Rear Propeller Shaft and Universal Joints 4C1 – 1

4C1 – 1

Section 4C1

Rear Propeller Shaft & Universal Joints

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 Information ...............................................................................................................................3

2 Service Operations.................................................................................................................................7

2.1 Propeller Shaft ....................................................................................................................................................... 7

Remove................................................................................................................................................................... 7

All VZ.................................................................................................................................................................. 7

All VZ With IRS Except AWD Wagon................................................................................................................. 8

VZ AWD Wagon............................................................................................................................................... 10

VZ AWD With Leaf Spring Rear Suspension ................................................................................................... 11

Reinstall................................................................................................................................................................ 12

All VZ With IRS Except AWD Models............................................................................................................... 12

VZ AWD Wagon............................................................................................................................................... 13

VZ With Leaf Spring Rear Suspension............................................................................................................. 14

2.2 Rubber Coupling.................................................................................................................................................. 15

Replace................................................................................................................................................................. 15

2.3 Centre Constant Velocity Joint (Plunge Type) – AWD Wagon......................................................................... 17

Remove................................................................................................................................................................. 17

Disassemble......................................................................................................................................................... 20

Inspect .................................................................................................................................................................. 21

Propeller Shaft and Boot.................................................................................................................................. 21

Constant Velocity Joint..................................................................................................................................... 21

Reassemble.......................................................................................................................................................... 22

Method 1 .......................................................................................................................................................... 22

Method 2 .......................................................................................................................................................... 22

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

2.4 Centre Constant Velocity Joint (Fixed Type) – Live Axle Models.................................................................... 26

Remove................................................................................................................................................................. 26

Inspect .................................................................................................................................................................. 28

Reassemble.......................................................................................................................................................... 29

Reinstall................................................................................................................................................................ 31

2.5 Centre Bearing Assembly ................................................................................................................................... 33

All VZ With V6 Engine and IRS (Except AWD Wagon)...................................................................................... 33

Remove............................................................................................................................................................ 33

Reinstall ........................................................................................................................................................... 35

AWD Wagon Models............................................................................................................................................ 37

Remove............................................................................................................................................................ 37

Reinstall ........................................................................................................................................................... 38

All VZ With a Live Axle........................................................................................................................................ 39

Remove............................................................................................................................................................ 39

Replace............................................................................................................................................................ 41

Rear Propeller Shaft and Universal Joints 4C1 – 2

4C1 – 2

2.6 Fixed, Rear Constant Velocity Joint................................................................................................................... 43

Remove................................................................................................................................................................. 43

Inspect .................................................................................................................................................................. 44

Propeller Shaft and Boot.................................................................................................................................. 44

Constant Velocity Joint..................................................................................................................................... 45

Reassemble.......................................................................................................................................................... 46

Reinstall................................................................................................................................................................ 48

2.7 Rear Plunge Type Constant Velocity Joint – Live Axle Models....................................................................... 49

Remove................................................................................................................................................................. 49

Inspect .................................................................................................................................................................. 51

Disassemble......................................................................................................................................................... 52

Reassemble.......................................................................................................................................................... 53

Reinstall................................................................................................................................................................ 53

3 Specifications.......................................................................................................................................55

4 Torque Wrench Specifications............................................................................................................56

5 Special Tools ........................................................................................................................................57

Rear Propeller Shaft and Universal Joints 4C1 – 3

4C1 – 3

1 General Information

There are a number of rear prope ller shaft assembly variants fitted to the MY2005 VZ range of vehicles. These variati ons

are due to the different engines, transmissions, exhaust and drive systems employed within the vehicle range.

The only common factors being that each propeller shaft assembly is of a two piece tubular design, incorporating a

sealed-for-life centre support bearing. The centre support bearing is a fully seale d ball be aring, mounted in a reinforced

rubber cup. This centre bearing rubber cup is supported in a cup guide and attached to a carrier, which is bolted to the

vehicle underbod y brac e. Depending on the exhaust system fitted to the vehicle and/or wheth er a specific tow bar

package is fitted, a heat shield may also be fitted to the centre bearing carrier. No periodic servicing of the centre bearing

nor any universal joint, is required .

For those MY2005 VZ vehicles with independent coil spring rear suspension (except V6 engined, six speed manual and

five speed automatic transmission models), servicing of the centre bearing is not possible. The reason for the non-

serviceability is that the interfe rence fit of the splin ed joint between the front and rear propeller shaft halves is such that

special tools and high press forces are re quired to separate the two shafts. As this operation would also require the re-

balancing of the propeller sha ft assembly, the centre bearing assembly and/or slinger are also non-servi ceable.

For those MY2005 VZ models fitted with the V6 engine and six speed manual or five speed automatic transmission, the

centre bearing assembl y, slip joint bo ot and clamp are serviced.

Other variations can be summarised by the following descriptions:

Front Universal Joint: While all propeller shafts have a rubber coupling in this location, dependent upon the

transmission, the coupling may be attached to the transmission output shaft, by a special thread formed bolt to the

transmission output flange (V6 Manual T r ansmission), b y nuts over special thread forme d stud (AWD transfer case), by a

bolt and nut (V6 5L40-E – automatic transmission) or by being bolted to a slip yoke that is splined to the output shaft

(GEN III V8 and manual or automatic transmission or V6 and 4L60-E four speed automatic transmission).

Centre Universal Joint: This design can b e a conventional cross type universal joint (Hooke’s joint) mou nted behind the

centre bearing, a plunge design constant velocity joint (AWD Wagon) or a fixed design constant velocity joint (those

vehicles with a live axle and leaf spring re ar suspension).

The cross type universal joint t ype is non-ser v iceable, as the bearing cups are set and retained by staking. T his requires

sophisticated equipment to ensure concentricity of the installed universal joi nt.

Rear Universal Joint: Again a number of variants are possible, depe nding on the application. For all independent coil

spring rear suspensions, except AWD Wagon, a rubber coupling is fixed to the rear final drive pinion flange by three

special thread formed bolts. The AWD Wagon has a fixed constant velocity joint and al l live axle with leaf spring

suspension vehicles have a plunge design constant velocity joint. Either of the constant velocity universal joints is fixed to

the final drive pinion by six bolts.

Provided the service information contained in this Section is followed, all constant velocity joints are able to be serviced.

Rear Propeller Shaft and Universal Joints 4C1 – 4

4C1 – 4

Figure 4C1 – 1 – All With IRS Except AWD Wagon

Legend

A1 Front Coupling – V6, 5L40-E Automatic Transmission (Early)

A2 Front Coupling – V6 Manual Transmission

A3 Front Coupling – V6, 5L40-E Automatic Transmission (Late)

A4 Front Coupling – GEN III V8 Manual/Automatic and V6,

4L60-E Automatic Transmission

B Centre Bearing

C Rear Coupling to Final Drive Pinion Flange

1 Front Rubber Coupling

2 Coupling to Transmission Stud Nut (3 Places)

3 Coupling to Transmission Flange Bolt (3 Places)

4 Coupling to Transmission Flange Bolt (3 Places)

5 Coupling to Transmission Flange Nut (3 Places)

6 Centre Bearing Cup Guide to Underfloor Bolt (2 Places)

7 Centre Bearing Cup Guide

8 Heat Shield – Centre Bearing (Where Fitted)

9 Rear Coupling To Final Drive Opinion Flange Bolt (3 Places)

Rear Propeller Shaft and Universal Joints 4C1 – 5

4C1 – 5

Figure 4C1 – 2 – AWD Wago n

Legend

1 Centre Bearing Carrier Assembly

2 Centre Bearing Carrier Retaining Bolt (2 Places)

3 Front Rubber Coupling

4 Front Coupling Retaining Nut (3 Places)

5 Front Constant Velocity Joint (Plunge Type)

6 Heat Shield

7 Heat Shield Retaining Clip (2 Places)

8 Rear Constant Velocity Joint Retaining Bolts (6 Places)

9 Rear Constant Velocity Joint (Fixed Type)

10 Locking Plate (3 Places)

Rear Propeller Shaft and Universal Joints 4C1 – 6

4C1 – 6

Figure 4C1 – 3 – Leaf Spring Rear Suspension

Legend

1 Front Rubber Coupling

2 Front Coupling to Transfer Case Flange Nuts (3 Places)

3 Centre Bearing Carrier Attaching Bolts and Nuts (2 Places)

4 Centre Bearing Carrier

5 Heat Shield (Where fitted)

6 Centre Bearing Cup Guide - Upper and Lower

7 Rear Constant Velocity Joint, Torx Headed Bolts (6 Places)

8 Rear Constant Velocity Joint Attaching Bolt Lock Plates

(3 Places)

Rear Propeller Shaft and Universal Joints 4C1 – 7

4C1 – 7

2 Service Operations

ATTENTION

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

result in major repair expense. W here specified in this Section, fasteners MUST be replaced w ith parts of the

same part number or an approved equivalent. Do not use fasteners o f an inferior quality or substitute design.

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 mechanical thread lock and

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

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

recommendation regarding that fastener must be adhered to.

2.1 Propeller Shaft

LT Section No. – 05-050

ATTENTION

The following fasteners have either micro encapsulation or incorporate a mechanical thread lock and should

only be used once. If in doubt , rep lacement is recommended when performing these operations:

 Propeller shaft rear constant velocity joint to pinion flange bolts.

The following fasteners MUST be replaced when performin g these operations:

 Rubber coupling to transmission/transfer case, rear output flange retaining bolts and nuts.

Remove

All VZ

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

support points.

2 To provide access to the propeller shaft fasteners, it is recommend ed that the intermediate exhaust pipe,

intermediate and rear muffler assemblies be removed. For information regarding the removal and installation

procedures for these components, refer to Section 8B Exhaust System.

Rear Propeller Shaft and Universal Joints 4C1 – 8

4C1 – 8

All VZ With IRS Except AWD Wagon

Front Coupling Attached to the Transmissi on/Transfer Case Output Flange

A number of different methods of attaching

the front coupling to the transmission output

flange can be noted:

• Hexagon headed bolts into threaded

flange holes. With this method, the output

flange threads are of the 'Spiralock' form

that can only be loosened/tightened a

maximum of ten times. Because of the

safety factor involved, if the complete

vehicle service history is not known, then

both the flange and the bolts MUST be

replaced on reassembly.

• Studs installed into the transmission

output flange facing rearward, with the

flange being secured by nuts.

• Hexagon headed bolts and nuts.

Figure 4C1 – 4 shows this method.

NOTE

If the reason for removing the propeller shaft is

not related to the front rubber coupling, then it is

recommended that the three bolts and nuts

securing the propeller shaft to the front coupling

be removed, leaving the coupling attached to the

transmission output shaft flange.

Release the park brake to relax any ‘wind-up’

in the flexible rubber coupling. Otherwise,

when the propeller shaft bolts are released

from the final drive pinion flange, personal

injury may result.

3 Select the Park/1st gear position with the transmission selector lever.

4 To enable the propell er shaft to be reinsta lled in the

original position relative to the transmissi on output

shaft flange, use a felt tipped pen or similar t o ide ntify

the relationship (‘A’) of the t wo components.

5 Using suitable socket equipment, loosen the three

bolts (2) and nuts (3) and securing the front coupling

(1) to the transmission output flange

6 With the transmission shift lever in the Neutral position

and the park brake released, remove the three Torx

headed bolts.

Figure 4C1 – 4

Rear Propeller Shaft and Universal Joints 4C1 – 9

4C1 – 9

All VZ With IRS Except AWD Wagon

7 To enable the propell er shaft to be reinsta lled in the

original position relative to the final drive pinion flange,

use a felt tipped pen or similar to identify the

relationship (‘A’) of the two components.

8 With the transmission in the Park/1st gear position,

check that the park brake is firmly applied.

9 Use Torx socket K04425E20 or a commercially

available E20 Torx equivalent to loosen the three Torx

headed bolts (1) securing the propeller shaft rear

rubber coupling (2) to the pini on flange (3).

10 Release the park brake to relieve any torque loading

on the rubber coupling, then remove the three Torx

headed bolts (1)

Figure 4C1 – 5

11 Remove the two centre bearing carrier (1) to

underbody reinforcement bolts (2).

12 While supporting the centre beari ng section, slide the

propeller shaft assembly forward to disengage from

the final drive pinion support pin, then lower the

assembly at the rear, sliding rearward to disengage

the front coupling.

13 Remove the propeller shaft assembly from the vehicle.

Figure 4C1 – 6

For VZ Series Models with a Sliding Front Y oke:

14 After completing all Steps except 4 to 6 inclusive, slide the propeller shaft assemb ly rearward to disengage the front

yoke from the transmission output shaft splines. Durin g this process:

a Locate a clean drain tray under the rear of the transmission to catch any spilled lubricant when the propeller

shaft is removed.

b Take care to protect the outer diameter of the front yoke. Nicks or abrasions will damage the transmission

extension seal during reassembly and result in subsequ ent lubricant leakage from this area.

c Insert a suitable plug in the end of the transmission re ar extension to prevent loss of transmission lubric ant.

Rear Propeller Shaft and Universal Joints 4C1 – 10

4C1 – 10

VZ AWD Wagon

1 Select the Park position with the transmission selector

lever.

2 To enable the propell er shaft to be reinsta lled in the

original position relative to the transfer case output

shaft flange, use a felt tipped pen or similar t o ide ntify

the relationship (‘A’) of the t wo components.

3 Using suitable socket equipment, loosen the three

nuts (2) and securing the front coupling (1) to the

transfer case output flange.

4 With the transmission shift lever in the Neutral position

and the park brake released, remove and discard the

removed nuts (2) as they must be replaced o n

reassembly.

Figure 4C1 – 7

5 To enable the propell er shaft to be installed in the

original position relative to the pinion flange, use a felt

tipped pen or similar (e.g. whiteout) to ide ntify the

relationship of the two components (‘A’).

If all six bolts are removed, the rear of the

propeller shaft must be supported using tie

wire or similar. Do not allow the propeller

shaft to hang, placing undue stress on the

front constant velocity joint and/or boot.

6 With the transmission in the ‘Park’ position and the

park brake firmly applied, loosen the six Torx bit

headed bolts (1), using a T 50 Torx bit and suitable

socket equipment.

7 Remove five of the six bolts and two locking plates (2)

securing the propeller shaft rear constant vel ocity joint

(3) to the final drive pinion flange (4). Do not remove

the sixth bolt at this time. Figure 4C1 – 8

8 Remove the two centre bearing carrier (1) to

underbody reinforcement bolts (2).

9 While supporting the centre beari ng section, remove

the final bolt (and locking plate) from the pinion flange.

10 Slide the propeller shaft assembly forward to

disengage from the final drive pinion flange, then lower

the assembly at the rear, sliding rearward to

disengage the front rubber coupling from the transfer

case output flange studs.

11 Remove the propeller shaft assembly from the vehicle.

Figure 4C1 – 9

Rear Propeller Shaft and Universal Joints 4C1 – 11

4C1 – 11

VZ AWD With Leaf Spring Rear Suspension

1 Select the Park position with the transmission selector

lever.

2 To enable the propell er shaft to be reinsta lled in the

original position relative to the transfer case output

shaft flange, use a felt tipped pen or similar t o ide ntify

the relationship (‘A’) of the t wo components.

3 Using suitable socket equipment, loosen the three

nuts (2) and securing the front coupling (1) to the

transfer case output flange.

4 With the transmission shift lever in the Neutral position

and the park brake released, remove and discard the

removed nuts (2) as they must be replaced o n

reassembly.

Figure 4C1 – 10

5 Use a suitable felt tipped marking pen to ma rk the

relationship of the rear constant velocit y joint (1) to the

rear axle pinion flange (2).

6 Remove the propeller shaft rear constant vel ocity joint

(1) to rear axle pinion flange (2) attaching bo lts and

locking plates.

NOTE

When removing the rear constant velocity joint

from the rear axle pinion flange, take care no t to

disturb the end cap of the constant velocity joint.

The end cap has a gask et to prevent the entr y of

foreign matter.

Figure 4C1 – 11

7 Loosen but do not fully remove the centre bearing

carrier bracket attaching bolts (1).

8 To remove the propeller shaft assembly from the

vehicle:

a Carefully prise the rear const ant velocity joint to

free it from the rear axle pinion flange, then push

forward to free the constant velocity joint from

the pinion flange lip.

b While supporting the rear propeller shaft half and

the centre bearing, fully remove both centre

bearing carrier bolts.

c Lower the rear of the propeller shaft and move

rearward to free the front coupling from the

transfer case studs.

d Continue to move the propeller shaft rearwards,

manoeuvring past the exhaust system, then

remove the propeller shaft assembly from the

vehicle. Figure 4C1 – 12

Rear Propeller Shaft and Universal Joints 4C1 – 12

4C1 – 12

Reinstall

All VZ With IRS Except AWD Models

Reinstallation is the reverse of removal procedures, except for the following items:

1 Lubricate the transmission rear output shaft and final drive pinion spigots with a molybdenum disulphide grease

such as an NLGI No. 2 lithium soap based EP grease with molybdenum disulphide, such as Shell Retinax HDX2

grease or BP Energrease LMS-EP 23 (or eq uivalent).

2 Reinstall the front of the propeller shaft assembly first, supporting the centre and rear sections.

3 Align the marks made before removal (refer to Figure 4C1 – 4) temporarily install either a coupling to flan ge bolt

and nut or nut to secure the propeller sh aft in this position.

4 While supporting the rear section, raise the centre bearing assembly and install the bolts and spring washers to

secure to the underbody r einforcement. Tighten both bolts to the correct torque specification.

Centre bearing carrier to underbody

reinforcement bolt torque specification ................22 N.m

5 Before installing the rear coupling to fin al drive flange bolts, align the marks made before remova l, refer to

Figure 4C1-5.

6 Provided no thread damage is evident, reinstall the original rear propeller shaft coupling to the final drive pinion

flange, Torx headed bo lts, tightening to the correct torque specification.

Propeller shaft rear coupling to pinion

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

Front Coupling Attached to the Transmission Output Flange

7 If bolts are used to secure the coupling to the transmission output flange, provid ed no thread damage is evident,

the original front propeller shaft coupling bolts may be re-used up to a maximum of ten times:

a Reinstall the three bolts and tighten to the correct torque specification.

b If bolts and nuts are used to secure the coupling to the tran smission output flange, install NEW bolts and nuts

and tighten to the correct torque specification.

Front coupling to transmission output

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

 Front coupling to transmission output

flange bolt and nut torque specification..............115 N.m

c If nuts are used to secure the front coupling to the transmission output flange studs, insta ll NEW nuts and

tighten to the correct torque specification.

 Front coupling to transmission output

flange nut torque specification .............................85 N.m

For VZ Models with a Sliding Front Yoke:

8 Clean the sliding yoke bearing surface, inspect for nicks or other damage.

9 If considered serviceable, lubricate the sli ding yoke with the recommended transmission lubricant, reinstall to the

transmission output shaft splines.

10 Lubricate the final drive pinion spigot with a molybdenum disulphide grease such as an NLGI No. 2 lithium soap

based EP grease with molybdenum disulph id e, such as Shell Retinax HDX2 grease or BP Energrease LMS-EP 23

(or equivalent).

11 While supporting the centre beari ng offer the rear coupling up to the final drive pinion flange and temporarily install

one of the retaining bolts to secure in this position.

Rear Propeller Shaft and Universal Joints 4C1 – 13

4C1 – 13

12 Raise the centre bearing assembly and install the bolts with spring washers to secure to the underbody

reinforcement. Tighten both bolts to the correct torque specification.

Centre bearing carrier to underbody

reinforcement bolt torque specification ................22 N.m

13 Before installing the rear coupling to fin al drive flange bolts, align the marks made before removal, refer to

Figure 4C1-5.

14 Provided no thread damage is evident, reinstall the original rear propeller shaft coupling to the final drive pinion

flange, Torx headed bo lts, tightening to the correct torque specification.

Rear coupling to pinion flange

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

15 Reinstall the exhaust system, refer to Section 8B Exhaust System, for the procedures an d clearances.

16 Road test the vehicle to check for correct operation.

VZ AWD Wagon

Reinstallation is the reverse of removal procedures, except for the following items:

1 Lubricate the transfer case out put spigot with a molybdenum disulphide gr ease such as an NLGI No. 2 lithium soap

based EP grease with molybdenum disulph id e, such as Shell Retinax HDX2 grease or BP Energrease LMS-EP 23

(or equivalent).

2 Align the transfer case output flange studs with the rubber coupling, while supporting the centre and rear sections.

3 While supporting the rear section, raise the centre bearing assembly, reinstall the t wo bolts and spring washers to

secure to the vehicle underbody reinforcement and tighten to the correct torque specification.

Centre bearing carrier to underbody

reinforcement bolt torque specification ................22 N.m

4 Slide the propeller shaft assembly forward to allow engagement of the rear constant velocity joint to the final drive

pinion flange, then slide rearward to fully engage.

5 Before reinstalling the attaching bolts and locking plates into the rear constant veloc ity joint and pinion flange, align

the marks on the pinion flange and rear joint, that were made prior to removal, refer to Figure 4C1-8.

6 Clean the threads of the six, rear constant velocity joint to pinion flange bolts, apply a thread sealant such as

Loctite 242 or equivalent, the n reinsta ll with locking plates and tighten to the correct torque specification, using a

T50 Torx bit and suitable sock et equipment.

(  ) Rear constant velocity joint to

pinion flange bolt torque specif ication

(V6)...................38 N.m

(GEN III V8)......68 N.m

7 Reinstall NEW retaining nuts to secure the front rubber coupling to the transfer case rear output flange studs.

8 Tighten the coupling nuts to the correct torq ue specification.

(  ) Rubber coupling to transfer case

output shaft flange retaining

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

9 Reinstall the exhaust system, refer to Section 8B Exhaust System for the procedures and clearances.

Rear Propeller Shaft and Universal Joints 4C1 – 14

4C1 – 14

VZ With Leaf Spring Rear Suspension

Reinstallation of the propeller shaft assembly is the reverse of the removal procedure noting the following points:

NOTE

Dependent upon a range of variables relating to

engine and transmissio n combinations, a number

of front rubber coupling attachment means are

possible.

Front Coupling Attached to the Transmissi on/Transfer Case Output Flange

1 Lubricate the transmission/transfer case output spigot with a molybdenum disulphide grease such as an NLGI No.

2 lithium soap based EP grease with molybd enum disulphide, such as Shell Retinax HDX2 grease or BP

Energrease LMS-EP 23 (or equivalent).

2 If bolts are used to secure the coupling to the transmission output flange, provid ed no thread damage is evident,

the original front propeller shaft coupling bolts may be re-used up to a maximum of ten times:

a Reinstall the three bolts and tighten to the correct torque specification.

b If bolts and nuts are used to secure the coupling to the tran smission output flange, install NEW bolts and nuts

and tighten to the correct torque specification.

Front coupling to transmission output

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

 Front coupling to transmission output

flange bolt and nut torque specification..............115 N.m

c If nuts are used to secure the front coupling to the transmission output flange studs, insta ll NEW nuts and

tighten to the correct torque specification.

 Front coupling to transmission output

flange nut torque specification .............................85 N.m

For MY 2005 VZ Models with a Sliding Fr ont Yoke:

3 Clean the sliding yoke bearing surface, inspect for nicks or other damage.

4 If considered serviceable, lubricate the sli ding yoke with the recommended transmission lubric ant, then reinstall the

slip yoke to the transmission output shaft splines.

For all VZ With Leaf Spring Rear Suspens ion

5 While supporting the rear section of the propeller shaft, raise the centre bearing assembly and install the two bolts

with spring washers, tightening to the correct torque specification.

Centre bearing carrier to underbody

reinforcement bolt torque specification ................22 N.m

6 Before reinstalling the attaching bolts and locking plates into the rear constant veloc ity joint and pinion flange, align

the marks on the pinion flange and rear joint, that were made prior to removal, refer to Figure 4C1-11.

NOTE

Take care not to disturb the end cap of the

constant velocity joint. The end cap has a gasket

to prevent contamination by foreign material.

7 Clean the threads of the six, rear constant velocit y joint to pinion flange bolts, then apply a thread sealant such as

Loctite 242 or equivalent.

8 Reinstall the six bolts and locking plates.

9 Gradually tighten the six rear constant velocity joint to rear final drive pinion flange bolts, working in an opposite

pattern to draw the constant velocity joint into the rear axle pinion flange until it is fully installed.

10 Finally, tighten the six bolts to the correct torque specification.

() Rear constant velocity joint to the

pinion flange bot torque specif ication:

V6 Engine ....................38 N.m

GEN III V8 Engine........68 N.m

11 If removed, reinstall the exhaust system, refer to Section 8B Exhaust System, for the procedures an d clearances.

12 Road test the vehicle to check for correct operation.

Rear Propeller Shaft and Universal Joints 4C1 – 15

4C1 – 15

2.2 Rubber Coupling

LT Section No. – 05-050

ATTENTION

The following fasteners have either micro encapsulation or incorporate a mechanical thread lock and should

only be used once. If in doubt , rep lacement is recommended when performing these operations:

 Propeller shaft rear constant velocity joint to final drive pinion flange (where applicable).

The following fasteners MUST be replaced when performin g these operations:

 Rubber coupling to transmission output flange/transfer case flange, slip joint or final drive pinion flange

bolts and nuts.

NOTE

While this operation details the procedure to

replace a rubber coupling where a slip yoke is

fitted, the procedure for all couplings is similar.

Replace

1 Remove the propeller shaft. Refer to 2.1 Propeller Shaft in this Section.

2 Using a back-up spanner on each of the three propeller shaft to coupling bolts (2), loosen then remove the nuts (1).

Discard the removed bolts and nuts. Remove the coupling from the front of the propeller shaft.

NOTE

View ‘A’ shows the rubber coupling to flange

arrangement (front or rear) while view ‘B’ shows

the front coupling arrangement when a slip yoke

is utilised.

Figure 4C1 – 13

Legend

1 Nut – Coupling to Propeller Shaft (3 Places)

2 Bolt – Coupling to Propeller Shaft (3 Places)

3 Nut – Coupling to Slip Yoke (3 Places)

4 Slip Yoke Flange

5 Bolt – Coupling to Slip Yoke (3 Places)

A Spigot Bush Requiring Lubrication

Rear Propeller Shaft and Universal Joints 4C1 – 16

4C1 – 16

3 Referring to view ‘B’, use a back-up spanner on each of the three, propeller shaft slip yoke bolts (5), loosen then

remove the nuts (3). Discard the removed bolts and nuts. Remove the sliding yoke from the coupling.

4 Install a replacement rubber coupling onto the end of

the propeller shaft, aligning the holes in such a way

that the triangular shape (‘A’) on the coupling ‘points’

to the propeller shaft flange lug (1), as shown.

5 Install NEW bolts and nuts to secure the couplin g to

the propeller shaft flange and tighten to the correct

torque specification, using a back-up sp anner on the

bolt head and angle wrench E 7115 to measure the

turn angle.

(  ) Propeller shaft to rubber coupling

nut torque specification.......................................20 N.m,

then 55° turn angle

6 Lubricate the spigot bush in the propeller shaft end (or

the slip yoke bushing) with 0.5 gm of a molybdenum

disulphide grease such as an NLGI No. 2 lithi um soap

based EP grease with molybdenum disulph id e, such

as Shell Retinax HDX2 grease or BP Energrease

LMS-EP 23 (or equivalent). Figure 4C1 – 14

7 Reinstall the sliding yoke bush onto the propeller shaft spigot and align the three bolt holes.

NOTE

If the rear bolts were placed correctly (refer to

Step 4), the triangular shapes (’A’) will ‘point’ to

the sliding yoke flange bo lt holes.

8 Install NEW bolts and nuts to secure the couplin g to the slip yoke flange and tighten to the correct torque

specification, using a back-up spanner on the bolt head and angle wrench E 7115 to measure the turn a ngle.

 Propeller shaft to rubber coupling

nut torque specification.......................................20 N.m,

then 55° turn angle

9 Reinstall the propeller shaft, Refer to 2.1 Propeller Shaft in this Sectio n.

Rear Propeller Shaft and Universal Joints 4C1 – 17

4C1 – 17

2.3 Centre Constant Velocity Joint (Plunge

Type) – AWD Wagon

LT Section No. – 05-050

There are two repair kits available, for this centre, constant velocity joint repairs:

a A DUST SHIELD KIT, which contains dust shield, gasket, strap, and tubes of grease and sealant (or gasket).

b A CONSTANT VELOCITY JOINT KIT, which contains the same items as in the DUST SHIELD KIT, plus the

constant velocity joint and appropriate retaining circlips.

Remove

Figure 4C1 – 15

Legend

1 Heat Shield

2 Propeller Shaft Splined Shaft – Front Section

3 Boot Clamp

4 Propeller Shaft – Rear Section

5 Circlip

6 Grease Cover

7 Front Constant Velocity Joint Assembly

8 Locking Plate (3 Places)

9 Allen Key Headed Screws - 6 Places

10 Dust Shield and Boot Assembly

11 Centre Bearing and Support Bracket Assembly

12 Inner Slinger

13 Outer Slinger

14 Propeller Shaft Tube – Front Section

1 Remove propeller shaft. Refer to 2.1 Propeller Shaft in this Section.

Rear Propeller Shaft and Universal Joints 4C1 – 18

4C1 – 18

2 To ensure correct alignment of parts at reassembly,

scribe an aligning mark on constant velocity joint (2)

and the rear propeller shaft mounti ng flange (3).

During the disassembly process, the front

propeller shaft half must be supported (e.g.

lay on the bench top) to avoid an excessive

joint angle.

3 While holding the rear half of the pro peller shaft in a

vice fitted with soft jaws, remove the six, 6 mm Allen

key headed screws (1) and three lock plates (4), using

suitable socket equipment.

4 If necessary, tap the sides of the constant velocity joint

(2) to free it from the rear section mounting flange (3).

Figure 4C1 – 16

5 Secure the constant velocity joint in a vice fitted with

soft jaws (1).

6 Using a cold chisel (2) and hammer, dislodge and

remove the grease cover (3) from the end of the

constant velocity joint.

7 Discard the removed cover.

Figure 4C1 – 17

8 Reposition the constant velocit y joint in the soft faced

vice jaws, then use a brass drift and hammer to tap

constant velocity joint dust shield (1) to dislodge it from

the constant velocity joint (2).

9 Using a small bladed screwdriver, lever the clamp tang

(3) upward releasing it from the clamp barbs. Remove

and discard the clamp.

Figure 4C1 – 18

Rear Propeller Shaft and Universal Joints 4C1 – 19

4C1 – 19

10 Wipe excess lubricant from the constant velocity joint,

then remove the retaining circlip (1).

Figure 4C1 – 19

11 Pull back constant velocit y joint outer race. Install

suitable press plates (approximately 8 mm thick),

between dust shield and constant velocity joint, to

support inner joint race (1). Press the front half of

propeller shaft from constant velocity joint, using a

suitable drift (2).

NOTE

Press plates J22912-01 are too thick to fit

between the constant velocity joint and the dust

shield.

12 Clean old gasket material from dust shield a nd

constant velocity joint mating surfaces. Figure 4C1 – 20

Rear Propeller Shaft and Universal Joints 4C1 – 20

4C1 – 20

Disassemble

Disassembly of the constant velocity joint 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 subsequent premature failure

of the joint. However, if disassembly must be

attempted, then it is vital that the following

procedure is carefully followed.

1 Obtain a piece of wood or suitable tray with enou gh depressions in the surface to accommodate the six balls of the

constant velocity joint, marking one divot to indic ate the ball closest to the alig nment marks to retain the original

orientation of each ball to its working components.

2 Remove the excess lubricant from the constant

velocity joint, wipe clean and mark the relationship of

the inner race, ball guide a nd outer race, using

correction fluid.

Figure 4C1 – 21

3 Pivot inner race and ball guide at 90° to centre line of

outer race as shown, and lift inner race, ball guide and

six balls as an assembly, from outer race.

NOTE

Even with grease surrounding the constant

velocity joint components, be careful not to allo w

any balls to slip from the cage. Each ball must

be reinstalled in its original position.

Figure 4C1 – 22

Rear Propeller Shaft and Universal Joints 4C1 – 21

4C1 – 21

4 Using a small screwdriver, lever balls from guide, as

shown. Keep balls in order, relative to the alignment

marks made in Step 1, for reassembly.

NOTE

Dependent on the length of time the constant

velocity joint has been in ser vice, individual balls

could slip from the cage and not require prising

to release.

5 Lift the inner race from the ball guide.

Figure 4C1 – 23

Inspect

Propeller Shaft and Boot

1 Clean propeller shaft, boot and dust shield in a suitable cleaning solvent.

2 Inspect propeller shaft for visible damage and twisting, cracking or excessive spline wear.

NOTE

If any damage is evident then the propeller shaft

must be replaced.

3 Inspect boot and dust shield, replacing if split, fatigued, cracked or worn.

4 Check that the vent hole in the front flange of the rear propeller shaft half, is clear and not blocked with mud or

other debris.

Constant Velocity Joint

1 Inspect the grease in the joint for contamination and/or dirt ingress. If either of these conditions is evident, then the

constant velocity joint will most probab ly have suffered damage and should be replac ed. If inspection shows that

the joint has not been contaminated, clean the joint by soaking in a suitable cleaning solvent.

2 Clean all components in suitable solvent, ensuring that the part relationships remain undisturbed.

3 Carefully inspect all compo ne nts for signs of severe p itting, galling, play between balls and the cage windows, any

cracking or damage to cage, pitting or galling or chips i n race ways. Repla ce the constant velocity joint if any of

these conditions are evident.

Shown is an exploded view of the centre propeller shaft

constant velocity joint. Note the two identification grooves on

the outer race (4) and the step (5) on the inner race (1).

These features and the angled ball tracks, identify that this

is a ‘plunge’ joint, when assembled.

NOTE

• The inner race (1) and cage (2), together with

the individual balls (3), must be maintained in

their original locations to minimise the

creation of a noisy joint.

• Under no circumstances are components

from one constant velocity joint to be mixed

with components from another constant

velocity joint.

Figure 4C1 – 24

Rear Propeller Shaft and Universal Joints 4C1 – 22

4C1 – 22

Reassemble

Method 1

1 Provided the balls are held captive in the ball cage when installed, reinstall each in its correct position.

2 While holding the inner race, cage and the six balls in position, reinstall to the outer race by turning the inner

assembly at 90° to the outer race, reinstall the two balls in their raceways, then rotate the inner assembly, to fully

reinstall. Refer to Figure 4C1- 27.

3 Check that the relationship marks are ali gned, refer to Figure 4C1-26.

Method 2

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

centrally within the cage, as sho wn in vie w ‘A’. Align

the relationship marks to confirm correct installation

NOTE

The flange on the inner diameter of the inner

race should be on the s ame side as the chamfer

on the inner edge of the ball c age.

Figure 4C1 – 25

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

(1), as shown.

3 Align a thick section (A) on the outer race, with a

narrow one (B) on the inner race. Note that the

relationship marks are also in alignment

Figure 4C1 – 26

4 Tilt the cage and inner race as shown, and fit the first

ball (1) in its original location.

Repeat this process for the remaining five balls.

Figure 4C1 – 27

Rear Propeller Shaft and Universal Joints 4C1 – 23

4C1 – 23

5 When assembly of the constant velocity joint is

complete, check for plunge movement of the inner

members (1), 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.

NOTE

The total plunge movement for the centre

constant velocity joint should be approximately

28 mm.

Figure 4C1 – 28

Reinstall

Installation is the reverse of removal procedure, noting the following points:

1 Cleanliness of constant velocity joint and associated parts is vital to ensure maximum life.

2 Install a new boot clamp at the small end of the dust boot.

3 From the 45 grams of lubricant suppli ed with the constant velocity joint repair kit for this application, insert

approximately 20 grams into the boot, half of the remainder into the joint itself and the final quarter into the dust

cap. Avoid having any grease in the centre of the dust cap, over the breather hole.

4 Clean mating surfaces of constant velocity joint, dust shield and rear propeller shaft companion flange.

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

Temperature Gasket Eliminator sealant or equivalent

to the dust shield and boot assembly mating surface.

Take care not to contaminate the constant velocity

joint grease with sealant.

6 Install a new boot clamp over the propeller shaft

splines.

7 Install the dust shield and boot assembly over the

propeller shaft splines, taking care not to damage the

boot in the process.

Figure 4C1 – 29

Rear Propeller Shaft and Universal Joints 4C1 – 24

4C1 – 24

8 Before pressing the constant velocity joint onto the

splined propeller shaft, support the shaft end (2) with a

suitable length of tube (1) of dimensions 48 mm OD,

32 mm ID and at least 30 mm long.

Figure 4C1 – 30

9 Press constant velocity joint (2) onto shaft using

installer J21426 or a suitable size socket or tube.

Ensure that the press force is applied to the inner rac e

(1), as shown.

10 Using circlip pliers, install a ne w circ lip to retain the

constant velocity joint. Be careful not to over-expand

the circlip during the installati on process.

11 Insert three attaching bolts through the dust shield

flange to align with the constant velocity joint, then tap

the dust boot flange assembly into place.

Figure 4C1 – 31

12 Apply Loctite 510 High Temperature Gasket Eliminator

sealant or equivalent, to the flanged area of propeller

dust cover, taking care not to contaminate the

constant velocity joint grease with sealant.

Figure 4C1 – 32

Rear Propeller Shaft and Universal Joints 4C1 – 25

4C1 – 25

13 With the three attaching bolts (2) still installed through

the dust boot flange and constant velocity joint, install

then tap a new dust boot cover (1) into place, over the

constant velocity joint.

14 Clean threads in rear propeller shaft companion flange

and the six Allen head bolts. Apply Loctite 242 or

equivalent thread sealant to the bo lt threads.

Figure 4C1 – 33

15 Ensure that the relationship marks on the constant velocity joint, dust boot flange and rear propeller shaft flange

(made before disassembly), are all aligned.

16 Reinstall and tighten the six Allen headed screws to the correct torque spe cification.

(  ) Centre constant velocity joint to

rear propeller shaft flange

bolt torque specification.......................................35 N.m

17 After locating the boot into the recess in the dust boot

groove, engage the strap of the clam p with the barb.

18 Tighten the new clamp (1) usi ng keystone clamp pliers

such as J 22610 or commercial equivale nt.

19 Reinstall propeller shaft. Refer to 2.1 Propeller Shaft in

this Section.

Figure 4C1 – 34

Rear Propeller Shaft and Universal Joints 4C1 – 26

4C1 – 26

2.4 Centre Constant Velocity Joint (Fixed

Type) – Live Axle Models

LT Section No: 05-050-1

ATTENTION

The following fasteners have either micro encapsulation or incorporate a mechanical thread lock and should

only be used once. If in doubt, replacement is recommended when performing this operation:

 Constant velocity joint to rear propeller shaft attaching bolts.

Remove

1 Remove the propeller shaft. Refer to 2.1 Propeller Shaft in this Section.

2 To ensure correct alignment of parts at reassembly,

scribe an aligning mark (or use a felt tipped pen) on

the constant velocity joint (2) and the rear propeller

shaft mounting flange (3).

3 While holding the rear half of the pro peller shaft in a

vice fitted with soft jaws, remove the six, 6 mm Allen

key headed screws (1) and three lock plates (4),

using suitable socket equipm ent.

4 Using a plastic hammer, tap the sides of the propeller

shaft rear half, companion flange (3) to break the

paint seal, then separate the two propeller sh aft

halves.

Figure 4C1 – 35

5 Using suitable circlip pliers (1), remove the constant

velocity joint, retaining circlip (2) from the front

propeller shaft spindle.

Figure 4C1 – 36

Rear Propeller Shaft and Universal Joints 4C1 – 27

4C1 – 27

6 Support the constant velocity joint body (1) in a vice

fitted with soft jaws. Using a brass drift and hammer

gently tap the dust cover and rubber boot assembly

(4) from the body of the constant velocity joint.

7 Remove the retaining clamp (3) attaching the rubber

boot (4) to the front propeller shaft spindle (5) by

releasing the clamp tang with a small bladed

screwdriver.

8 Push the dust cover and rubber boot assembly (4)

back toward the propeller shaft centre bearing (2).

Figure 4C1 – 37

9 Remove the centre bearing ca rrier retaining nuts (2)

and bolts (3), the support carrier strap (1) and the

heat shield (4), if fitted.

10 Separate the centre bearing cup guide halves (5 and

6), removing them from the centre bearing assembl y.

Figure 4C1 – 38

11 Remove the excess lubricant from the constant

velocity joint (1), wipe clean, then use a felt tipped pen

or correction fluid (2), to identify the relations hip of the

three joint components.

12 Remove the gasket (3) bet ween the propelle r shaft

companion flange and the constant velocity joint.

Discard the removed gasket.

Figure 4C1 – 39

Rear Propeller Shaft and Universal Joints 4C1 – 28

4C1 – 28

13 Push the cap and boot back along the propeller shaft,

enough to allow the fitment of press plates such as

J 22912-01.

14 Support the constant velocity joint inner race (1) with

the press plates (J 22912-01) then, using a suitable

mandrel (2), press the propeller shaft from the

constant velocity joint.

15 Remove the boot and dust shield from the propeller

shaft, being careful not to damage the boot on the

propeller shaft splines.

Figure 4C1 – 40

Inspect

1 Inspect the grease in the joint for signs of

contamination. If contamination is evident, then the

constant velocity joint will probably have suffered

damage, and should be replaced.

2 If inspection shows that contamination has not

occurred, clean the joint by soaking it in a s uitab le

cleaning solvent.

If there is severe pitting, galling, play between

the balls and the cage windows, cracking or

damage to the cage, pitting or galling or c hips in

the raceways, replace the constant velocity joint.

3 Inspect the internal components b y tilting the inner

race to one side to expose each bal l individually, while

observing the condition of each component.

NOTE

Take care that no bal ls becom e dis lod ged d u ring

this inspection process. Figure 4C1 – 41

Rear Propeller Shaft and Universal Joints 4C1 – 29

4C1 – 29

Reassemble

During the removal, cleaning, inspection or

replacement of a constant velocity joint, it is

possible for the joint to become

disassembled. Should an inadvertent

disassembly of a constant velocity joint

occur, and notwithstanding the earlier

recommendation, it is possible to reassemble

the constant velocity joint, provided the

following procedure is followed EXACTLY.

1 Obtain a piece of wood or suitable tray with enou gh depressions in the surface to accommodate the six balls of the

constant velocity joint, marking one divot to indic ate the ball closest to the alig nment marks to retain the original

orientation of each ball to its working components.

As shown in the exploded view of the fixed constant velocity

joint, the groove (4) is provided on the outer race to receive

the dust cover and boot assembly.

The fact that the ball grooves in both the outer and inner

races (1) are equally spaced, identifies this constant velocity

joint as a “fixed” type. Note also the fine gr oove on the front

edge of the ball cage (2) and the larger, plain chamfer on

the rear edge.

NOTE

• The inner race (1) and cage (2), together with

the individual balls (3), must be maintain ed in

their original locations 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 constant

velocity joint.

Figure 4C1 – 42

2 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 4C1 – 43

Rear Propeller Shaft and Universal Joints 4C1 – 30

4C1 – 30

3 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 4C1 – 44

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 4C1 – 45

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

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

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

alignment.

6 Check that axial movement is minimal.

Figure 4C1 – 46

Rear Propeller Shaft and Universal Joints 4C1 – 31

4C1 – 31

Reinstall

Reinstallation is the reverse of removal procedure, noting the following points:

1 Cleanliness of the constant velocity joint and associated parts is of prime importance to ensure maximum life of the

joint assembly.

2 Install a new small boot clamp over the spl in ed propeller shaft splines, then install the boot and dust shi eld

assembly, taking care not to damage the boot on the propeller shaft splines.

3 Pack the constant velocity joint with 32 g of lubricant supplied in either of the two available Repair Kits, to the fixed

joint. Work joint by hand to distribute grease onto all surfaces inside the joint. Pack the remaining 5 g of the

lubricant into the tube adaptor recess.

4 Clean mating surfaces of constant velocity joint, dust shield and rear propeller shaft companion flange.

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

Temperature Gasket Eliminator sealant or equivalent,

to the grease cover mating surface. Take care not to

contaminate the constant velocity joint grease with

sealant.

Figure 4C1 – 47

6 Before pressing the constant velocity joint onto the

front propeller shaft half splines, ensure that the front

of the propeller shaft (2) is supported on a suitable

length of tube (1) (dimensions; 48 mm OD, 32 mm ID

and at least 30 mm long), as shown.

Figure 4C1 – 48

Rear Propeller Shaft and Universal Joints 4C1 – 32

4C1 – 32

7 Press constant velocity joint onto the rear propeller

shaft splines, using a suitable size socket or tube.

Ensure that socket or tube presses on inner race of

joint.

8 Secure the constant velocity joint with a new circlip,

being careful not to over-exp and the circlip during the

installation process.

9 Install at least three of the constant velocity joint Allen

key headed bolts aligning the dust shield and boot

assembly to the constant velocity joint.

10 Using a plastic faced hammer, install the dust cap to

the constant velocity joint.

11 Reinstall new gasket to end of constant vel ocity joint.

Figure 4C1 – 49

12 Clean threads in rear propeller shaft companion flange and the six Allen he ad bolts. Apply Loctite 242 or equivalent

thread sealant to the bolt threads.

13 Ensure that the relationship marks on the constant velocity joint, dust boot flange and rear propeller shaft flange

(made before disassembly), are all aligned.

14 Apply thread sealant such as Loctite 242 or equivalent o th e cleaned threads of the six Allen headed screws

15 Reinstall and tighten the six Allen headed screws to the correct torque spe cification.

(  ) Centre constant velocity joint to

rear propeller shaft flange bolt

torque specification..............................................35 N.m

16 After locating the boot into the recess in the dust boot groove, install and tighten the new clamp, using keystone

clamp pliers such as J 22610 or commercial equivalent.

17 Reinstall propeller shaft. Refer to 2.1 Propeller Shaft in this Section.

Rear Propeller Shaft and Universal Joints 4C1 – 33

4C1 – 33

2.5 Centre Bearing Assembly

LT Section No. – 05-050

All VZ With V6 Engine and IRS (Except AWD Wagon)

NOTE

• This operation is not possible with the

propeller shaft fitted to GEN III V8 vehicles.

Refer to 1.1 Service Notes, in this Section for

further information.

• During the removal process described, the

rubber bearing support will be damaged,

resulting in the requirement for the complete

centre bearing assembl y to be replaced.

Remove

1 Remove the propeller shaft. Refer to 2.1 Propeller Shaft in this Section.

2 With the propeller shaft assembly (4) laying on a

bench, use a scre wdriver (1) or similar and l ever up o n

the boot clamp (2) strap, releasing the tension.

Figure 4C1 – 50

This is a critical operation, as propeller shaft

phasing and balance will be affected if the

two propeller shaft halves are not aligned

correctly on reassembly.

3 Extend the sliding joint until re sistance is felt, then use

a felt tipped pen or similar to mark alignment marks on

the front propeller shaft section (1) and the rear (2)

Figure 4C1 – 51

Rear Propeller Shaft and Universal Joints 4C1 – 34

4C1 – 34

4 With the two propeller shaft halves extended, a snap

action is required to separate them, because of the O-

ring seal (3) mounted on the end of the re ar shaft (1).

5 Once separated, the ribbed boot (3) and O-ring seal

(4) are released. NOTE

Once separated, the O-ring seal (4) may be

retained in the propeller shaft front half (1).

Retrieve by inserting a hooked piece of wire.

Figure 4C1 – 52

6 Remove the slinger (1), by levering off, using two

similar sized screwdrivers (2) or similar, as sho wn.

NOTE

Removal of the slinger is requir ed to gain access

to a circlip underneath.

Figure 4C1 – 53

7 Using suitable, commercial ly available circlip pliers (1),

remove the circlip (2) securing the centre bearing.

Figure 4C1 – 54

Rear Propeller Shaft and Universal Joints 4C1 – 35

4C1 – 35

8 Install suitable press plates such as J 22912-01 under

the centre bearing, carrier (1) and rubb er support, with

the flat face towards the bearing and carrier (1).

9 Tighten the clamp nuts on the press plates until the

two halves are firmly secure around the bearing.

10 Support the press plates on the bed of an hydraulic

press and press the rear propeller shaft, splined shaft

from the centre bearing.

NOTE

This operation will damage the rubber bearing

support, requiring the cent re bearing, rubber and

carrier assembly to be replaced.

Figure 4C1 – 55

11 Shown is the relationship of the centre bear ing

assembly (3) to the rear propeller shaft (4), together

with the slinger (1) and the retaining circlip (2).

Figure 4C1 – 56

Reinstall

1 With the front universal joint ‘ears’ (1) supported on

press plates (2), press a NEW centre bearing

assembly (3) onto the front section of the rear

propeller shaft, using press tube J5590 and adaptor

AU273-9.

NOTE

If these tools are not available, then a 150 mm

length of pipe with an ID of 30 mm (and a wall

thickness of 5 mm), can be used as a substitute.

Figure 4C1 – 57

Rear Propeller Shaft and Universal Joints 4C1 – 36

4C1 – 36

2 Install a NEW centre bearing retaining circlip (2), using

commercially available circlip pliers (1), taking care not

to over-stretch the circlip.

3 Install a NEW slinger, using press tool J5590.

Figure 4C1 – 58

4 Install a NEW boot and ring assembly over the splines

of the rear propeller shaft.

5 Lubricate the splines of the rear prop eller shaft with

approximately 1 – 2 gm of molybdenum disulphide

grease (such as Molybond GA10 or Shell ML10).

6 Install a NEW O-ring seal onto the nos e of the rear

propeller shaft.

7 Taking care to align the two propeller shaft halves with

the marks made before disassembly (1 and 2), push

the two halves together until the O-ring seal clears the

inner splines of the front half.

NOTE

At this time it should be possi ble to slide the two

halves back and forth with little resistance.

Figure 4C1 – 59

8 With the boot and ring assembly located correctly in

the grooved section of the front propeller shaft, install

a NEW retaining clamp to secure.

9 After installing a new clamp around the boot and ring

assembly bend the tab over as shown by ‘A’ in Figure

4C1-60.

10 Using keystone clamp pliers such as J 22610 (Also

released as E1896 and 3A13) or commercial

equivalent, tighten the clamp (1) until the g ap ‘B’ is

from 1 – 2 mm.

11 Install the propeller shaft assembly.

Refer to 2.1 Propeller Shaft, in this Section.

Figure 4C1 – 60

Rear Propeller Shaft and Universal Joints 4C1 – 37

4C1 – 37

AWD Wagon Models NOTE

• This bearing cannot be removed from the

propeller shaft without causin g damage to the

rubber ball race carrier and housing

assembly. New parts must be installed when

the propeller shaft is being reassembled.

• The replacement centre bearing kit contains

front and rear dust slingers, centre bearing

and rubber cup assembly.

Remove

1 Remove propeller shaft, refer to 2.1 Propeller Shaft in this Section.

2 Remove constant velocity joint, refer to 2.3 Centre Constant Velocity Joint (Plunge Type) –AWD Wagon, in this

Section.

3 Using suitable press plates, such as J22 91 2-01 or

equivalent and a suitable drift (4), support rubber ball

race carrier and housing asse mbly (2), then press the

propeller shaft (3) from the rear slinger (1) and rubber

ball race carrier and housi ng assembly (2).

NOTE

This action will separate the bearing from the

rubber support, requiring the replacement of the

complete assembly.

Figure 4C1 – 61

4 Support the centre bearing (1 ) with suitable press

plates such as J22912-01, then press the propeller

shaft front half (2) from the bearing. Discard the

bearing (1) following removal.

Figure 4C1 – 62

5 If required, remove centre bearing front slingers (1 and

2), using a suitable lever (3), such as a flat bladed

screwdriver. NOTE

The slingers will be distorted during remov al and

must be replaced with new parts on reassembly.

Figure 4C1 – 63

Rear Propeller Shaft and Universal Joints 4C1 – 38

4C1 – 38

Reinstall

1 Install new front slingers (one at a time), onto front half

of the propeller shaft using J5590 or a suitable sized

tube.

During this reinstallation proce ss, ensure that th e

front of the propeller shaft (2) is supported on a

suitable length of tube (1) (dimensions; 48 mm

OD, 32 mm ID and at least 30 mm long), as

shown.

Figure 4C1 – 64

2 Reinstall new centre bearing assembly (1) to propeller

shaft (2) using installer J21426 or a suitable size tube.

NOTE

Only apply press force to the centre ball race.

Figure 4C1 – 65

3 Again using installer J2 1426 or a suitable size tube,

install a new slinger (1) to the centre be aring, as

shown.

Figure 4C1 – 66

4 Reinstall centre constant velocity joint. Refer to 2.3 Centre Constant Velocity Joint (Plunge Type) –AWD Wagon, in

this Section.

5 Reinstall the rear propeller sh aft assembly. Refer 2.1 Propeller Shaft in this Section.

Rear Propeller Shaft and Universal Joints 4C1 – 39

4C1 – 39

All VZ With a Live Axle

Remove

NOTE

The centre bearing cannot be removed from the

propeller shaft without causing damage to the

ball race and dust slinger. New parts must be

installed when the propeller shaft is being

reassembled.

1 Remove the propeller shaft.

Refer to 2.1 Propeller Shaft in this Section.

2 Remove the centre constant velocity joint, rubber b oot

and dust shield. Refer to 2.4 Centre Constant Velocity

Joint (Fixed Type) – Live Axle Models) in this Section.

3 Remove the centre bearing ca rrier retaining nuts (2)

and bolts (3), the support carrier strap (1) and the heat

shield (4), if fitted.

4 Separate the centre bearing cup guide halves (5 and

6), then remove them from the centre bearing

assembly. Figure 4C1 – 67

NOTE

The centre bearing rear slinger once removed,

must be discarded. A new part MUST be

installed when the propeller shaft is being

reassembled.

5 Using a hammer and suitable punch, remove the rear

slinger (1) by tapping the edge of the slin ger evenly

away from the centre bearing (2).

Figure 4C1 – 68

6 Remove the retaining circlip (1) from the centre

bearing (2), using suitable circlip pliers.

Figure 4C1 – 69

Rear Propeller Shaft and Universal Joints 4C1 – 40

4C1 – 40

7 Using Tool No. J 22912-01 to support the centre

bearing (1), press the propeller shaft spindle (2) from

the centre bearing (1).

Figure 4C1 – 70

NOTE

The centre bearing front slinger once removed

must be discarded. A new part MUST be

installed when the propeller shaft is being

reassembled.

8 Using a hammer and suitable punch, remove the front

slinger (1) by tapping the edge of the slin ger evenly

away from propeller shaft spindle (2).

Figure 4C1 – 71

Rear Propeller Shaft and Universal Joints 4C1 – 41

4C1 – 41

Replace

1 Install a new front slinger (1) onto the propeller shaft

spindle (2) using a suitable tub e (3).

Figure 4C1 – 72

2 Install a new centre bearing (1) onto the propeller shaft

spindle (2) using a suitable tub e (3).

Figure 4C1 – 73

3 Install a new retaining circlip (1) to the centre bearing

(2).

Figure 4C1 – 74

Rear Propeller Shaft and Universal Joints 4C1 – 42

4C1 – 42

NOTE

Ensure the rear slinger is not installed too far

onto the propeller shaft spindle, as the slinger

and centre-bearing cup will rub.

4 Install a new rear slinger (1) onto the propeller shaft

spindle (2) using a suitable tub e (3).

Figure 4C1 – 75

5 Install the centre constant velocity joint, rubber boot

and dust shield. Refer to 2.4 Centre Constant Velocity

Joint (Fixed Type) – Live Axle Models) in this Section.

6 Assemble the centre bearing cup gu ide halves (5 and

6), install the heat shield (4) (if removed) and support

carrier strap (1), securing all with the two bolts (3) and

nuts (2).

7 Tighten the carrier bracket attaching bolts (3) and nuts

(2) to the correct torque specification.

Centre bearing upper carrier bracket to

lower carrier bracket attaching

bolt torque specification.......................................25 N.m

8 Reinstall the propeller shaft.

Refer to 2.1 Propeller Shaft in this Section.

Figure 4C1 – 76

Rear Propeller Shaft and Universal Joints 4C1 – 43

4C1 – 43

2.6 Fixed, Rear Constant Velocity Joint

LT Section No. – 05-050

NOTE

The rear propeller shaft, rear constant velocity

joint (constant velocity joint), fitted to AWD

Wagon models, is a “fixed” joint, which means

that any axial end play is minimal.

Remove

1 Remove rear propeller shaft from the vehicle. Refer to 2.1 Propeller Shaft, in this Section.

2 Using a small bladed screwdriver, lever up the boot

clamp tang to release, then remove and discard the

boot clamp (1).

Figure 4C1 – 77

3 Grip the constant velocity joint in a vice fitted with soft

jaws.

4 Using a suitable cold chisel and hammer, dislodge and

remove the crimped end cap from the end of the

constant velocity joint. Discard the removed end cap.

5 Reposition the constant velocity joint in the vice, to

allow access to the crimped dust boot cap, then

dislodge it, using the same cold chisel and hammer.

NOTE

Assuming that the constant velocity joint is to be

reinstalled, be careful not to damage the outer

race, during the cap removal process.

Figure 4C1 – 78

Rear Propeller Shaft and Universal Joints 4C1 – 44

4C1 – 44

6 Using suitable circlip pliers (1), remove the circlip (2)

from the end of the propeller shaft and discard.

NOTE

Do not re-use the circlip once it has been

removed. Always fit a new part on reassembly.

Figure 4C1 – 79

7 Push the cap and boot back along the propeller shaft,

enough to allow the fitment of press plates such as

J22912-01.

8 Support the constant velocity joint inner race (1) with

the press plates (22912-01) then, using a suitable

mandrel (2), press the propeller shaft from the

constant velocity joint.

9 Remove the boot and dust shield from the propeller

shaft, being careful not to damage the boot on the

propeller shaft splines.

Figure 4C1 – 80

Inspect

Propeller Shaft and Boot

1 Clean propeller shaft splines and boot, using suitable cleaning solv ent.

2 Inspect the propeller shaft splines for twisting, cracking or excessive wear. If any of these conditions are observed,

then the propeller shaft must be replaced.

3 Carefully inspect the boot and replace if split, fatigued, cracked or worn.

Rear Propeller Shaft and Universal Joints 4C1 – 45

4C1 – 45

Constant Velocity Joint

Complete disassembly of the constant

velocity joint is not recommended. The

internal components are a precision fit and

develop their own characteristic wear

patterns. The inter-mixing of components

could result in looseness, binding and/or

premature failure of th e jo int.

1 Remove the excess lubricant from the constant

velocity joint (1), wipe clean, then use correc t ion fluid

(2), to identify the relationship of the three joint

components.

2 Remove gasket (3) and discard.

Figure 4C1 – 81

3 Inspect grease in joint, and if obviousl y contaminated

and/or been subjected to dirt ingress, the joint has in

all likelihood suffered damage and should be replaced.

If inspection reveals that the joint has not been

contaminated, clean joint by soaking in a suitable

cleaning solvent.

4 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 sha rply,

as the balls can become dislodged. If this does

occur and the original l ocation of the balls is lost,

then the constant velocity joint should be

replaced.

5 Replace joint assembly if there is severe pitting,

galling, play bet ween balls and the cage windows, any

cracking or damage to cage, pitting or galling or chips

in raceways. Figure 4C1 – 82

Rear Propeller Shaft and Universal Joints 4C1 – 46

4C1 – 46

Reassemble

During the removal, cleaning, inspection or

replacement of a constant velocity joint, it is

possible for the joint to become

disassembled. Should an inadvertent

disassembly of a constant velocity joint

occur, and notwithstanding the earlier

recommendation, it is possible to reassemble

the constant velocity joint, provided the

following procedure is followed EXACTLY.

As shown in the exploded view of the fixed constant velocity

joint, two grooves (4) are provided on the outer race for the

crimped dust covers – the wide one is to receive the front

cover and boot assembly, while the narrow groove is for the

rear cover.

The fact that the ball grooves in both the outer and inner

races are equally spaced, identifies this con s tant velocity

joint as a “fixed” type. Note also the fine gr oove on the front

edge of the ball cage and the larger, plain chamfer on the

rear.

NOTE

• The inner race (1) and cage (2), together with

the individual balls (3), must be maintained in

their original locations to minimise the

creation of a noisy joint.

• Under no circumstances are components

from one constant velocity joint to be mixed

with components from another constant

velocity joint. Figure 4C1 – 83

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 4C1 – 84

Rear Propeller Shaft and Universal Joints 4C1 – 47

4C1 – 47

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 4C1 – 85

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 4C1 – 86

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 4C1 – 87

Rear Propeller Shaft and Universal Joints 4C1 – 48

4C1 – 48

Reinstall

Reinstallation is the reverse of removal procedure, noting the following points:

1 Cleanliness of constant velocity joint and associated parts is of prime importance to ensure maximum life of the

assembly.

2 Install a new small boot clamp over the spl in ed propeller shaft splines, then install the boot and dust shi eld

assembly, taking care not to damage the boot on the propeller shaft splines.

3 Pack the constant velocity joint with the majority of the 29 g lubricant supplied in either o f the two available Repair

Kits. Work joint by hand to distribute grease onto all surfaces inside the joint. Apply the remainder to the dust cover,

ensuring that the vent hole is not blocked with grease.

4 Clean mating surfaces of constant velocity joint, dust shield and rear propeller shaft companion flange.

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

Temperature Gasket Eliminator sealant or equivalent,

to the grease cover mating surface. Take care not to

contaminate the constant velocity joint grease with

sealant.

Figure 4C1 – 88

6 Press constant velocity joint onto the rear propeller

shaft splines, using a suitable size socket or tube.

Ensure that socket or tube presses on inner race of

joint.

During this pressing operation, ensure that

the outer surface of the centre constant

velocity joint is supported by press plates

such as J22912-01 or equ ivalent.

7 Secure the constant velocity joint with a new circlip,

being careful not to over-exp and the circlip during the

installation process.

8 Install at least three of the rear constant velocity joint

Allen key headed bolts aligning the dust shield to the

constant velocity joint.

Figure 4C1 – 89

9 Using a plastic faced hammer, install the dust cap to the constant velocity joint.

10 Use keystone clamp pliers such as J22610 o r commercial equivale nt, to tighten the small boot clamp.

11 Reinstall new gasket to end of constant vel ocity joint.

12 Press the outer cover into place over the guide bolts, with press plates such as J22910-01 (or equivalen t)

supporting the dust shield, with a suitable sized sleeve acting on the outer edges of the end cap.

13 Reinstall propeller shaft. Refer to 2.1 Propeller Shaft, in this Section.

Rear Propeller Shaft and Universal Joints 4C1 – 49

4C1 – 49

2.7 Rear Plunge Type Constant Velocity

Joint – Live Axle Models

LT Section No: 05-050-1

Remove

1 Remove the propeller shaft. Refer to 2.1 Propeller Shaft in this Section.

2 Support the constant velocity joint body (1) in a vice

fitted with protective soft metal jaws.

3 Using a suitable cold chisel and hammer, dislodge and

remove the crimped end cap from the end of the

constant velocity joint. Discard the removed end cap.

Figure 4C1 – 90

4 Remove excess grease and wipe clean before placing

a daub of paint to mark the relationships of the

propeller shaft spindle (1), inner race (2), ball guide (3)

and outer race (4).

Figure 4C1 – 91

Rear Propeller Shaft and Universal Joints 4C1 – 50

4C1 – 50

5 Using suitable circlip pliers, re move the constant

velocity joint, rear-retaining circlip.

Figure 4C1 – 92

6 Support the constant velocity joint body (1) in a vice

fitted with protective soft metal jaws, with the

remainder of the propeller shaft resting on the bench

top.

7 Using a suitable cold chisel and hammer, dislodge and

remove the dust cover and rubber boot assembly (2)

from the body of the constant velocity joint (1).

8 Push the dust cover and rubber boot assembl y back

toward the propeller shaft centre bearing.

Figure 4C1 – 93

9 Support the constant velocity joint with press plates,

Tool No J 22912-01 and pr ess the propeller shaft

spindle (1) from the constant velocity joint (2).

Figure 4C1 – 94

Rear Propeller Shaft and Universal Joints 4C1 – 51

4C1 – 51

10 Remove the dust shield and rubber boot assembly

retaining clamp. Remove the boot and dust shield

assembly from the propeller shaft.

Figure 4C1 – 95

Inspect

1 Inspect the grease in the joint for signs of

contamination. If contamination is present then the

constant velocity joint will hav e probably suffered

damage and should be replaced.

2 If no contamination is evident , clean the joint by

soaking it in a suitable cleaning solvent.

NOTE

If there is severe pitting, galling, play between

the balls and the cage windows, cracking or

damage to the cage, pitting or gall ing or chips in

the raceways, replace the constant velocity joint.

3 Inspect the internal components b y tilting the inner

race to one side to expose each bal l individually, while

observing the condition of each component.

Figure 4C1 – 96

Rear Propeller Shaft and Universal Joints 4C1 – 52

4C1 – 52

Disassemble

Disassembly of the constant velocity joint

beyond this point is not recommended. The

internal components are a precision fit and

during operation develop their own

characteristic wear patterns. Intermixing of

components could result in looseness,

binding and/or subsequent premature failure

of the constant velocity joint.

If disassembly must be attempted, then each

component of the joint must be returned to its

original orientation.

1 Ensure the aligning marks (4) made in step four of the

removal procedure are maintained at all times during

this procedure.

2 Obtain a piece of wood or suitable tray with enou gh

depressions in the surface to accommodate the six

balls of the joint, marking one divot to indicate the ball

closest to the alignment marks to retain the or iginal

orientation of each ball to joint.

Figure 4C1 – 97

3 Taking care not to dislodge any b alls from the joint,

pivot the inner race and ball guide at 90º to the centre

line of the outer race and lift the inner race and ball

guide from the outer race.

Figure 4C1 – 98

Rear Propeller Shaft and Universal Joints 4C1 – 53

4C1 – 53

4 Using a screwdriver if required as a lever, remove

each ball in order from the ball guide an d place the

balls on to the previously obtain piece of wood or tray

as detailed in step 2 of this procedure.

5 Pivot the inner race 90º to the centre line of the ball

guide and lift the inner race from the ball gui de.

Figure 4C1 – 99

Reassemble

The reassembly procedure for the constant velocity joint is the reverse of the disassembly procedure, noting the following

points:

1 Ensure all alignment marks are ali gned to return all components to their original orientation.

2 Check the multi-direction movement of the constant velocity joint for binding or restriction.

3 Check the plunge movement for the constant velocity joint.

4 Ensure the reassembled constant velocity joint is kept free from contamination until required for reinstallation to the

propeller shaft.

Reinstall

The installation procedure is the reverse of the removal procedure, noting the following points:

1 Ensure the constant velocity joint and associated parts are clean to ensure maximum life expectancy.

2 Inspect the dust shield and boot assembly for cracks, tears or damage, replacing if necessary, then install it and a

new small clamp to the front propeller shaft spindle.

3 Pack half (~105 g) of the lubricating grease supplied with the kit, into the boot, then work approximately 120 g

thoroughly into the constant v elocity joint. Apply the remaining 5 g of lubricant into the end grease cover, ensuring

that the vent hole is not covered.

4 Prior to pressing the constant velocity joint onto the front propeller shaft spindle, ensure all alignment marks are in

their original orientation.

5 Ensure the mating surfaces of the constant velocity

joint, dust shield and rubber boot assembly are clean.

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

Temperature Gasket Eliminator sealant or equivalent,

to the grease cover mating surface. Take care not to

contaminate the constant velocity joint grease with

sealant.

Figure 4C1 – 100

Rear Propeller Shaft and Universal Joints 4C1 – 54

4C1 – 54

Support the centre constant velocity joint

with press plate such as J 22912-01, under

the six Allen key headed attaching bolts

before pressing the rear constant velocity

joint onto the rear propeller shaft half.

7 Using a suitable socket or tube (1), press the constant

velocity joint (2) onto the propeller s haft (3), spindle

while ensuring the socket or tube presses on the inner

race of the joint only.

8 Secure the constant velocity joint with a new circlip,

being careful not to over-exp and the circlip during the

installation process.

Figure 4C1 – 101

9 Install at least three of the rear constant velocity joint Torx bit head ed bolts to align the dust shield and boot

assembly to the constant velocity joint.

10 Using a plastic faced hammer, install the dust cap to the constant velocity joint.

11 Install a new gasket between the consta nt velocity joint and the rear grease cover.

12 Install the rubber boot to propeller shaft spin dle retaining clamp.

13 After locating the boot into the recess in the dust boot groove, install and tighten the new clamp, using keystone

clamp pliers such as J 22610 or commercial equivalent.

14 Press the grease cover into place over the g uid e bolts, with press plates such as J 22912-01 (or equivalent)

supporting the dust shield, with a suitable sized sleeve acting on the outer edges of the end cap.

15 Reinstall the propeller shaft, as detailed in 2.1 Propeller Shaft in this Section.

Rear Propeller Shaft and Universal Joints 4C1 – 55

4C1 – 55

3 Specifications

Propeller Shaft Identification

Refer to the digit identification letters on the tag attached to the rear propeller shaft tube and the following table.

Body Style Engine Transmission I.D. Code

SWB Sedan/Coupe Alloytec (LE0) 6 Speed Manual (MV5) NH

Station Wagon (2WD)/ Utility Alloytec (LE0) 6 Speed Manual (MV5) NJ

SWB Sedan/Coupe Alloytec (LE0) or

Alloytec 190 (LY7) 4L60-E Automatic (M30) NW

Station Wagon (2WD)/ Utility Alloytec (LE0) or

Alloytec 190 (LY7) 4L60-E Automatic (M30) NX

SWB Sedan/Coupe GEN III V8 (LS1) 6 Speed Manual (MM6)/4L60-E Automatic (M30) NE

Station Wagon (2WD)/ Utility GEN III V8 (LS1) 6 Speed Manual (MM6)/4L60-E Automatic (M30) NF

SWB Sedan/Coupe Alloytec 190 (LY7) 5L40-E Automatic Transmission (M82) NZ

Regular Cab/Cre w Cab (2WD) Alloytec (LE0) 4L60-E Automatic (M30) NN

Regular Cab/Crew Cab (2WD) Alloytec (LE0) 6 Speed Manual (MV5) NT

Regular Cab/Crew Cab (2WD) GEN III V8 (LS1) 4L65-E Automatic (M32) JV

Regular Cab/Cre w Cab (AWD) Alloytec (LE0) 4L60-E Automatic (MK2) 6827U

Regular Cab/Crew Cab (AWD) GEN III V8 (LS1) 6 Speed Manual (MM6) MG

Regular Cab/Crew Cab (AWD) GEN III V8 (LS1) 4L65-E Automatic (MD6) 6827U

AWD Wagon Alloytec 190 (LY7) 5L40-E Automatic Transmission (M82) JY

AWD Wagon GEN III V8 (LS1) 4L60-E Automatic (M30) JY

Centre Bearing

Type.........................................................................Rubber Mounted – Single Row Ball Race

Lubrication.........................................................................................................Sealed for Life

Universal Joints

Front (All Model Variants) .......................................................................................Rubber Coupling

Centre (All Models with RWD and IRS)..................................................Non-Serviceable Cross Type

Constant Velocity (AWD Wagon).......................................................Plunge Type with 6 Balls

Constant Velocity (Live Axle Variants).................................................Fixed Type with 6 Balls

Rear (All Models with RWD and IRS).....................................................................Rubber Coupling

Constant Velocity (AWD Wagon).........................................................Fixed Type with 6 Balls

Constant Velocity (Live Axle Variants)...............................................Plunge Type with 6 Balls

Constant Velocity Joint – Lubricant Quantity

Centre Plunge Type .....................................................................................................45 ± 2.5 grams

Fixed Type........................................................................................................36 ± 2.5 grams

Rear Fixed Type........................................................................................................29 ± 2.5 grams

Plunge Type ....................................................................................................230 ± 10 grams

Sealants and Thread Sealing Compound

Constant Velocity Joint to Dust Shield...............................................Loctite 510 or equivalent

Propeller Shaft Fasteners (refer to text).............................................Loctite 242 or equivalent

Rear Propeller Shaft and Universal Joints 4C1 – 56

4C1 – 56

4 Torque Wrench Specifications

ATTENTION

 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 mechanical thread lock and

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

Centre Bearing Carrier to Underbody Reinforcement Bolt............................ 22 N.m

Centre bearing upper carrier bracket to lower bracket attaching bolt ...........25 N.m

 Centre Constant Velocity Joint to Rear Propeller Shaft Flange Bolt.............35 N.m

Front Rubber Coupling to Transmission Output Flange Bolt......................115 N.m

 Front Rubber Coupling to Transmission Output Flange Bolt and Nut.........115 N.m

 Front Rubber Coupling to Transmission Output Flange Nut.........................85 N.m

 Propeller Shaft To Rubber Coupling Nut.................... 20 N.m , then 55° turn angle

 Rear Constant Velocity Joint to Pinion Flange Bolt (V6 Engine).................38 N.m

(GEN III V8 Engine)....68 N.m

 Rear Rubber Coupling to Pinion Flange Bolt..............................................115 N.m

 Rubber Coupling to Transfer Case Output Shaft Flange Nut .......................85 N.m

Rear Propeller Shaft and Universal Joints 4C1 – 57

4C1 – 57

5 Special Tools

Tool Number Illustration Description Tool Classification

J21426

Installer

Used to install the centre bearing and

outer slinger to the rear propeller

shaft.

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

J5590

Press Tube

Used to install centre bearing slingers.

Previously released.

Unique

J22610

Keystone Clamp Pliers

Used to tighten the constant velocity

joint boot clamps. Also released as

E 1896 and 3A13.

Previously released

Desirable

J22912-01

Press Plates

Also released as E6673

Previously released.

Desirable