward.

10 While holding Tool No. J8614-10, tighten the original

pinion flange retaining nut, using a commercially

available, 30 mm deep socket and socket bar (3), until

pinion front bearing is squarely engaged on the pinion

shaft and not cocked. Figure 4B1 – 182

Rear Final Drive and Drive Shafts Page 4B1-97

Page 4B1-97

11 With Tool Nos J8614-10 and DT-47580 still installed,

thread the forcing screw, Tool No. J8614-3, in to the

adaptor, Tool No. J8614-2. Install this sub-assembly

into holding bar, Tool No. J8614-10, then rotate

through 45° to locate in the recesses in J8614-10.

12 While holding J8614-10, use a socket and bar to rotate

the forcing screw J8614-3 in the direction s hown, to

remove the pinion flange.

Figure 4B1 – 183

For All RWD Models

13 Install pinion flange and the original pinion flange

retaining nut.

14 Install Tool No. DT-47735 then, using a suitable length

of pipe (1) to over the holding tool tang, tighten

retaining nut until pinion front bear ing is squarely

engaged on the pinion shaft and not cocked.

NOTES

• If not done before, drill out holes stamped ‘B’

on Tool No. DT-47735 to 12.5 mm.

• Use either the rear coupling to pinion flange

retaining bolts with a 25 mm spacer (e.g. flat

washers) installed first or use three bolts M12

x 1.5 x 40, with the thread ext ending to within

12 mm of the head.

15. Insert a suitable length of pipe (1) over the tang of the

installed tool for leverage, then remove the pinion

flange retaining nut, using a commercia lly available

deep socket and socket bar (2).

Figure 4B1 – 184

16 Install extractor, Tool No. KM628-A to the pinion

flange using the same three b olts used to se cure the

flange holding tool, DT-47735 (refer step 9).

NOTE

• If not done before, drill out holes stamped ‘B’

on Tool No. DT-47735 to 12.5 mm.

• If using the original bolts, they must have 25

mm spacers fitted so the tool is clamped to

the pinion flange. If this is not done, the

screw thread on the extractor Tool No.

KM628-A will not be long enough to fully

remove the pinion flange.

17 While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening the

forcing screw in the direction indic ated.

Figure 4B1 – 185

Rear Final Drive and Drive Shafts Page 4B1-98

Page 4B1-98

For All Models

18 Lubricate pinio n oil seal lips and the pinion oil seal

bore in the carrier housing with Mobilgrease XHP 222

or equivalent grease.

19 Install oil seal into carrier bore using T ool No. E9055

and a plastic faced hammer (1) until the seal fits flush

to 0.25 mm below carrier housing surface.

Figure 4B1 – 186

For AWD Models

20 Reinstall pinion flange and fit a NEW retaining nut.

21 Install packing flange, T ool No. DT -47580 into the

pinion flange recess, aligning the holes with those in

the pinion flange.

22 Using two of the propeller shaft constant velocity joint

bolts (2), with flat washers, secure the holding bar,

Tool No. J8614-10 (part of Tool No. J 8614- O1) to the

pinion flange (1). The central recesses in the holding

tool should face inward.

23 While holding Tool No. J8614-10, gradually tighten the

pinion flange retaining nut, while rotating pinion in both

directions to seat bearings.

Figure 4B1 – 187

If the retaining nut is over-tightened and pre-

load exceeded, it will be necessary to remove

the pinion from the carrier and a new

collapsible spacer installed. Under no

circumstances must the retaining nut be

backed off to decrease the pre-load reading.

24 Check bearing pre-load freq uently by removing flange hold ing tool (J 8614-10) and installing a pulley and string to

the pinion flange. Refer to 7 Special Tools at the end of this Section for pulley details.

Rear Final Drive and Drive Shafts Page 4B1-99

Page 4B1-99

For All RWD Models

25 Reinstall pinion flange and fit a NEW retaining nut.

26 Hold pinion flange using Tool No. DT-47735 and a

suitable length of pipe (1).

27 Gradually tighten the retaining nut while rotating pinion

in both directions to seat bearings.

If the retaining nut is over-tightened and pre-

load exceeded, it will be necessar y to remo ve

the pinion from the carrier and a new

collapsible spacer installed. Under no

circumstances must the retaining nut be

backed off to decrease the pre-load reading. Figure 4B1 – 188

28 Check bearing pre-load freq uently by removing flange ho lding tool (DT-47735) and installing a pulle y and string to

the pinion flange. Refer to 7 Special Tools at the end of this Section for pulley details.

For All Models

29 Using a spring scale, measure rotationa l torque.

30 Continue to tighten the nut until specified torque is achieved.

Pinion Rotational To rqu e Specification

New Bearings (With Pinion Oil Seal Installed )

Timken Koyo

1.4 – 2.4 N.m 1.5 – 2.1 N.m

Used Bearings (With Pinion Oil Seal Installed)

Timken Koyo

0.7 – 1.2 N.m 0.7 – 1.2 N.m

31 The torque figure is calculated b y multiplying the radius of the pulley by the sprin g balance reading.

Example: If the pulley diameter is 152 mm, the radius is 76 mm which equals 0.076 m. The spring bala nce reading is

25 N. Therefore, the pre-load equals 0.076 m x 25 N = 1.9 Nm.

Differential Backlash Setting

1 Check threads of screw adjusters and ensure that they are free of damage.

2 Holding differential case in carrier, with ring gear in

mesh with pinion, fit screw adjusters and side bearing

cup assemblies to both sides of carrier. Usin g Tool No.

205-463 (or AU407), continue tightening adjusters until

case assembly is supported by side bearin gs.

3 Rotate differential case several times, to ensure that

side bearings are correctly seated.

4 Tighten screw adjusters to the torque setting recorded

previously. Refer to Step 6, ‘Differential Case Side

Bearing Pre-load Setting ’, in this Sectio n.

Figure 4B1 – 189

Rear Final Drive and Drive Shafts Page 4B1-100

Page 4B1-100

5 Mount a dial indicator on carrier and check gear

backlash between the ring ge ar and pinion at four

equally spaced positions around the ring gear.

NOTE

Position the dial indicator so that the indicator

stylus is perpendicular to th e ring gear tooth and

in line with gear rotation.

6 Backlash should be within the following specification.

Backlash specification.........................0.10 - 0.18 mm at

the tightest point.

7 If backlash is excessive or insufficient, adjust by

slackening off screw adjuster on the side that the ring

gear (differential case) needs to move towards. Re-

tighten opposite screw adjuster the same amount,

then tighten both as detailed in step 4.

8 With backlash correctly set, check gear contact pattern

as detailed in the follo wing in structions. Figure 4B1 – 190

Ring Gear and Pinion Contact Pattern

1 Thoroughly cle an ring gear and pinion teeth.

2 Paint ring gear teeth lightly and evenly with gear marking compound of a suitable consistency to produce a contact

pattern.

3 Rotate pinion through several revolutions in both directions whil e lightly loading gear set, using a suitable bar to

lever between ring gear o uter diameter and differential carrier.

NOTE

When rotating pinion, ensure that no metal swarf

from contact with rotating ring gear and bar is

allowed to enter gear teeth.

4 Inspect contact pattern produced b y above procedure.

5 After a satisfactory contact pattern is produced, clean the ring gear an d pinion gear teeth and pour a liberal quantity

of the correct rear axle lubricant onto the gears and beari ng s . T urn the gear set to work the lubricant into all

surfaces.

Tooth Marking Nomenclatur e

The large end of the tooth is called the 'HEEL' and the small end the 'TOE', also the top of the tooth which is above the

pitch line is called the 'FACE' while the area below the pitch line is called the 'FLANK'. The clearance between the pinion

and ring gear teeth is referred to as 'BACKLASH'.

Figure 4B1-191 illustrates correct and incorrect contact patterns.

Contact pattern 'A' provides the ideal marking for quietness and long life. If the pattern shows a toe contact as in 'B', it

indicates not enough backlash. T o correct, move the ring gear away from the pinion by screwing the side bearing

adjuster out on the ring gear side a djuster and screwing in the pi nion side adjuster by an equal amo unt.

If the pattern shows a heel contact 'C', it indicates too much backlash. To correct, move the ring gear towards the pinion

by screwing the side bearing adjuster out on the pinion side adjuster and screwing in the ring gear side adjuster by an

equal amount.

NOTE

Each time an adjustment is made, check gear

contact with gear marking compound and

continue adjustment until tooth contact appears

as in 'A'. Backlash must remain within specified

limits.

Rear Final Drive and Drive Shafts Page 4B1-101

Page 4B1-101

To correct a pattern shown in 'D', it will be necessary to install a thicker pin ion p ositioning shim; refer to

Hypoid Pinion Positioning Shim Selection, in this Section. A shim that is thicker by 0.025 mm is recommended as a

starting point. Continued changes may be necessary to obtain the correct setting. If the pattern shows a flank contact 'E',

it indicates that the pinion is in too far. To correct, replace the pinion shim with a 0.025 mm thinner shim and recheck

contact pattern.

In making pinion position adjustments, be sure backlash is correct before testing each contact pattern. Moving the pi nion

'IN' reduces backlash and moving pinion 'OUT' increases backlash.

Figure 4B1 – 191

Legend

1 Convex Side (Drive)

2 Concave Side (Coast)

3 Heel

4 Toe

A Low Flank Contact – Decrease Pinion Shim Thickness

B Heel Contact – Decrease Backlash

C High Face Contact – Increase Pinion Shim Thickness

D Toe Contact – Increase Backlash

E Ideal Contact

Rear Final Drive and Drive Shafts Page 4B1-102

Page 4B1-102

Ideal Contact

Figure 4B1 – 192

Legend

A Drive Side

B Coast Side 1 Face Width

2 Toe

3 Heel

Drive Side

A central toe contact marking, lengthwise in position and slightl y low contact in the profile position.

Total length approximat ely 5/8th of the gear face width.

There should be clearance of about 1 mm between the contact marking and the toe and alon g the top face angle line.

Coast Side

A centrally located marking, lengthwise in position and sli gh tly high in the profile position.

Total length approximat ely 5/8th of the gear face width.

There should be clearance between the contact and the face angle li ne of the gear.

Acceptable Heel Contacts

Figure 4B1 – 193

Legend

A Drive Side

B Coast Side 1 Face Width

2 Toe

3 Heel

Drive Side

A central face contact marking, lengthwise in position, is shown in Figure 4B1-193. This represents the limit of

acceptability of the contact marking towards the heel.

The marking should fade out at least 5 mm before the heel end.

A central profile marking position is sh own and is acceptable, although lo w contact marking is preferre d.

Coast Side

The centre of the contact marking is located at 5/8th of the face width from the toe and it does not approach the heel en d

by less than 5 mm.

A high contact marking, as shown in Figure 4B1-193, is pre ferred for coast side contacts which tend to be toward the

heel.

A central profile marking position is acceptable, providing the pinion face angle edge li nes do not appear lo w on the gear .

Rear Final Drive and Drive Shafts Page 4B1-103

Page 4B1-103

Acceptable Toe Contacts

Figure 4B1 – 194

Legend

A Drive Side

B Coast Side 1 Face Width

2 Toe

3 Heel

Drive Side

The contact markings begin almost at the toe end face and exte nd in length by approximately half the face width.

A slightly low contact marking is sho wn in Figure 4B1-1 94. This is preferable although a centrally located profile position

is acceptable.

Coast Side

The contact marking being almost at the toe end face and may appear pointed as sh own in Figure 4B1-194. A squ are

end is equally acceptable.

The total length of the contac t marking is approximately 1/2 of the face width.

A high profile marking positi on is desirable, although a cen tral profile is acceptable.

Rear Final Drive and Drive Shafts Page 4B1-104

Page 4B1-104

3.4 Limited Slip Differential

ATTENTION

The following fasteners MU ST be replaced when performing these operations:

 Final drive ring gear attaching bo lts.

 LSD case cap to cover attaching bolts.

NOTE

• The overhaul procedures, ring gear and

pinion positioning and tooth markings for the

limited slip differential are the same as

described for the standard type of rear axle

assembly, except for the servicing of the

internal components of the limited slip

differential assembly.

Disassemble

1 Before disassembling the differential case, inspect differential side bearings for any signs of damage.

NOTE

The side beari ngs can be manufactured by either

one of two manufacturers; Timken or Koyo. When

replacing the differential side bearings, the two

bearings and cups must be of the same brand.

The pinion bearings may be of a different

manufacture but again, they must be a matched

pair. The reason for matched pairs of bearings is

that a different preload specification is required

for each brand.

2 If replacing side bearings, use Tool No. E1673MT,

adaptors E1673N15 an d stepped plug E1673B16 to

remove side bearings from differential cas e.

3 Discard the removed side bearin gs.

4 To remove side bearing cups, refer to 3.3 Removed

Final Drive Assembly – Disassemble, Step 12 in this

Section.

Figure 4B1 – 195

Rear Final Drive and Drive Shafts Page 4B1-105

Page 4B1-105

5 Grip differential case in a vice fitted with soft jaws.

6 Remove ring gear attaching bolts (1).

NOTE

Ring gear attaching bolts (2) use a left hand

thread and are identified by an 'L' on the bolt

head.

7 Remove differential case from vice.

Figure 4B1 – 196

8 Using a soft faced hammer (2), remove ring gear (1)

from differential case (3) by hitting do wn on ring ge ar.

Support ring gear during this operation so that it does

not strike bench top as it comes free of case.

Do not use a screwdriver to prise between ring

gear and case.

9 Place differential case in a vice equip ped with soft

jaws.

Figure 4B1 – 197

10 Loosen and remove differenti al case ca p to cover

attaching bolts (1) evenly. Lift off differential case

cover. If necessary, remove clutch cup from cover

(sometimes the cone will remain inside the c over).

Figure 4B1 – 198

11 Remove the integrated clutch cone (1)/side gear (2)

and thrust spring plate (3) from pinion cross shaft.

NOTE

The integral clutch cones and side gears must

stay assembled to each other.

Figure 4B1 – 199

Rear Final Drive and Drive Shafts Page 4B1-106

Page 4B1-106

To ensure that the clutch cones (1) (are not

interchanged during reassembly, mark the cone

and corresponding side of the differential case

(2) with a felt tipped pen or similar.

Figure 4B1 – 200

12 Remove three concentric differential pre-load springs

(1) from centre of pinion cross shaft.

Figure 4B1 – 201

13 Lift pinion cross shaft (1), pinion gears and thrust

washers from case. Remove pinion gears and thrust

washers from cross shaft.

NOTE

Keep the pinion gears with their respective thrust

washers in sets so they can be reinstalled in

their original position.

14 Remove remaining thrust spring plate, side gear, shim

(if fitted) and clutch cone from differential case cap.

Figure 4B1 – 202

Rear Final Drive and Drive Shafts Page 4B1-107

Page 4B1-107

Inspect

All components should be thoroughly cleaned and dried, then inspected.

Differential Case

Check the case for general soun dness and pay particular attention to the following points:

1 If differential case side bearings have been removed, check case journals for damage and that seating surfaces

are free from dirt and burrs.

2 The ring gear spigot and mounting face should be clean and free from dirt and burrs.

3 The mating surfaces for differential case halves should be clean and free from burrs.

4 The thrust surfaces for the differentia l pinions should be examined for excessive wear.

5 The clutch cone seats in t wo hous ing halves should be smooth and free from any excessive scoring. Slight grooves

and scratches are permissible and norm al.

NOTES

• The land surface of the heavy spirals on

clutch cones will duplicate the housing

surface condition.

• Excessive wear or damage on the clutch cone

surface will require renewal of both clutch

cones (3.08:1 ratio only) or the clutch

cone/side gear assemblies (all other units)

and the housing.

6 Inspect axle splines of the clut ch cones for excessive wear.

7 Check thrust spring plates for excessive wear or damage.

8 Inspect pinion gear cross shaft bores for ovality.

Differential Side Gears and Pinion Gears

1 Examine all gear teeth for cracks or hard contact marks.

2 The differential side gear spli nes should be checked for excessive wear. Wear on splines can contribute to

excessive driveline backlash.

3 The differential pinion bores and thrust surfaces should be smooth and free from scores. Inspect all thrust washers

for cracks, nicks or burrs. Wear of thrust washers or thrust surfaces on gears can contribute to excessive driveline

backlash.

4 Check that pinion gear cross shaft is not bent and that surfaces on which pinions run, are not scored or worn.

Ring Gear and Pinion

1. Inspect gear teeth for scoring or damage. Scoring of the gear teeth is usually caused by excessiv e shock loading,

use of the incorrect lubricant or insufficient "run in" before towing a heavy load. (Refer to the appropriate Owner's

Handbook for more information). Scored g ears must be replaced.

2 If on reassembly, a new gear set is to be installed,

ensure that the same matching number 'A' appears on

both the pinion and ring gear. The pinion installation

marking figure is indicated by ‘B’.

3 On ring gear bolts, clean the serrations under each

bolt flange.

Figure 4B1 – 203

Rear Final Drive and Drive Shafts Page 4B1-108

Page 4B1-108

Bearings

1 Bearing cups should have an even wear pattern and be free from flaking or pitting. Ensure the seating surfaces are

clean and free from burrs or raised metal.

2 The bearing assembli es should feel smooth when turned in the cups.

3 The assembly should be free from loose particles.

4 There should be no cracks pr esent in the roller cages and the bores should show no evidence of flaking or pitting.

NOTE

Refer to 4.4 Final Drive Bearing Diagn osis, in this

Section, for identification of bearing failures.

Reassemble

1 Lubricate all gears, bearings, thrust washers and pinion gear cross shaft with rear axle lubricant befor e assembly.

2 Clamp the left hand inner axle shaft (1) in a vice

equipped with soft jaws (2), after removing the snap

ring from the end of the shaft.

Figure 4B1 – 204

3 Place differential case cap (1) over axle shaft mounted

in vice with interior of the housing faci ng upwards.

4 Paint a mixture of an EP grease with molybdenum

disulphide, such as Shell Retinax HDX2 grease, BP

Energrease LMS-EP 23, or equivalent, with the

recommended differential carrier lubricant onto faces

of side gears and clutch cone surfaces.

Figure 4B1 – 205

Rear Final Drive and Drive Shafts Page 4B1-109

Page 4B1-109

5 Install the clutch cone/side gear assembl y (1 ) into the

housing.

Figure 4B1 – 206

6 Place a thrust spring plate (1), stepped side up on side

gear (2).

7 Assemble the four pinions and thrust washers onto

pinion cross shaft.

8 Install pinions and cross shaft assembly to case cap,

ensuring that pinions mesh with side ge ar.

Figure 4B1 – 207

9 Install three new concentric differential pre-load

springs (1) into centre of the pinion cross shaft (2).

Only install NEW pre-load springs (1) on

reassembly: DO NOT RE-USE OLD SPRINGS.

Figure 4B1 – 208

10 Assemble second thrust spring plate (1), stepped side

down, onto pre-load springs.

Figure 4B1 – 209

Rear Final Drive and Drive Shafts Page 4B1-110

Page 4B1-110

11 With other ratio differentials, install the clutch

cone/side gear assembly (4) into the case cover (2).

Figure 4B1 – 1

12 Install case cover onto case cap.

NOTE

Check that the cut outs (1) on each side of the

case cover and cap are aligned.

Figure 4B1 – 210

13 Install two NEW differential case cap-to-cover

attaching bolts in opposite bolt holes and finger

tighten.

14 Install other inner axle shaft (1) through case cover,

rotating axle shaft to engage clutch cone splines and

then side gear splines. Leave axle shaft in this

position. Install remaining, NEW, cap-to-cover

attaching bolts and tighten evenl y to the correct torque

specification.

 Differential case cap to cover

attaching bolt torque specification........................40 N.m

Figure 4B1 – 211

Rear Final Drive and Drive Shafts Page 4B1-111

Page 4B1-111

NOTE

For ease of assembly, it may be necessary to

heat the ring gear on a hot plate until it is hot to

the hand, prior to installing onto the differential

case cap.

A flame must never be used to heat the ring

gear.

NOTE

Use left hand threaded guide pins (3) to pilot the

ring gear over the differential case spi got.

15 Place ring gear (1) into position on differential case

cap (2) and install ring gear attaching bolts.

16 Install NEW ring gear attaching bolts evenly until gear

face is flush with differential case spigot.

17 Tighten bolts to the correct torque specification. Figure 4B1 – 212

 Final drive ring gear

bolt torque specification.....................................140 N.m

NOTE

Ring gear attaching bolts use a left hand thread

and are identified by an 'L' on the bolt head.

18 If installing new side bearings (1), use Tool No. E9277

to press on side bearings (1) to differential case

journals.

19 Continue rear axle assembly, proceeding from

'Differential Case Side Bearing Pre-Load Setting', on

page 4B1-87, in this Section.

Figure 4B1 – 213

Rear Final Drive and Drive Shafts Page 4B1-112

Page 4B1-112

3.5 Rear Axle

Reassemble

1 Apply a 1.5 – 2.0 mm diameter continuous bead of sealant, such as Loctite 587 (‘Ultra Bl ue’) or equivalent to inside

edge of rear cover and bolt holes and completely around drain pl ug hole.

2 Install rear cover to differential carrier housing. Fit screw adjuster lock plates to rear cover, ensuring that lock plates

fit over ribs or between ribs on the screw adjusters.

3 Tighten rear cover attaching bolts to the correct torque spec ification.

Rear cover attaching bolt

torque specification..............................................27 N.m

4 If removed, reinstall a spring clip to the end of each

inner axle shaft (1), then reinstall.

To avoid premature seal failure, ensure axle

shaft splines or spring clip do not score or

damage the seal lips during installation.

5 Lightly tap on end of each shaft flange (1) with a soft

faced hammer (2) to compress spring clip on shaft into

clutch cup and side gear splines. Fully engage both

shafts until clips snap into side gear grooves.

Figure 4B1 – 214

6 If equipped with ABS, check that sensor to toothed inner axle shafts air gap is to specification.

ABS Sensor Air Gap..................................0.4 – 1.5 mm

7 Reinstall differential carrier assembly to the vehicle. Refer to 3.2 Final Drive Assembly, in this Section.

Rear Final Drive and Drive Shafts Page 4B1-113

Page 4B1-113

4 Diagnosis

4.1 General Information

Very often, final drive assemblies are consid ered as noisy, when in reality, the noise is emanating from some other

source, such as tyres, front wheel bearings, rear wheel bearings, manual tr ansmission rear bearings, engine noises,

muffler roar, automatic transmission or power steering pumps.

All final drive assemblies have some slight humming noise. This will vary with the t ype of body construction, load and tyre

pressure.

Noise which emanates from any one of these can quite ea sily be confused with a final drive assem bly noise and unless a

series of elimination tests are carried out to d efinite ly confirm the real source of the noise, differential assemblies may be,

and often are, dismantled unnecessarily.

Although not infallible, the following diagnosis guide will assist in locating and defining the different characteristics of the

components which could be responsible for a noise.

Road Test

Ensure that the final drive assembly lubricant is correct and at the correct level. Drive at low speed until thoroughly

familiar with vehicle noises b y which time the final drive assembly should have warmed up. Accelerate gradually from the

lowest practical speed in a direct ratio gear (1:1) to 100 km/h, noting any noises and the s peeds at which they occur.

Release the accelerator and without using the brakes, allo w the vehicle to lose speed. Next, allow the vehicle to coast to

rest from 100 km/h with the transmission in neutral position. Any noises common to earlier tests may be elimi nated as

final drive assembly gear noise, as the final drive assembly is not under load under these conditions. Engine noise is

gauged by gradually accelerating the engine with the vehicle at rest.

Only drive at high speeds when it is legal and

safe to do so.

Tyre Noise

Tyre noise can easily be mistaken for fina l drive assembly noise even though the noisy t yres may be operating on the

front wheels. Tyre noise changes with different road conditions, but final drive assembly noise does not. Final drive

assembly noise usually ceases when coasting with the transmission in neutral at speeds under 50 km/h. Tyre noise

continues, but with a lower tone as vehicle speed is reduced.

Tyre noise naturally should be first eliminated; driving on a grass surface is ideal to check against this condition. It should

be noted though, that dry grass can impose a fire hazard with the heat emanating from the catalytic converter and wet

grass can cause excessive wheel spin. Inflating tyres temporarily to high pressures will change the contact with the road

and assist in reducing t yre noise. Pressures up to 276 kPa may be used temporarily.

Tyres which have the surface of the non-skid divisions worn with one end higher than the other (saw-tooth wear) are

usually noisy. Interchanging tyres can prove effective in reducing noise.

Front Wheel Bearings

Worn, brinelled or chipped fro nt wheel bearings will cause a nois e, very similar to tyre noise. It is a constant noise, does

not vary on 'drive' or 'coast' and still persists when coasting with the transmission in neutral. T his noise does n ot

noticeably change on differing road surfaces to the same degree as does tyre noise.

Although not so pronounced, front wheel bearing noise can also be compared to a road surface noise, which is produced

when the vehicle is travelling over a surface such as penetrated bitumen type road.

Rear Final Drive and Drive Shafts Page 4B1-114

Page 4B1-114

Transmission Rear Bearing (Manual Transmission)

A rough or pitted rear transmission beari ng, usually produces a very definite bearing noise and sets up a distinct

'whirring' condition, which is most audible when accelerating from slow speed under a high throttle opening and tends to

diminish as vehicle speed increases.

This noise is also prominent under a co nstant throttle opening, but disappears on over-run when coasting with the

transmission in neutral.

When driven in second gear, noise can be amplified by lightly accelerating.

Backlash Clunk

Excessive clunk with accelera tion and deceleration may be caused by worn differential pinion shafts, excessive

clearance bet ween inn er axle shaft and side gear splines, drive shaft companion flange and wheel spindle flange splin es,

excessive clearance b etween side gear hub and counterbore in case, worn pini on and side gear teeth, worn thrust

washers and excessive drive pinion and ring gear backlash. Remove worn parts and repl ace as required, selecting close

fitting parts when possible. Adjust pinio n an d ring gear backlash.

Drive-Line Snap

A snap on sudden start, either forward or reverse, may be caused by a loose pinion flange. If loose, replace nut or flange

as outlined under 2.11 Pinion Flange, in this Section.

This condition may also be caused by incorrect lubricant in an LSD. Drain and refill with correct lubricant.

Engine and Other Contributing Factors

Noises which emanate from the eng ine, transmission or muffler are occasionally c onfused with final drive assemb ly

noises.

To isolate these noises, first carefully note the approximate vehicle speed and conditions where the supposed final drive

assembly noise is most pronounced, then with the vehicle stationary and in a quiet place to avoid interfering noises

(depress the clutch pedal on vehicl es with manual transmission), run the engine u p and down slowly through the engine

speeds that correspond to the vehicle speeds at which the noise was prominent and ob s erve whether there is any

similarity to a final drive assembl y noise.

For vehicles with manual transmission: With transmission still in neutra l, again run the engine at similar s peed while

slowly letting the clutch engage, and listen for noises from the transmission.

Muffler noises are usually readily identifi ed, possibly an exception being when a muffler emits a high-pitched periodic

whistling noise, which could be confuse d with a bearing noise.

Rear Final Drive and Drive Shafts Page 4B1-115

Page 4B1-115

4.2 Final Drive Assembly Noise

Final drive assembly noises fall into two categories:

a Gear related noises.

b Bearing related noises.

Before testing for final drive assembly noise, ensure that the lubricant is the correct type and at the correct level.

Gear Related Noise

Ring Gear and Pinion Noise

Noise produced by the ring gear and pinion set is of a cyclic nature and gener ally shows up as a 'drive noise' , 'coast

noise', or 'float noise'.

1 Drive noise is most pronounced on co nstant acceleration through the speed range of 50 to 90 km/h.

2 Coast noise is most pronounced when the vehicle is allowed to coast through the speed range from 90 to 50 km/h.

3 Float noise is most pronounced while the vehicle is kept at constant speed for periods between 50 to 90 km/h.

Final drive assembly noise will always change when comparing 'drive' and 'coast' and will usually cease when coasting

with transmission in neutral at speeds under 50 km/h.

Differential Side Gear and Pinion Noise

Noise produced by these gears occurs when there is excessive wear between the side gear hubs and the differential

case bores. This can cause a 'clunking' noise when the vehicle is driven at low speeds.

Noise produced due to excessive wear between the gear te eth will be most pronounced on turns.

Common Causes of Gear Related Noises

1 Low lubricant level or incorrect lubricant used.

2 Incorrect meshing of gear teeth (i.e. incorrect pinion positioning shim or backlash setting shims).

3 Scored gear teeth:- usually the result of incorrect lubricant type or level.

4 End play in bearings.

5 Bruised or chipped teeth.

6 Excessive runout of pinion head or ring gear backlash.

7 Ring gear creeping on differential case resulting from ring gear bolts loosening - noise from this source usuall y

appears as a sharp metallic sound when shifting from reverse to first gear.

Rear Final Drive and Drive Shafts Page 4B1-116

Page 4B1-116

Bearing Related Noise

Differential Pinion Gear Bearings

Worn, rough or loose bearings will tend to aggravate and magnify drive, float and coast noise, and result in heavy,

irregular drive nois e on co nstant acceleration and float, and also an irregular noise on deceleratio n.

Pinion bearings, if rough or brinelled, will produce a continuous whine, which will persist when coasting with transmission

in neutral even to a low speed.

End play in the pinion beari ng s, even from natural wear, which permits the pinion to feed back into the ring ge ar, will

cause a noise on over-run.

Outer Rear Wheel Drive Shaft Wheel Bearings

Outer rear wheel drive shaft bearings that are rough or pitte d can be responsible for a growling noise which on first

impression could be likened to a final drive noise.

The noise, however, does not vary on 'drive' or 'coast' and still persists when coasting with transmission in neutral.

Frequently this noise can be readily identified by the sound being conveyed in an eccentri c form. It can also be

intermittent as the noise may fade for a short period.

To confirm the diagnosis of a drive shaft bearing n oise:

1 Support the rear of the vehicle on safety stands and remove both rear wheels and brake discs.

2 Start the engine and, with top gear engaged, spee d engine up to a fast idle.

3 If a stethoscope is available, it is ideal to compare the noise of one wheel bearing against the other. To obtain the

best results with a stethoscope, keep the volume adjustment down low.

4 A difference in the noise of the outer rear wheel drive shaft bearings can also be discerned by placing a steel-

shafted screwdriver to the ear and in close pr oximity to each bearing in turn.

With practice, a noticeable difference i n no ise can, at most times, be observed between a good an d less than good

bearing.

Differential Side Bearings

Side bearings will produce a constant grinding noise of a slower nature than pinion be arings (side bearing noise ca nnot

be determined by the diagnosi s procedure for drive shaft bearing noise), but will be in the same frequency as drive shaft

bearings.

Common Causes of Bearing Related Noises

1 Low lubricant level or incorrect lubricant used.

2 Foreign matter in the lubricant.

3 Incorrect pre-load setting.

4 Bearings incorrectly mounted e.g. dirt trapped behind abut ment faces during assembly.

Rear Final Drive and Drive Shafts Page 4B1-117

Page 4B1-117

4.3 LSD Noise

If LSD stick-slip chatter is diagnosed, the differential carrier lubricant should be drain ed immediately after a run to warm

up the lubricant. This is to remove as much old lubricant and wear debris as possible. Refill carrier with the specified

lubricant and additive (if reco mmended), then re-evaluate LSD operation for a minimum of 20 km. Chatter will usually

disappear within this time.

Should chatter still occur, remove carrier and overhaul LSD. Refer to 3.4 Limited Slip Diffe rential, in this Section.

Rear Final Drive and Drive Shafts Page 4B1-118

Page 4B1-118

4.4 Final Drive Bearing Diagnosis

Consider the following factors when diagnosing bearing condition:

1 General condition of all parts during disassembly and inspection.

2 Classify the failure with the aid of the follo wing illustr ations.

3 Determine the cause.

4 Make all repairs, following recommended procedures.

Abrasive Roller Wear

Description:

Pattern on races and rollers caused by fine abrasives.

Correction:

Clean all parts and housings

Check seals and bearings, replacing if leaking, rough or nois y.

Galling

Description:

Metal smears on roller ends due to overheating, lubricant failure or overload.

Correction:

Replace bearing, check seals and check for proper lubrication.

Bent Cage

Description:

Cage damage due to improp er handling or tool use.

Correction:

Replace bearin g.

Abrasive Step Wear

Description:

Pattern on bearing ends caused by fine abrasives.

Correction:

Clean all parts and housing. C heck seals and bearings, replacing if leaking,

rough or noisy.

Etching

Description:

Bearing surfaces appear grey or greyish-black in colour with related etching

away or material, usually at the roller spacing.

Correction:

Replace bearings. Check sea ls and check for proper lubrication.

Rear Final Drive and Drive Shafts Page 4B1-119

Page 4B1-119

Bent Cage

Description:

Cage damage due to improp er handling or use of tools.

Correction:

Replace bearin g.

Indentations

Description:

Surface depressions on race and rol lers caused by hard particles of foreign

material.

Correction:

Clean all parts and housing. C heck seals and replace bearin gs if rough and

noisy.

Cage Wear

Description:

Wear around outside diameter of cage and roller pockets cause d by abrasive

materials and inefficient lubrication.

Correction:

Replace bearings. Check sea ls and check for proper lubrication.

Misalignment

Description:

Outer race misalignment due to foreign obje ct.

Correction:

Clean related parts and replace bearing. Make sure races are properl y seated.

Cracked Inner Race

Description:

Race cracked due to improp er fit, cocking or poor bearing seats.

Correction:

Replace bearings and correct bearing seats.

Fatigue Spalling

Description:

Flaking of surface metal resulting from fatigu e.

Correction:

Replace bearings and clean all related parts.

Rear Final Drive and Drive Shafts Page 4B1-120

Page 4B1-120

Brinelling

Description:

Surface indentations in raceway caused by rollers either u nder impact, loading

or vibration while the bearing is not rotating.

Correction:

Replace bearing if rough or noisy.

Frettage

Description:

Corrosion set up by relative movement of parts with no lubrication.

Correction:

Replace bearing. Clea n related parts. Check seals and check for proper

lubrication.

Stain Discoloration

Description:

Discolouration can range from light brown to black, caused by incorrect

lubrication or moisture.

Re-use bearing if stains can be removed by light polishing or if no evidence of

overheating is observed.

Correction:

Check seals and related parts for damage.

Heat Discoloration

Description:

Heat discolouration can range from faint yellow to dark blue, resulting from

overload or improper lubricant.

Excessive heat can cause softening of races or rollers.

To check for loss of temper on races or rollers, a simple file test may be made. A

file drawn over a tempered part will grab and cut metal, whereas a file drawn

over a hard part will glide readily with no metal cutting action.

Correction:

Replace bearings if overheating damage is indicated. Check seals and other

parts.

Smears

Description:

Smearing of metal due to slippage that can be caused by poor fits, lubrication,

overheating, overloads or handling damage.

Correction:

Replace bearings. Clea n related parts and check for proper fit and lubrication.

Rear Final Drive and Drive Shafts Page 4B1-121

Page 4B1-121

5 Specifications

General

Rear Axle Assembly Type ......................................................................................M80 Series

Axle Type................................................................................................Independent Housing

Standard and LSD Axles

Gear Type......................................................................................................................Hypoid

Gear Ratios (For application refer to Final Drive Applications)

2.87:1 3.07:1 3.08:1 3.46:1 3.73:1

No. of Teeth:

Ring Gear................................................ 43............ 43............ 37............45.........41

Drive Pinion Gear.................................... 15............ 14............12............13.........11

Lubricant

Capacity (Total) .......................................................................................................... 1.6 litres

Type...............................................Refer to 2.2 Checking Differential Carrier Lu brica nt Level

Differential Gears

Type....................................................................................................................Straight Bevel

No. of Teeth:

Pinion Gears – All ratios..................................................................................................10

Side Gears – All ratios ....................................................................................................15

Final Drive Pinion Gear Bearings

Bearing Type .................................................................................. Adjustable Tapered Roller

Bearing Adjustment ....................................................................................Collapsible Spacer

Bearing Pre-Load: Timken Koyo

Dummy pinion - New bearings............................................. 1.4 – 2.0.......... 1.5 – 1.9 N.m

Dummy pinion - Used bearings............................................ 0.7 – 1.2.......... 0.7 – 1.2 N.m

New with oil seal .................................................................. 1.4 – 2.4.......... 1.5 – 2.1 N.m

New without oil seal ............................................................. 1.4 – 2.0.......... 1.5 – 1.9 N.m

Used with oil seal................................................................. 0.7 – 1.2.......... 0.7 – 1.2 N.m

Used without oil seal............................................................ 0.7 – 1.2.......... 0. 7 – 1.2 N.m

Differential Carrier side Bearings

Type................................................................................................ Adjustable Tapered Roller

Adjustment...........................................................Screw adjusters on each side of the carrier.

Bearing Pre-Load (Refer to text for measuring procedure) Timken Koyo

New Bearings.......................................................................15 – 35 N................. 8 – 24 N

Used Bearings ......................................................................8 – 18 N.................. 5 – 13 N

Rear Final Drive and Drive Shafts Page 4B1-122

Page 4B1-122

Run-Out Specifications

Outer rear wheel driveshaft Assembly Hub ..........................0.06 mm Total Indicated Run-out

Case Assembly (without ring gear attached) ...........................................0.05 mm (maximum)

Ring Gear Rear Face (assembled to case flange)...................................0.13 mm (maximum)

Backlash Specifications

Ring Gear to Drive Pinion.............................................. 0.10 – 0.18 mm (at the tightest point)

LSD Torque Check

Torque Check Specificat ion......................................................................... 45 Nm (minimum)

ABS Sensor

Air Gap (non-adjustable)......................................................................................0.4 – 1.5 mm

Sealants

Drive Shaft Dust Caps/Shield ..............................RTV 732 Sealant, or commercial equivalent

Rear Cover to Carrier Housing ..................................... Loctite 587 (‘Ultra Blue’) or equivalent

As Required....................................................................Loctite 242 or commercial equivalent

Greases

Where Specified ......NLGI No. 2 lithium soap based EP grease with molybdenum disulphide,

such as Shell Retinax HDX2 grease,

BP Energrease LMS-EP 23, or equivalent.

Where Specified ................................... Commercially available Lithium Soap Based Grease.

Rear Final Drive and Drive Shafts Page 4B1-123

Page 4B1-123

6 Torque Wrench Specifications

ATTENTION

Fastener torque wrench specifications may be accompanied with the following identification marks:

 Fasteners must be repl aced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanic al thread lock and

should only be re-used once. If in doubt, replacement is recommended

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to..

Brake caliper anchor plate to trailing arm bolts.......................................85 N.m

 Collar nut to outer rear wheel driveshaft assembly...............................300 N.m

Crossmember front mounting bolt ........................ 125 N.m, plus 35° turn angle

 Crossmember front mounting brace to underbody bolts.........................75 N.m

 Differential case cap to cover bolt (LSD only).........................................40 N.m

Drain plug...............................................................................................30 N.m

 Drive shaft constant velocity joint bolt.....................50 N.m, plus 90° turn angle

Filler plug................................................................................................30 N.m

 Final drive to crossmember attaching bolts............ 90 N.m, plus 40° turn angle

 Final drive ring gear bolts.....................................................................140 N.m

Rear cover attaching bolt........................................................................27 N.m

Rear disc brake shield to trailing arm. .......Upper bolts..........................75 N.m

 Lower bolts..........................85 N.m

 Rear mount to vehicle underbody attaching bolts.... 35 Nm, plus 60° turn angle

 Rear mount to differential carrier rear cover attaching bolts...................95 N.m

Road wheel attaching nut...........................................................110 – 140 N.m

z Shock absorber lower mounting bolt ....................................................115 N.m

Rear Final Drive and Drive Shafts Page 4B1-124

Page 4B1-124

7 Special Tools

Tool Number Illustration Description Classification

1150

Puller

Used with forcing screw E6661S and

adaptor AU412 to remove side bearing

cups from the screw adjusters.

Previously released.

Unique

205-463

Screw Adjuster Socket

Used for checking and adjusting final

drive side bearings.

(Also released as AU407)

Previously released.

Unique

205-551 Adaptors

Used to remove the pinion bearing cups,

in conjunction with Remover/Installer

E9293. 205-551-1 is require d for all but

the 3.08:1 assembly.

Previously released.

Unique

205-552 Adaptors

Used to install the pinion bear ing cups, in

conjunction with Remover/Installer E 9271.

205-552-2 is requir ed for all but the 3.08:1

assembly. Previously released.

Unique

7208

Rear Axle Removal Adaptor

Previously released.

Unique

7374

Slide Hammer & Plate

Used to remove inner axle shafts from the

rear axle assembly.

Previously released.

Available

AU408

Dummy Arbour

Used with dummy pinion from E9300A.

Previously released.

Unique

Rear Final Drive and Drive Shafts Page 4B1-125

Page 4B1-125

Tool Number Illustration Description Classification

AU409 Press Fixture Unique

AU410

Seal Installer

Used to install inner axle seals to screw

adjuster.

Previously released.

Unique

AU411

Bearing & Cup Remover

Used in conjunction with AU409.

Previously released.

Unique

AU412 Adaptor

Used with forcing screw E6661S and

puller 1150 to remove side bearing cups

from screw adjusters.

Previously released.

Unique

AU416 Torx Bit

Used to remove and reinstall upp er rear

brake backing plate to trailing arm bolts

Previously released.

Unique

AU 534

Torque Limiting Socket

Used in conjunction with an impact gun to

tighten wheel nuts.

Previously released.

Unique

C4150-C

Press Tool

Used to remove rear wheel studs from the

trunnion flange.

Previously released.

Unique

DT-47580

Packing Flange

Fits into the AWD Wagon pinion flang e to

act as a spacer for holding tool J8614-O1.

Previously released.

Available

Rear Final Drive and Drive Shafts Page 4B1-126

Page 4B1-126

Tool Number Illustration Description Classification

DT-47695

Rear Pinion Bearing Cup Remover Unique

DT-47696

Spacer

Used in conjunction with the dumm y

pinion from E9300A when checkin g pin ion

depth on all but 3.08:1 assemblies.

Previously released.

Unique

DT-47735

Holding Tool

Used to hold the final drive pin ion flange

when loosening/tightening the pinion nut.

New release

Unique

DT-47736

Extractor Tool

Used to remove the final drive pinion

flange.

New release.

Unique

DT-47737

Pinion Height Setting Gauge

Includes dummy pinion, 3C10E/11, Pad,

3C10E/13, Sleeve, 3C10E/14, Dummy

Pinion Spacer DT -47696, F orcing Nut,

6651/13 and Arbour AU 408.

Previously released as E9300 A .

New release.

Unique

E1673A15 Basic Puller

Used with adaptors to remove bearings

from the final drive assembly.

Previously released.

Unique

E1673A15 Adaptor

Used with puller E1673MT and stepped

plug E1673B16 to remove the rear pinion

bearing on 3.08:1 assemblies.

Previously released.

Unique

E1673B16

Stepped Plug

Used with puller E1673MT and adaptor

E1673N15 to remove bearings from the

differential case.

Previously released.

Unique

Rear Final Drive and Drive Shafts Page 4B1-127

Page 4B1-127

Tool Number Illustration Description Classification

E1673N15 Adaptor Unique

E1673S15 Adaptor

Used with puller E1673MT to remove the

rear pinion bearing on 3.07:1 and 3.46:1

assemblies.

Previously released.

Unique

E3C10AER

Pinion Rear Bearing Installer

Used to install the rear pinion bearing

during final drive overhaul.

Previously released.

Unique

E308

Seal Remover

Used as a universal seal remover. Also

released as 56750.

Previously released.

Available

E6661S

Forcing Screw

Used in conjunction with puller 1150 and

adaptor AU412.

Previously released.

Unique

E7115

Angle Wrench

Used to tighten fasteners when an angle

torque is specified.

Also released as BT 8653-A

Previously released.

Unique

E9055 Pinion Oil Seal Installer

Used to install the pinion oil seal.

Also released as 17-010A.

Previously released.

Unique

E9271

Pinion Bearing Cup Installer

Used to install the pinion bear ing cups on

3.08:1 assemblies and, with adaptor 205-

552-2, to install the inner pinion bearing

cup on all other ratios.

Previously released.

Unique

Rear Final Drive and Drive Shafts Page 4B1-128

Page 4B1-128

Tool Number Illustration Description Classification

E9277

Side Bearing Installer

Used to install bearings to the differential

case.

Previously released.

Unique

E9293

Pinion Bearing Cup Remover

Used to remove the pinion bearing cups

on 3.08:1 assemblies and, with adaptor

DT-47695, to remove the inner pinion

bearing cup on all other ratios.

Previously released.

Unique

J 3289-20

Holding Fixture Base

Used with either KM480 or fabricated

bracket to hold the final drive assembl y.

Previously released.

Unique

J 8614-O1 Flange/Pulley Holding Tool

Required for AWD Wagon, includes

J 8614-2, J 8614-3 and J 861 4-10.

Previously released.

Unique

J 22610

Clamp Pliers

Used to crimp the drive shaft boot clamps.

Also released as E1896.

Previously released.

Available

J 22912-01

Press Plates

Used in a number of different applicati ons

for separating components when pressing

operations are required.

Previously released.

Unique

KM468

Holding Bar

Used to stop the rear outer rear wheel

driveshaft from rotating.

Previously released.

Available

KM480 Holding Fixture

Modify by drilling two 14 mm holes as

shown. Fixture originall y relea s ed for

THM 125 automatic transaxle (’J’ car).

Previously released.

Unique

KM620-B Remover/Installer

Used for removing and installing outer

rear wheel driveshaft flange and rear

wheel bearing.

Previously released.

Unique

Rear Final Drive and Drive Shafts Page 4B1-129

Page 4B1-129

Tool Number Illustration Description Classification

KM620-7AUS

Supports

These two revised length sup ports are

required when using KM620-B on the rear

outer rear wheel driveshaft and/or

bearing, except for the AWD Wagon.

Previously released.

Unique

Pinion Flange Pulley

Fabricate this pulley to incl ude all VZ applications, inclu ding AWD

models.

1. Made from a 13 mm thick piece of wood.

2. Drill a small hole at '1' and attach a one metr e length of

string at this point, knotted at one end.

3. Drill two, 8.5 mm holes (3) opposite to each other on a pitch

circle diameter of 86 mm (AWD models, pinion flan ge).

4. Drill three, 13 mm holes (2) on a pitch circl e diameter of 96

mm, 120 mm apart (All other VZ models).

Dial Indicator Plate

Used to mount a magnetic based indicator stand when checking

the outer rear wheel driveshaft assembly hub for runout.

Fabricated from 6 mm, flat Mild Steel plate.

If using the brake caliper bolts to fasten to the trailing arm, then 17

mm spacers will need to be installed on each bolt, prior to

installing.

Fabricated Differential Carrier Holding Fixture

If KM480 is not available, fabricate as shown.