SECTION 4B - FINAL DRIVE AND DRIVE SHAFTS

Click on the button for more information. CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). An SRS

will consist of either seat belt pre-tensioners and a driver's side air bag, or seat belt

pre-tensioners and a driver's and front passenger's side air bags. Refer to

CAUTIONS, Section 12M, before performing any service operation on or around any

SRS components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in SRS d eployment, result ing in po ssible person al injury or unnecessary

SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas. In the interests of

safety, the LPG fuel system should be isolated by turning OFF the manual service

valve an d then draining the LPG service lines, bef ore any service work is carried out

on the vehicle. Refer to the LPG leaflet included with the Owner's Handbook for

details or LPG Section 2 for more specific servicing information.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is

disturbed during Service Operations, it is vital that the complete ABS or ABS/ETC

system is checked, using the procedure as detailed in 4. DIAGNOSIS, ABS or

ABS/ETC FUNCTION CHECK, in Section 12L ABS & ABS/ETC.

1. GENERAL DESCRIPTION

Independent rear sus pension is fitted as s tandard equipment on all VT Series vehicles and all are fitted with a final

drive assembly, production option GU4. This assembly has a four pinion type rear differential assembly. The ring

gear diam eter for V6 engined m odels, is 190.5 m m and for V8 and V6 supercharged, engined m odels, is 205 mm .

The final drive ratio for V6 engined models is 3.08:1 and for V8 and V6 supercharged, engined models, is 3.07:1.

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

available on all models . While the m ajority of illustrations shown in this Sec tion relate to vehicles fitted with the ABS

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

The final drive assem bly is m ounted directly to a crossm ember which is rubber mounted to the vehicle underbody.

The differential case and drive pinion are m ounted in opposed taper roller bearings in the carrier. Differential case

side bearing pre-load adjustm ent is pr ovided by s crew adjusters in the sides of the c ase. Pinion bearing pre-load is

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

pinion flange which is splined to the hypoid pinion. The 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 Limited Slip Differential 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, with V6 models, are splined to the

inner axle shafts and their tapered faces contact corresponding faces in the differential case.

The cones for V8 and V6 supercharged models however, form an integral part of the side gears. The four pinion

type Limited Slip Dif fer ential has three pr e-load springs enc los ed in the centr e of the pinion c r oss s haf t. T he Limited

Slip Diff erential directs the m ajor driving f orce to the wheel with the greater amount of traction, but will not interf ere

with steering characteristic s or dif ferential action. T he partial locking ac tion, 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 differential as applied torque is increased.

Techline

W hen the rear wheels ar e under extr emely unbalanced conditions, s uch as a wheel on a dry r oad and the other in

mud or ic e, with the standard differ ential, wheel spin eas ily occurs if over-acceleration is attempted. However, with a

Limited Slip Differential, when the tendency for wheel spin occurs, the friction generated inside the case, transfers

the major driving force to the non-spinning wheel. In the event of continued spinning, a whirring sound from the

over-running cones is produced but this condition/sound does not indicate failure of the unit.

The f inal drive ass em bly should be removed f rom the vehic le for all service operations 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 trunnion flange at the rear trailing arm.

Figure 4B

1. LH Inner Axle Shaft 4. Identification Label 7. Breather

2.. Pinion Flange 5. Frain Plug 8. Filler Plug

3. RH Inner Axle Shaft 6. Rear Cover 9. Lubrication Tag

Figure 4B-2

1. 1 FINAL DRIVE ASSEMBLY IDENTIFICATION

The type of differential fitted to this final drive

assem bly can be identified by referr ing to either the

identification label attached to the RHS of the

carrier housing and from the lubrication tag under

the filler plug on the rear cover.

The location of the label and tag are as shown, in

Figure 4B-2. The identification tag carries the

Holden's part number for the final drive assembly,

final drive ratio and the serial number of the

assembly.

The code number and bar code is used for

production identification of the final drive assembly.

CODE TAG LETTERING FINAL DRIVE ASS’Y TYPE

STD. BRAKES ABS

EF EC CONVENTIONAL - V6

ED EE LSD - V6

EA EJ CONVENTIONAL - V8

V6 Supercharged and

Wagon with

manual transmission

EB EH LSD - V8,

V6 Supercharged and

Wagon with

manual transmission

When fitted, the information on the lubrication tag

under the filler plug, (see Figure 4B-3), will be;

With V6 and LSD; “SPIN RESISTANT DIFF. USE

APPROVED LUBRICANT ONLY”

With V8 (or V6 supercharged) and conventional

differential; “HIGH PERFORMANCE. USE

APPROVED LUBRICANT ONLY”

With V8 (or V6 supercharged) and LSD; “LSD -

HIGH PERFORMANCE. USE APPROVED

LUBRICANT ONLY”

Figure 4B-3

1. 2 FINAL DRIVE ASSEMBLY MAINTENANCE

MAINTENANCE

Drive Shaft Bearings and Constant Velocity

Joints

The drive shaft outer bearings and constant

velocity joints are lubricated for life and therefore

require no periodic maintenance.

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

2.6 DRIVE SHAFT ASSEMBLY and to

2.7 DRIVE SHAFT AND/OR CONSTANT

VELOCITY JOINTS in this Section.

Differential Carrier Assembly

Check for lubricant leaks at every maintenance

service. If ther e is evidence of leak age, co rr ec t leak

and add lubricant as necessary. (Refer to

2 MINOR SERVICE OPERATIONS in this Section).

At the time or distance interval specified in the VT

Series Owner's Handbook, check to ensure that the

lubricant level is to the bottom of the filler plug hole

when the differential carrier assembly is COLD.

Final Drive Assembly Breather

The breather hose should be checked regularly to

ensure that it is correctly routed and not kinked.

The top end of the breather hose should be

inserted at least 25 mm into the vehicle underbody

crossmember hole.

Figure 4B-4

LIMITED SLIP DIFFERENTIAL PRECAUTIONS

CAUTION:

When servicing a vehicle fitted with a Limited

Slip Differential, never run the engine with the

transmission in gear and one w heel raised. T he

driving force to the wheel on the ground may

cause the vehicle to move.

NOTE:

'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 rem oving 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.

LUBRICATION

The lubricant level s hould be check ed and topped up, if required at the tim e or dis tance intervals outlined in the VT

Series Owner's Handbook with the differential carrier COLD; refer to 2.1 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section. At this temperature, the lubricant should be level with the bottom of the filler

plug hole. Operation 2.1 also details the recommended lubricants for all final drives fitted to VT Series vehicles.

NEVER USE ANY OTHER THAN THE RECOMMENDED LUBRICANT.

NOTE 1:

The lubricant for vehicles with the V6 engine and either the standard or Lim ited Slip Dif fer ential (LSD) dif fer ential, is

a mineral based oil. W ith LSD final drives however, an approved LSD com patible lubricant MUST be used. Using a

straight run mineral oil in an LSD final drive assembly, will cause ‘stick-slip’ chatter to occur when turning corners.

Alternatively, if a synthetic type lubricant is used in any rear axle of a V6 engined, VT Series vehicle, oil seal

deterioration with the possibility of lubricant leakage may occur.

NOTE 2:

The lubric ant used in the rear ax les of all V8 and V6 super charged engined vehicles, is a synthetic product. T he oil

seals of the V8 type rear axle assemblies have been specially formulated to tolerate this lubricant. It m ust also be

noted that, using a mineral type lubricant in any final drive fitted to a V8 or V6 supercharged engined vehicle, may

cause gear set and/or bearing damage under high load driving conditions.

NOTE 3:

If the incor rect lubricant is ac cidentally used in the r ear axle of any VT Series vehic le, then the rear axle should be

drained, flushed (with the recommended lubricant) and then refilled with the correct lubricant.

The procedure for this operation is detailed in 2.2 CHANGING/FLUSHING REAR AXLE LUBRICANT, in this

Section.

2. MI NOR SERVICE OPERATIONS

2.1 CHECKING DIFFERENTIAL CARRIER LUBRICANT LEVEL

1. Ensure vehicle is level.

2. Clean area around filler plug.

3. Remove filler plug from right hand side of

differential carrier (do not lose the lubrication

tag from the plug, if fitted).

4. The lubricant level is to be maintained at the

bottom edge of the filler plug hole, WHEN

COLD. Use only the recommended lubricant.

Figure 4B-5

ENGINE & AXLE TYPE RECOMMENDED LUBRICANT

All V6 excluding

V6 Wagon with manual

Transmission &

V6 Supercharged

Vehicles

Mineral Hypoid Gear Oil, such as

AMPOL Gearlube SRD90, BP Limslip 90,

CALTEX Gear Oil LSD, CASTROL LSX90

MOBIL Lubrite LS90, SHELL XD90LS

VALVOLINE HP Gear Oil LS90

or equivalent lubricant to

Holden Specification HN 1561

All V8,

V6 Wagon

with Manual

Transmission &

V6 Supercharged

Vehicles

Synthetic Hypoid Gear Oil, such as

AMPOL Synthetic Gear Oil 80W/140

CALTEX Synstar GL 80W-140

CASTROL SAF-XA

MOBIL Mobilube SHC 80W-140 ID

VALVOLINE Synthetic Gear 75W-140

or equivalent lubricant to

Holden’s Specification HN 2040

5. Inspect filler plug for damage, if OK, refit in

carrier (including the lubrication tag). If

damaged, replace plug.

6. Tighten filler plug to the correct torque

specification.

FILLER PLUG 23 - 31

TORQUE SPECIFICATION Nm

Techline

2.2 CHANGING/FLUSHING REAR AXLE LUBRICANT

To drain lubricant from differential carrier

assembly, remove filler and drain plugs (see

Figure 4B-5) and allow (preferably warm) lubricant

to drain into a suitable container.

If flushing is required, use an undiluted quantity of

the recommended lubricant for the operation.

When the draining and flushing (if required),

operation is completed, apply thread sealing tape to

rear cover drain plug thread. Install and tighten

attaching plug to the correct torque specification.

REAR AXLE DRAIN PLUG 23 - 31

TORQUE SPECIFICATION Nm

Fill the final drive assembly with 1.65 litres of the

recommended lubricant, install the filler plug and

lubrication tag (if fitted) and tighten to the correct

torque specification.

REAR AXLE FILLER PLUG 23 - 31

TORQUE SPECIFICATION Nm

Techline

2.3 TRAILING ARM TRUNNION ASSEMBLY HUB

CHECK FOR RUN-OUT

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle, then place

safety stands under trailing arms to support

weight of vehicle.

2. Remove rear wheel cover (steel wheels) or

centre cap (alloy wheels) on that side of the

vehicle where the trunnion is to be checked.

3. Mark relationship of wheel to m ounting f lange.

Remove road wheel attaching nuts and

remove wheel.

4. Disconnect rear shock absorber lower

mounting bolt from trailing arm, and pull lower

end of shock absorber from trailing arm.

Figure 4B-6

5. Remove brake caliper anchor plate to trailing

arm attaching bolts, remove caliper from disc.

Using wire, tie up caliper to lower end of s hock

absorber upper mounting. DO NOT ALLOW

CALIPER TO HANG BY BRAKE HOSE.

6. Remove brake disc.

Figure 4B-7

7. Mount a dial indicator with magnetic base to

rear brake backing plate, and stylus of gauge

perpendicular to outside of trunnion assembly

hub flange.

8. Rotate trunnion assem bly hub and read later al

run-out.

TRUNNION ASSEMBLY HUB,

TOTAL INDICATED 0.060 mm

RUN-OUT SPECIFICATION

Figure 4B-8

If Run-out is Within Specification:

9. Install brake disc and brake caliper. Install

brake caliper anchor plate to trailing arm

attaching bolts and tighten to the correct torque

specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING 70 - 100 Nm

BOLT TORQUE SPECIFICATION

Figure 4B-9

10. Install shock absorber to trailing arm, fit

washer to the lower mounting bolt, install bolt

and tighten to the correct torque specification.

SHOCK ABSORBER LOWER

MOUNTING BOLT 105 - 125 Nm

TORQUE SPECIFICATION

NOTE:

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

11. Install road wheel and tighten attaching nuts.

NOTE:

When installing the wheel, align the marks made

prior to removal.

12. Remove safety stand and lower vehicle.

13. Tighten road wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

14. Refit wheel cover/centre cap.

If the Run-out Check, Exceeds Specification:

15. The trunnion assembly must be replaced, refer

to 3.1 TRAILING ARM TRUNNION FLANGE,

TRUNNION ASSEMBLY AND/OR WHEEL

BEARING in this Section.

NOTE:

The trunnion shaft for VT Series vehicles is 1 mm

shorter than previous models and is identified by a

circumferential groove on the outside diameter of

the flange (see Figure 4B-8).

Figure 4B-10

2.4 TRAILING ARM TRUNNION ASSEMBLY HUB STUDS

REPLACE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle, then place

safety stands under trailing arms to support

weight of vehicle.

2. Remove rear wheel cover (steel wheels) or

centre cap (alloy wheels) on that side of the

vehicle where the stud/s are to be replaced.

3. Mark relationship of wheel to m ounting f lange.

Remove road wheel attaching nuts and

remove wheel.

4. Disconnect rear shock absorber lower

mounting bolt from trailing arm and pull lower

end of shock absorber from trailing arm.

Figure 4B-11

5. Remove brake caliper anchor plate to trailing

arm attaching bolts and remove caliper from

disc.

Using wire, tie up caliper to lower end of s hock

absorber upper mounting. DO NOT ALLOW

CALIPER TO HANG BY BRAKE HOSE.

6. Remove brake disc.

Figure 4B-12

7. Using Tool No. AJ24292-C or equivalent,

press stud/s from hub.

Figure 4B-13

8. Install Tool No. KM-468 holding bar, with two

wheel nuts to the trunnion assembly hub

studs. Install 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.

Install any remaining studs in the same

manner.

9. Remove Tool No. KM468.

Figure 4B-14

10. Install brake disc and brake caliper. Install

brake caliper anchor plate to trailing arm

attaching bolts and tighten to the correct

torgue specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING 70 - 100 Nm

TORQUE SPECIFICATION

Figure 4B-15

11. Install shock absorber to trailing arm, install

and tighten lower mounting bolt to the c orrect

torque specification.

SHOCK ABSORBER

LOWER MOUNTING BOLT 105 - 125 Nm

TORQUE SPECIFICATION

NOTE:

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

12. Install road wheel and tighten attaching nuts.

NOTE:

When installing the wheel, align the marks made

prior to removal .

13. Remove safety stand and lower vehicle.

14. Tighten road wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

15. Refit wheel cover/centre cap. Figure 4B-16

2.5 LIMITED SLIP DIFFE RENTIAL

TORQUE CHECK

1. Place transmission in neutral with engine

turned OFF.

2. Jack up one rear wheel and support trailing

arm on a safety stand. Release park brake

lever to fully OFF position.

3. Remove wheel cover (steel wheels) or centre

cap (alloy wheels).

4. Mark relationship of road wheel to mounting

flange. Remove road wheel attaching nuts and

remove wheel.

5. Disconnect rear shock absorber lower

mounting bolt from trailing arm, and pull lower

end of shock absorber from trailing arm.

Figure 4B-17

6. Remove brake caliper anchor plate to trailing

arm attaching bolts, remove caliper from disc.

Using wire, tie up caliper to lower end of s hock

absorber upper mounting. DO NOT ALLOW

CALIPER TO HANG BY BRAKE HOSE.

7. Remove brake disc.

Figure 4B-18

8. Using a torque wrench in conjunction with

adaptor, Tool No. 7208, and torque wrench

adaptor E6662B, rotate trunnion as sem bly in a

forward direction. If the unit is operating

satisfactorily, a torque reading of

approximately 70 Nm should be obtained while

turning the trunnion 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 4B-19

9. Install brake disc and brake caliper. Install

brake caliper anchor plate to trailing arm

attaching bolts and tighten to the correct

torque specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING 70 - 100 Nm

BOLT TORQUE SPECIFICATION

Figure 4B-20

10. Install shock absorber to trailing arm, install

and tighten lower mounting bolt to the correct

torque specification.

SHOCK ABSORBER

LOWER MOUNTING BOLT 105 - 125 Nm

TORQUE SPECIFICATION

NOTE:

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

11. Install road wheel and tighten attaching nuts.

NOTE:

When installing the wheel, align the marks made

prior to removal.

12. Remove safety stand and lower vehicle.

13. Tighten road wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

14. Refit wheel cover/centre cap. Figure 4B 21

2.6 DRIVE SHAFT ASSEMBLY

REMOVE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under trailing arms.

2. Using an 8 m m Allen key socket, r emove dr ive

shaft inner constant velocity joint to inner axle

shaft and outer constant velocity joint to

trunnion flange attaching bolts and plates,

remove drive shaft.

NOTE 1:

As it is only the inner, constant velocity joint that is

a plunge joint, it is important that which end is

which, is remembered for correct installation.

NOTE 2:

During drive shaft removal and installation, keep

drive shaft supported so that it does not hang on

one end because drive shaft joint deflection must

be kept to within the angular movement of an

installed drive shaft. Figure 4B-22

REINSTALL

Installation of the drive shaft is reversal of the

removal procedure, noting the following points.

NOTE:

The outer CV joint is marked with two grooves,

while the inner, plunge joint has only one groove. It

is important that the drive shaft is installed

correctly.

1. Tighten drive shaft to trunnion flange and

inner axle shaft attaching bolts to the correct

torque specification.

DRIVE SHAFT CONSTANT

VELOCITY JOINT TO TRUNNION 50 Nm, then

FLANGE AND INNER AXLE 60° - 75°

SHAFT ATTACHING BOLT turn angle

TORQUE SPECIFICATION

2.7 DRIVE SHAFT AND/OR CONSTANT VELOCITY JOINTS

There are three repair kits available for drive shaft

constant velocity joint repairs.

The first kit is a BOOT KIT, which consists of a

boot, boot clamps, snap ring and two tubes of

grease.

The sec ond k it is a CONST ANT VELOCIT Y JO INT

KIT, which contains the same items as the BOOT

KIT plus the inner, constant velocity joint.

The Third kit is a CONSTANT VELOCITY JOINT

KIT, which contains the same items as the BOOT

KIT plus the outer, constant velocity joint.

DISASSEMBLE

1. Remove drive shaft assembly, refer to

2.6 DRIVE SHAFT ASSEMBLY in this

Section.

2. Clean outside of assembly with a suitable

solvent before disassembling.

3. Clamp as sem bly, by drive s haft, in a vic e fitted

with soft metal jaws.

4. Using tin snips or other suitable cutting tool,

cut boot clamps in raised crimped area and

remove clamps.

Figure 4B-23

5. Using a suitable drift and hammer, tap dust

shields and caps from both sides of constant

velocity joints.

Figure 4B-24

Techline

6. Remove snap rings from each end of drive

shaft and discard.

NOTE:

Do not use snap rings once they have been

removed. Always use new snap rings on

reassembly.

7. Remo ve assembly from vice. Slide dus t shield

and boots towards centre of shaft.

Figure 4B-25

8. Using suitable press plates (such as Tool No.

E1312), supporting inner race, press drive

shaft from constant velocity joint.

Repeat process to re move rem aining constant

velocity joint.

9. Remove boots and dust shields from drive

shaft, ensuring boots are not damaged on

edges of shaft.

Figure 4B-26

INSPECT

Drive Shaft and Boots

1. Clean shaft and boots in a suitable cleaning

solvent.

2. Inspect drive shaft for twisting, cracking or

excessive spline wear.

NOTE:

Because the drive shaft is not serviced separately,

if the drive shaft is found to be defective, then it

must be replaced as an assembly.

3. Inspect boots and replace if split, fatigued,

cracked or worn.

Constant Velocity Joints

NOTE:

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 with and/or been subjected to

dirt ingress, the joint has in all likelihood

suffered damage and should be replaced.

If inspec tion reveals that the j oint has not been

contaminated, clean joint by soaking in a

suitable cleaning solvent.

2. Once grease has been removed, inspect

internal components by tilting inner race to one

side to expose each ball.

Replace joint assembly if there is severe

pitting, galling, play between balls and the

cage windows, any cracking or damage to

cage, pitting or galling or chips in raceways. Figure 4B-27

REASSEMBLE

Constant Velocity Joints

NOTE 1:

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 (CV) joint occur, and notwithstanding the

earlier recommendation, it is possible to

reassemble the CV joint, provided the following

procedure is followed EXACTLY.

NOTE 2:

Ideally, the inner race and cage, together with the

individual balls, should be maintained in their

original locations to minimise the creation of a noisy

joint.

NOTE 3:

Under no circumstances are components from one

constant velocity joint to be mixed with components

from another CV joint.

Shown are exploded views of each constant

velocity joint; view “A” is the inner joint, while view

“B” shows the outer. Note the single identification

groove on the outer race and the identification step

on the inner race for the inner joint and the two

grooves and recess on the outer joint.

Figure 4B-28

1. Place the inner race into the cage and position

centrally within the cage.

Figure 4B-29

2. Place the inner race and cage into the outer

race. Make sure that the identification

markings on both the inner and outer races

are on opposite sides of the assembly, as

shown.

Figure 4B-30

3. Align the thick sections on the outer race, with

the narrow ones on the inner race.

Figure 4B-31

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

one ball.

Repeat this process for the remaining five

balls.

Figure 4B-32

5. When assembly of the CV joint is complete,

check for plunge movement as shown. If NO

plunge movement can be achieved, then

the constant velocity joint has been

incorrectly assembled.

If such a situation occurs, the CV joint must be

disassembled and the assembly process

repeated until such time that the required

plunge movement is achieved.

NOTE:

This check only applies to the inner plunge joint.

The outer CV joint should have no plunge

movement.

Figure 4B-33

Drive Shaft and Boots

1. Remove old sealing bead of silicon from dust

shields, dust caps and constant velocity joints.

2. Position new large boot clamp over boot and

place boot over dust shield. Using Tool No.

E1896, securely crimp boot clamp, ensuring

crimp is in correct location.

Figure 4B-34

3. Apply a 2 mm diameter bead of RTV 732

sealant (Holden's Specification HN1373) to

dust caps/shields as shown and allow

approximately one hour to cure.

4. Place new small boot clamps onto drive shaft.

5. Place both dust shield and boot assemblies

onto drive shafts, ensuring that boots are not

damaged by sharp edges on each end of

shaft.

Figure 4B-35

6. Install inner, constant velocity joint onto shaft

with step on the inner race facing toward the

shoulder on the shaft, as shown.

NOTE:

The recess on the inner race of the outer CV joint,

also faces the drive shaft.

7. Press constant velocity joints onto shaft and

install NEW circlips.

NOTE:

When pressing joints onto shaft, ensure that the

joint inner races take the press load.

Figure 4B-36

8. 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.

9. Position dust caps and dust shields onto

constant velocity joints, ensuring that all bolt

holes align.

10. Using a suitable punch and ham m er, tap caps

and shields into place.

Figure 4B-37

11. Locate small ends of boots into boot grooves

on drive shafts, ensuring that boots are not

twisted.

With both joint, pry up small ends of boots

from shaft to equalise air pressure inside and

outside of boots and work out any dimples

before applying new small clamps.

IMPORTANT:

The location distance shown, ONLY applies to the

inner, plunge joint and should be set before

applying the small clamp.

Figure 4B-38

12. Position small clamps over ends of boots and

using Tool No. E1896, crimp ends of clamps.

13. Reinstall drive shaft, refer

2.6 DRIVE SHAFT ASSEMBLY - REINST ALL

in this Section.

Figure 4B-39

2.8 INNER AXLE SHAFT SEAL

REPLACE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under body rear jacking points.

Refer to Section 0A GENERAL

INFORMATION for location of jacking points.

2. Remo ve drive shaft f rom side of vehicle which

seal is to be replaced, refer to

2.6 DRIVE SHAFT ASSEMBLY in this

Section.

NOTE 1:

During drive shaft removal, keep drive shaft

supported so that it does not hang on one end.

NOTE 2:

Drive shaft joint deflection should be kept to a

minimum.

3. Remove inner axle shaft by installing a slide

hammer, Tool No. 09520-32012 with three

suitable size bolts to axle flange. Use slide

hammer to release axle shaft spring clip.

As the axle shaft is removed, a small amount

of lubricant may leak from differential carrier.

CAUTION:

If V6 engined vehicle is fitted with LSD, do not

rotate the opposite axle shaft, as side gear and

clutch cone splines will become misaligned.

Then the axle shaft cannot be reinstalled

without removing differential case, dismantling

and realigning gear and cone splines.

NOTE:

The above ‘Caution’ does not apply to the V8 or V6

superchar ged engine final drives, because the side

gear and LSD cone is an integrated component.

4. Clean around seal bore and housing area to

make sure that no foreign matter enters axle

shaft needle bearing in the screw adjuster.

Figure 4B-40

5. Using a suitable screwdriver and a block of

wood, lever seal from screw adjuster bore.

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 was fitted.

Figure 4B-41

6. Before installation of 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 be fitted.

NOTE 1:

The left hand inner axle shaft is shorter in length

than the right hand shaft.

NOTE 2:

If vehicle is equipped with ABS, the inner axle

shafts are unique for this application.

NOTE 3:

Check spring clip in end of axle s haf t to ens ure that

it is not damaged and moves freely in groove.

Replace spring clip if necessary, by expanding

ends of clip and removing f rom shaft. Only expand

the ends of a new clip sufficiently to allow

installation into shaft groove.

7. Examine seal bore in screw adjuster and

remove any nicks or burrs.

8. Lubricate seal lips and outside diameter with

lithium soap grease (Holden's Specification

HN1147). Install seal using Tool No. AU410,

until seal bottoms in bore.

Figure 4B-42

9. Install inner axle shaft, aligning splines with

clutch cone (if fitted with a Limited Slip

Differential) and side gear.

NOTE:

To avoid premature seal failure, ensure axle shaft

splines or s ecuring c lip do not scor e or dam age the

seal lips during installation.

10. Lightly hit on end of axle shaft flange with a

soft faced hammer to compress spring clip on

shaft into clutch cone and side gear splines.

Fully engage shaft until clip snaps into side

gear groove.

Figure 4B-43

11. Reinstall drive shaft, refer to

2.6 DRIVE SHAFT ASSEMBLY in this

Section.

12. Remove safety stands and low r vehicle.

13. Check and fill differential carrier to correct

level with specified lubricant. Refer to

2.1 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

2.9 PINION OIL SEAL

REPLACE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under trailing arms.

2. Mark the position of the propeller shaft rear

flange to pinion flange then remove propeller

shaft, refer to Section 4C PROPELLER

SHAFT AND UNIVERSAL JOINTS. This

operation will also mean that the exhaust

system has to be removed.

NOTE:

If the paint alignment marks on the rear universal

joint and pinion flanges are not visible, then lightly

scribe a mark on both flanges so they can be

installed in their original positions during

reassembly.

3. Lightly centre-punch alignment marks on the

pinion flange nut, pinion flange and pinion end

as an aid for reassembly.

By reassembling in the original position, the

flange run-out will be m inim ised and the pinion

bearing preload will be maintained.

Figure 4B-44

4. Using Tool No. J8614-10 with two suitable

bolts and nuts to hold pinion flange, remove

flange retaining nut.

Figure 4B-45

5. Withdraw pinion flange using the three

component parts of Tool No. J8614-01,

assembled as shown. Place a drain tray

beneath differential carrier housing.

Figure 4B-46

6. Prise pinion oil seal from carrier bore using

Tool No. 56750 or a universal seal removing

tool.

7. Lubricate new pinion oil seal lips with the

recommended rear axle lubricant. Lightly coat

the outside of the replacement seal with a non-

hardening gasket cement.

Figure 4B-47

8. Start oil seal into differential carrier housing

and drive seal squarely into position using Tool

No. 17-010A. Seal fits f lush to 0.25 m m below

carrier housing surface.

Figure 4B-48

9. Ensure that pinion shaf t is fr ee from burrs and

that flange oil seal surface is free from

damage.

10. Coat splines and seal surface of pinion f lange

with differential gear lubricant, and install

flange onto pinion shaft splines. Ensure that

centre-punch marks align.

11. Install flange retaining nut and tighten nut until

centre-punch marks align, then tighten nut

carefully to a position not more than 5° past

aligned setting.

NOTE:

The pinion flange is an interference fit on pinion

shaft splines and should only be pulled into place

by tightening retaining nut. DO NOT, UNDER ANY

CIRCUMSTANCES, USE FORCE OR HAMMER

FLANGE DURING INSTALLAT ION ONTO PINION

FLANGE.

CAUTION:

Should the retaining nut be overtightened 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.

12. Reconnect propeller shaft rear universal joint

flange to pinion flange, refer

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS.

13. If removed previously, reconnect exhaust

system, in the reverse to the removal

procedure. Refer to

3.2 FINAL DRIVE ASSEMBLY, in this

Section, for details.

14. Remove safety stands and lower vehicle.

15. Check lubricant level and top up as

necessary. Refer to

2.1 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section, for

details.

16. Start vehicle and check for exhaust leaks.

2.10 PINION FLANGE

REPLACE (USING OLD OIL SEAL)

NOTE 1:

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 and/or pinion nut.

NOTE 2:

For this oper ation, new dual muff ler support to rear

crossmember retainers must be used on

reassembly.

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under trailing arms.

2. Remove propeller shaft, refer to

2.1 PROPELLER SHAFT in Section 4C

PROPELLER SHAFT AND UNIVERSAL

JOINTS.

3. Remove both drive shafts, refer

2.6 DRIVE SHAFTS in this Section.

4. Check and record pre-load at pinion flange as

follows:

a. Fit a pulley to pinion flange and attach a

cord around pulley and to a spring scale.

NOTE:

For 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 reading of spring balance.

This pre-load reading includes pinion

bearings, side bearings, m es hing ef f ec t of

gear set and pinion oil seal.

To determine pre-load, multiply reading

on spring balance by radius of pulley.

EXAMPLE:

W ith a pulley diameter of 152 m m, the radius is 76

mm, which equals 0.076 m. W ith a spring balance

reading of 25 N, the pre-load equals 0.076 m x 25

N = 1.9 Nm.

5. Remove pulley from pinion flange. Figure 4B-49

6. Using Tool No. J8614-10 with two suitable

bolts and nuts, hold pinion flange and remove

flange retaining nut.

Figure 4B-50

7. Place drain tray beneath differential carrier.

8. Remove holder from pinion flange and

assemble the three component parts of Tool

No. J8614-01, as shown. Install assembly to

pinion flange using two suitable bolts and nuts.

With the holder J8614-10 secured, tighten

screw J8614-3 and remove the pinion flange.

Figure 4B-51

9. Ensure that pinion shaft thread is free from

burrs, then coat splines and seal surface of

pinion flange with the recomm ended rear axle

lubricant.

10. Install pinion flange and retaining nut.

NOTE:

The new flange will be an interference fit on pinion

shaft splines and should only be pulled into place

by tightening retaining nut. DO NOT, UNDER ANY

CIRCUMSTANCES, USE FORCE OR HAMMER

FLANGE DURING INSTALLAT ION ONTO PINION

FLANGE.

11. Tighten flange retaining nut gradually until

pinion shaft end play is reduced to

approximately 0.50 mm.

12. Attach pulley to pinion flange and us ing spring

balance, check pre-load. Continue tightening

nut while alternatively turning pinion to seat

bearings, until the pre-load figure recorded

previously (Step 4b) is reached. Further

increase this original pre-load reading by 0.5

Nm.

ROTATE PINION AN EXTRA 30-40 TURNS

AND RE-CHECK THE PRE-LOAD TO

ENSURE THAT NO CHANGE HAS

OCCURRED.

CAUTION:

Should the retaining nut be overtightened 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.

13. Reinstall drive shafts, refer to

2.6 DRIVE SHAFTS in this Section.

14. Reinstall propeller shaft, refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS.

15. If removed previously, reconnect exhaust

system, in reverse to the removal procedure.

16. Remove safety stands and lower vehicle.

17. Check lubricant level and top up as necessary

with the recommended lubricant, refer to

2.1 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

18. Start vehicle and check for exhaust leaks.

REPLACE (USING NEW OIL SEAL)

For this oper ation, new dual muff ler support to rear

crossmember retainers must be used on

reassembly.

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under trailing arms.

2. Remove propeller shaft, refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS.

3. Remove both drive shafts, refer to

2.6 DRIVE SHAFTS in this Section.

4. Check and record pre-load at pinion flange as

follows:

a. Fit a pulley to pinion flange and attach a

cord around pulley and to a spring

balance.

NOTE:

For 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.

This pre-load reading includes pinion

bearings, side bearings, m es hing ef f ec t of

gear set and pinion oil seal.

To determine pre-load, multiply reading

on spring balance by radius of pulley.

EXAMPLE:

W ith a pulley diameter of 152 m m, 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 26

N = 1.9 Nm.

5. Remove pulley from pinion flange.

Figure 4B-52

6. Using Tool No. J8614-10 with two suitable

bolts and nuts, hold pinion flange and slacken

flange retaining nut until end play can be f elt in

pinion shaft. Check oil seal and differential

side bearing pre-load, using spring scale as

outlined in steps 4a and 4b and record oil seal

and side bearing pre-load for later use.

Figure 4B-53

7. Place drain tray beneath differential carrier

housing.

8. Withdraw pinion flange using the three

component parts of Tool No. J8614-01, as

shown.

Figure 4B-54

9. Prise pinion oil seal from carrier bore using

Tool No. 56750 or a universal seal removing

tool.

Figure 4B-55

10. Examine carrier seal bore and remove any

nicks or burrs.

11. Lubricate new pinion oil seal lips with the

recommended rear axle lubricant. Lightly coat

outside of seal shell with a non-hardening

gasket cement.

12. Start oil seal in differential carrier and drive

seal squarely into position using Tool No. 17-

010A. Seal fits flush to 0.25 mm below carrier

seal bore leading surface.

13. Ensure that pinion shaft threads are free from

burrs, then coat splines and seal surface of

pinion flange with differential gear lubricant.

14. Coat splines and sealing surface of the pinion

flange with the recommended lubricant and

install flange on pinion shaft splines.

NOTE:

The new flange will be an interference fit on pinion

shaft splines and should only be pulled into place

by tightening the retaining nut. DO NOT, UNDER

ANY CIRCUMSTANCES, USE FORCE OR

HAMMER FLANGE DURING INSTALLATION

ONTO PINION FLANGE.

15. Tighten flange retaining nut gradually until

pinion shaft end play is reduced to

approximately 0.5 mm.

Figure 4B-56

16. Check new oil seal and differential assembly

pre-load using spring balance as previously

outlined in steps 4a and 4b. Record pre-load

for reassembly reference.

17. The pre-load reading for differential assembly

obtained in step 6, is s ubtracted f rom pre-load

reading obtained in step 16. The difference

between these figures represents extra lip

tension of new seal expressed as a Nm pre-

load figure. The difference between the pre-

load readings obtained in step 6 and 16 must

be added to pre-load reading obtained in step

4b to obtain a total pre-load reading.

THEORETICAL EXAMPLE

STEP 16 NEW OIL SEAL AND

SIDE BEARING PRE-

LOAD SETTING 1.47 Nm

STEP 6 OLD OIL SEAL AND

SIDE BEARING PRE-

LOAD READING 1.02 Nm

SUBTRACT STEP 6

FROM STEP 16 0.45 Nm

STEP 4b COMPLETE

DIFFERENTIAL

ASSEMBLY PRE-LOAD

READING

1.47 Nm

THE PRE-LOAD READING

COMBINATION WILL BE

THE SUM OF:-

1.47 Nm

plus

0.45 Nm

WHICH GIVES A TOTAL

PRE-LOAD READING OF:-1.92 Nm

CAUTION:

Should the retaining nut be overtightened 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.

18. Continue tightening retaining nut while

alternately turning pinion to seat bearings until

total pre-load figure obtained in step 17 is

achieved, then increase this pre-load reading

by 0.11 to 0.34 Nm. Further rotate pinion an

extra 30-40 turns and recheck pre-load to

ensure that no change has occurred.

NOTE:

It mus t be realised that the pr e-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.

19. Reinstall drive shafts, refer to

2.6 DRIVE SHAFTS in this Section.

20. Reinstall propeller shaft, refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS.

21. If removed previously, reconnect exhaust

system, reverse of the removal procedure.

22. Remove safety stands and lower vehicle.

23. Check lubricant level and top up as

necessary, refer to

2.1 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

24. Start vehicle and check for exhaust leaks.

3. MAJOR SERVICE OPERATIONS

3.1 TRAILING ARM TRUNNION FLANGE, TRUNNION ASSEMBLY AND/OR

WHEEL BEARING

Figure 4B-57

The following procedure involves the removal of the trunnion flange, trunnion and/or wheel bearing with the trailing

arm installed on the vehicle. A similar procedure is included in Section 4A REAR SUSPENSION, involving the

trailing arm removed from the vehicle.

For this operation, a new lock plate and collar nut must be used on reassembly.

NOTE 1:

The rear wheel bearing should only be removed if it is faulty, or if the trunnion assembly is removed.

NOTE 2:

The trunnion assembly for VT Series vehicles is 1 mm shorter than previous models and is identified by a

circumferential groove on the outside diameter of the flange.

REMOVE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under trailing arms.

2. Remove wheel cover (steel wheels) or centre

cap (alloy wheels) from side of vehicle which

component/s are to be removed.

3. Mark relationship of wheel to m ounting f lange.

Remove road wheel attaching nuts and

remove wheel.

4. Using holding bar, Tool No. KM468 to hold

trunnion assembly from rotating, loosen and

remove drive shaft constant velocity joints to

inner axle shaft and trunnion flange attaching

bolts and plates, remove drive shaft.

Figure 4B-58

5. Remove rear shock absorber lower mounting

bolt from trailing arm, and pull shock absorber

from trailing arm.

Figure 4B-59

6. Remove rear brake caliper anchor plate to

trailing arm attaching bolts, remove caliper

from disc.

Using wire, tie up caliper to lower end of s hock

absorber upper mounting. DO NOT ALLOW

CALIPER TO HANG BY BRAKE HOSE.

7. Remove rear brake disc.

Figure 4B-60

8. Using Torx bit socket, Tool No. AU416,

rem ove brake back ing plate to trailing arm two

upper rear bolts. Then remove the longer,

hexagon headed, lower bolts

Figure 4B-61

9. Secure Tool Nos . KM620-1-A and KM620-2 to

trunnion flange with three drive shaft constant

velocity joint to trunnion flange attaching bolts.

Figure 4B-62

NOTE:

Align holes marked 'B' on KM620-1-A and KM620-2

with holes in trunnion flange before installing bolts.

Figure 4B-63

10. Install a suitable length and diameter steel

tube over handle of KM620-1-A, and while

holding KM620-1-A from rotating, loosen and

remove collar nut and lock plate.

NOTE:

Once c ollar nut and lock plate have been rem oved,

they m ust be discarded as they are only to be us ed

once.

Figure 4B-64

11. Apply grease to ball of Tool No. KM620-5-B.

Assemble KM620-3 to KM620-4-A and install

KM620-5-B into KM620-3. Assemble bearing

assembly (part of KM620-A) to KM620-4 and

install KM620-4 to KM620-1-A using three

bolts (part of KM620-A).

Secure the assembled tool and spacer ring,

Tool No. KM620-2, to the trunnion assembly,

using three drive shaft constant velocity joint to

trunnion flange attaching bolts.

Figure 4B-65

12. While holding KM620-1-A from rotating, turn

the screw KM620-3, forcing the flange free

from the trunnion.

Separate components from flange once it has

been removed.

Figure 4B-66

13. Working from the rear of the backing plate,

install the three distance pieces, KM620-7, to

the backing plate to trailing arm bolt holes.

Assemble KM620-4-A, KM620-3 and KM620-

5-B with three bolts to KM620-1-A (as in step

10). Install and tighten attaching nuts (part

KM620-A), to KM620-7.

Figure 4B-67

14. While holding KM620-1-A from rotating, turn

the screw KM620-3 to press trunnion from rear

wheel bearing.

Once trunnion has been removed, remove

nuts holding KM620-1-A assembly to the

distance pieces, KM620-7. Rem ove KM620-1-

A, and remove KM620-5-B from KM620-3.

Figure 4B-68

15. Remove wheel bearing retaining ring from

trailing arm.

Figure 4B-69

16. Install KM620-6 to rear of bearing. Install

KM620-1-A assembly and install attaching

nuts, as shown.

17. While holding KM620-1-A, turn the screw

KM620-3, to press wheel bearing from trailing

arm.

Figure 4B-70

REINSTALL

To install new bearing:

1. Ensure that bearing bore of trailing arm is

clean and free of any foreign matter.

2. Coat outside diameter of new wheel bearing

and bore of trailing arm with lubricant meeting

Holden's Specification HN1326 (Molybond

HE50, or equivalent).

3. Remove KM620-1-A from distance pieces

KM620-7. Install sleeve KM620-9-A over

KM620-3, with the stepped end facing away

from the trunnion bearing.

Install KM620-8-A to new bearing and insert

into the bore of the trailing arm. Screw the

threads of KM620-8-A and KM620-3 together.

Reinstall KM620-1-A to KM620-7, tightening

the attaching nuts. Then, while holding

KM620-3 and KM620-1-A from turning, rotate

KM620-4-A to draw bearing into position.

When the bearing is fully installed, remove

KM620-8-A and fit retaining ring into trailing

arm, ensuring that it is seated correctly. Figure 4B-71

To reinstall trunnion:

1. Remove KM620-1-A from distance pieces,

KM620-7. Install KM620-9-A over KM620-3,

with the stepped shoulder facing away from

the trunnion bearing. Reinstall KM620-1-A to

KM620-7, tightening the attaching nuts.

2. Screw the threaded end of the trunnion into

KM620-3. While holding KM620- 3 and KM620-

1-A from turning, rotate KM620-4-A to draw

trunnion into wheel bearing.

3. Remove KM620-3 from trunnion and remove

the three distance pieces of KM620-7 from

trailing arm. Figure 4B-72

4. Assemble KM620-2 and KM620-1-A to

trunnion flange using three drive shaft

constant velocity joint to flange bolts.

5. Lubricate trunnion flange splines and trunnion

threads with the recommended differential

carrier lubricant.

6. With KM620-4-A, ball bearing assembly and

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

thread of KM620-3 onto trunnion assembly.

Figure 4B-73

7. While holding KM620-3 from turning, rotate

KM620-4-A to draw trunnion flange onto

trunnion.

Figure 4B-74

8. Remove the components of KM620-A from

trunnion and trunnion flange.

9. Install NEW collar nut to trunnion assembly

and, using KM620-1-A and KM620-2 to hold

trunnion assembly from turning, tighten collar

nut to the correct torque specification.

COLLAR NUT TO TRUNNION ASSY 295 - 305

TORQUE SPECIFICATION Nm

Figure 4B-75

10. Using a 1.25 inch socket, 150 mm socket bar

and a soft faced hammer, install new lock

plate over collar nut.

Figure 4B2-76

11. Assemble drive shaft outer constant velocity

joint to trunnion flange, aligning bolt holes.

Install attaching bolts with plates and tighten

bolts to the correct torque specification.

DRIVE SHAFT CONSTANT

VELOCITY JOINT TO TRUNNION 50 Nm, then

FLANGE ATTACHING BOLT 60° - 75

TORQUE SPECIFICATION turn angle

Figure 4B-77

12. Install rear disc brake shield to trailing arm

bolts and tighten to the correct torque

specification.

REAR DISC

BRAKE SHIELD TO Upper: 70 - 80 Nm

TRAILING ARM

ATTACHING BOLT Lower: 85 - 90 Nm

TORQUE SPECIFICATION

NOTE 1:

The two upper bolts have washers. The washers

are installed with the cut-out surface facing around

the trailing arm hub outer surface.

NOTE 2:

Apply Loctite 242 thread sealant or equivalent (to

Holden's Specification HN1256, Class 2 Type 1) to

the threads of the two longer, lower hexagon

headed bolts, before installation.

Figure 4B-78

13. Install brake disc and brake caliper. Install

brake caliper anchor plate to trailing arm

attaching bolts and tighten to the correct

torque specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING 70 - 100 Nm

BOLT TORQUE SPECIFICATION

Figure 4B-79

14. Install shock absorber to trailing arm, install

and tighten lower mounting bolt to the correct

torque specification.

SHOCK ABSORBER LOWER

MOUNTING BOLT 105 - 125 Nm

TORQUE SPECIFICATION

NOTE:

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

15. Install road wheel and tighten attaching nuts.

NOTE:

When installing the wheel, align the marks made

prior to removal.

16. Remove safety stands and lower vehicle.

17. Tighten road wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

18. Refit wheel cover/centre cap. Figure 4B-80

3.2 FINAL DRIVE ASSEMBLY

IMPORTANT:

Before disturbing the rear suspension crossmember mounting bolts, an alignment procedure is required on

installation 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.

CAUTION :

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, using the procedure as detailed in DIAGNOSIS, ABS

FUNCTION CHECK, in Section 12L ABS/Traction Control.

NOTE 1:

For this operation, NEW rear crossmember rear mount to vehicle underbody attaching bolts, differential carrier to

crossmember attaching bolts and intermediate muffler support to rear crossmember retainers must be used on

reassembly.

NOTE 2:

If rear mount is removed from rear cover, NEW bolts must also be installed on reassembly.

REMOVE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under body rear jacking points.

Refer to Section 0A GENERAL

INFORMATION for location of jacking points.

2. Remove rear wheel covers (steel wheels) or

centre caps (alloy wheels).

3. Mark relationship of wheels to mounting

flange. Remove road wheel attaching nuts and

remove wheel.

4. Disconnect exhaust system from rear of

catalytic converter (V6) or converters (V6

Supercharged and V8).

NOTE:

Only one side of the V6 Supercharged/V8

arrangement is shown.

Figure 4B-81

5. Remove the two retainers from the top posts

and discard. Disconnect exhaust system

support rings from the rear hanger of the rear

muf fler. Both V6 and V8 arrangem ents are the

same.

Figure 4B-82

6. Remove muffler support to rear crossmember

hanger retainers (2 places - V6, 4 places - V6

Supercharged and V8) and discard.

7. Lift up intermediate section of exhaust system

and remove intermediate muffler support

rubbers. Remove intermediate and rear

sections of exhaust system from vehicle.

Figure 4B-83

8. Remove propeller shaft, refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS.

9. Set park brake in fully released position.

10. Release each of the underbody to park brake

cable retaining clips and free cables.

Figure 4B-84

11. Remove park brake outer cable retaining

bracket bolt from the vehicle underbody.

12. Pull each park brake inner cable forward and

up, (1) out of the cable retainer. Pull the cable

rearwards (2) to remove from the retaining

bracket.

Figure 4B-85

13. Disconnect brake pipes from brake hoses at

trailing arm brackets and remove brake hose

retaining clips.

Remove brake hoses from brackets.

Cap ends of brake pipes to prevent the entry

of foreign matter.

Figure 4B-86

14. Pull differential carrier breather hose from

underbody crossmember hole.

15. If equipped with ABS, disconnect both sensor

electrical connectors, as shown.

Figure 4B-87

16. Using a scriber, mark rear mount to vehicle

under body location. This will aid in rear

crossmember reinstallation and to ensure that

rear end 'toe' setting is maintained.

Figure 4B-88

17. Support weight of differential carrier with floor

jack.

18. Remove rear mount to vehicle underbody

attaching bolts and discard.

Lower rear of differential carrier and rear

crossmember assembly at least 60 mm.

Figure 4B-89

19. Position a second floor jack under left and

right trailing arm s in turn and raise jac k slightly

to take spring load off trailing arms.

Disconnect rear shock absorber lower

mounting bolts from trailing arms, and pull

shock absorber lower ends from lower trailing

arms.

NOTE:

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.

This bruising will lead to premature failure of the

boots and eventual failure of the joints if left

unchecked.

Figure 4B-90

20. Remove rear springs and insulators from

vehicle underbody and trailing arms.

Figure 4B-91

21. If replacing differential carrier assembly, rear

cover or rear m ount, loosen rear m ount to rear

cover attaching bolts.

Figure 4B-92

22. Raise differential carrier and rear

crossmember on floor jack until rear mount

contacts underbody.

23. Remove brace to vehicle underbody attaching

bolts.

24. With the aid of an assistant, remove rear

crossmember to underbody bolts and braces.

25. With assistant supporting front end of rear

crossmember, lower assembly on jack and

remove from beneath vehicle.

Figure 4B-93

26. Using an 8 m m Allen key socket, r emove dr ive

shaft inner constant velocity joint to inner axle

shaft attaching bolts and plates.

Disconnect joints from inner axle shafts.

NOTE:

Support drive shafts so that they do not hang on

one end. Drive shaft joint def lection should be kept

to within the angular movement of an ins talled dr ive

shaft.

Figure 4B-94

27. Remove differential carrier to rear

crossmember attaching bolts, remove rear

crossmember assembly from differential

carrier and discard attaching bolts.

28. If not carried out in step 21, remove rear

mount to rear cover attaching bolts, remove

mount and discard attaching bolts.

Figure 4B-95

REINSTALL

Installation is the reverse of removal procedure with

attention to the following points:

1. If necessary, install NEW rear mount to rear

cover but leave bolts finger tight at this stage.

2. Line up mounting holes in differential carrier

and rear crossmember. Install new attaching

bolts and tighten to the correct torque

specification.

DIFFERENTIAL CARRIER TO REAR 90 Nm, then

CROSSMEMBER ATTACHING 30° - 45°

BOLT TORQUE SPECIFICATION turn angle

Figure 4B-96

3. Inspect drive shaf t constant veloc ity joint boots

for damage, replace as necessary.

4. Tighten drive s haft inner c onstant veloc ity j oint

to inner axle shaft attaching bolts to the

correct torque specification.

DRIVE SHAFT CONSTANT

VELOCITY JOINT TO TRUNNION 50 Nm, then

FLANGE ATTACHING BOLT 60° - 75°

TORQUE SPECIFICATION turn angle

Figure 4B-97

5. With the aid of two assistants, place the

differential carrier and rear crossmember

assembly onto a floor jack.

Position assembly under vehicle, and raise up

assembly on jack with assistants guiding

crossmember front mounting points into

location.

NOTE:

When raising assembly, take care that the rear

mount does not foul on fuel tank or fuel hose from

sender unit.

6. Install crossmember front mounting braces

and bolts but do not tighten bolts at this

stage.

Figure 4B-98

7. Lower rear of as s embly to allow access to r ear

mount-to-rear cover attaching bolts. Tighten

NEW attaching bolts to the correct torque

specification. At the same time, ensure that

the mount does not twist (mount to vehicle

underbody mating surface should be parallel

to rear crossmember, as shown in Figure 4B-

105).

NOTE:

Use a spirit level on rear mount to underbody and

top surface of crossmember to ensure that both

surfaces are parallel.

REAR MOUNT TO REAR COVER

ATTACHING BOLT 85 - 105 Nm

TORQUE SPECIFICATION

Figure 4B-99

8. Lower differential carrier and rear

crossmember assembly on floor jack and

safety stands. Install rear springs and

insulators.

NOTE:

During this operation, the differential carrier and

rear crossmember assembly rear mount must be

lowered at least 60 mm from the vehicle

underbody, or else damage to the drive shaft

constant velocity joint boots will occur.

Figure 4B-100

9. Use a second floor jack to raise each trailing

arm up far enough to allow shock absorber

lower mounting to be installed.

Install bolts and washers to shock absorber

lower mounts and trailing arms. Tighten bolts

to the correct torque specification.

SHOCK ABSORBER LOWER

MOUNTING BOLT 105 - 125 Nm

TORQUE SPECIFICATION

NOTE 1:

Vehicle must be at curb weight and on all four

wheels before this torque is applied.

NOTE 2:

Sedan and station wagon torque specifications are

the same.

Figure 4B-101

10. Raise differential carrier and rear

crossmember assembly until rear mount

contacts vehicle underbody.

11. Align mount with marks on underbody, made

on disassembly, and install and tighten new

attaching bolts but do not fully tighten at

this stage.

12. The rear crossmember MUST now be aligned

to the vehicle centreline, us ing the special tool

and procedure, as detailed in

Section 1A2 BODY DIMENSIONS.

IMPORTANT:

Failure to correctly align the rear crossmember

to the centreline of the vehicle will result in

steering abnormalities and uneven tyre wear!

Figure 4B-102

14. Tighten all crossmember mounting fasteners

to the correct torque specifications.

REAR MOUNT TO

VEHICLE UNDERBODY 30 Nm, then

ATTACHING BOLT 60° turn angle

TORQUE SPECIFICATION

REAR CROSSMEMBER FRONT 125 Nm, then

MOUNTING BOLT 30° - 45°

TORQUE SPECIFICATION turn angle

CROSSMEMBER FRONT

MOUNTING BOLT 60 - 70 Nm

TORQUE SPECIFICATION

14. If vehicle is equipped with ABS, reconnect

sensor wiring harness connectors.

15. Reinstall park brake inner cables to the front

retainer, install and secure outer cables in the

underbody retainers, then install the outer

cable retaining bracket bolt to the vehicle

underbody.

16. Check and fill differential carrier to correct level

with specified lubricant, refer to

2.1 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

17. Chec k park brak e adjustment and bleed br ake

hydraulic system, refer to

Section 5A, STANDARD BRAKES.

18. Reinstall propeller shaft. Refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS.

19. Reconnect exhaust system, in reverse to the

removal procedure, ensuring that a new

intermediate exhaust pipe to catalytic

converter gasket is installed on V8 powered

vehicles. Tighten the retaining bolts to the

correct torque specification.

INTERMEDIATE EXHAUST PIPE All Engines

TO CATALYTIC CON VERTER 40 - 50 Nm

BOLT TORQUE SPECIFICATION

20. Check exhaust clearances as detailed in

Section 8B EXHAUST SYSTEM.

21. Start vehicle and check for exhaust leaks,

repair as necessary.

Figure 4B-103

3.3 REMOVED FINAL DRIVE ASSEMBLY

Figure 4B-104

REF. No. PART NAME REF No. PART NAME

1 NUT - Pinion flange retaining

2 FLANGE ASSEMBLY - Differential pinion

3 SEAL - Rear axle pinion oil

4 BEARING ASSEMBLY - Pinion front

5 SPACER - Pinion bearing

6SHIM - Pinion position adjusting

7 BREATHER ASSEMBLY - Rear axle

8 BEARING ASSEMBLY - Pinion Rear

9 RING GEAR AND PINION

10 BEARING ASSEMBLY - Differential side

11 SCREW - Differential side bearing

adjusting

12 BEARING ASSEMBLY - 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 - Rear axle

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 SHIM - Differential side gear (LSD, V6

only)

32 PLATE - Thrust spring (LSD only)

33 CONE - Clutch (LSD, V6 only)

34 SPRING - Differential pre-load - outer

(LSD only)

35 SPRING - Differential pre-load -middle

(LSD only)

36 SPRING - Differential pre-load -inner

(LSD only)

37 SHAFT - Cross (LSD only)

38 BOLT - Ring gear to case

39 PIN - Dowel

40 BOLT - Case cap to cover

41 CARRIER

42 TAG - Lubrication

43 LABEL - Rear axle identification (Not

shown. See Figure 4B-2)

DISASSEMBLE

1. Remove differential carrier assembly. Refer to

3.2 FINAL DRIVE ASSEMBLY in this

Section.

2. Secure holding tool (either fabricated or Tool

No. KM480) to differential carrier using two of

the discarded differential carrier to rear

crossmember attaching bolts.

For details of holding tool, refer to

7 SPECIAL TOOLS at the end of this Section.

3. Install holding tool into bench mounted fixture

base, Tool No. J-3289-20.

Figure 4B-105

4. Remove rear cover to differential carrier

attaching bolts and sc rew adjuster loc k plates.

Using a soft faced hammer, tap rear cover at

rear mount area to break rear cover to

differential carrier seal. Remove rear cover

and allow differential lubricant to drain into a

suitable container.

Figure 4B-106

5. Before removing differential case assembly

and drive pinion from differential carrier, the

following inspection procedures should be

adopted. These inspections can help find the

cause of final drive assembly noise and

determine corrections needed.

a. Visually inspect the moving parts for

chipped or scuffed surfaces.

b. Check the torque of the ring gear bolts

and the pinion flange nut.

NOTE:

Ring gear bolts have a left hand thread.

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 0.13 mm

RUN-OUT SPECIFICATION maximum

d. Leave the dial indicator set up and push

the ring gear hard one way, then hard the

opposite way to m easur e side play. There

should be no side play present.

Check to ensure that there is no pinion

end play.

If end play is evident, then special

attention should be made to the bearing

inspection process, after disassembly.

Figure 4B-107

e. Set up the dial indicator to measure ring

gear backlash at three equally spaced

positions.

BACKLASH 0.10 - 0.18 mm, at

SPECIFICATION the tightest point

f. If no obvious faults are found, check the

gear tooth contact pattern. Refer to Ring

Gear and Pinion Contact Pattern in this

Section.

Figure 4B-108

6. Remove inner axle shafts by installing a slide

hammer, Tool No. 09520-32012 and three

suitable size bolts to each axle flange. Use

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 4B-109

7. 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 4B-110

8. Remove screw adjusters from housing using

Tool No. AU407.

9. Remove differential case assembly from

carrier housing.

Figure 4B-111

10. To remove side bearing cups from screw

adjusters, install screw adjusters, reversed,

into differential carrier. 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 are only to be removed if side

bearing assemblies are to be replaced.

Figure 4B-112

11. Install Tool No. 4A39/1 to the pinion flange

using two suitable bolts and nuts. While

holding 4A39/1, loosen and remove pinion

flange retaining nut.

Figure 4B-113

12. Remove holder from pinion flange and

assemble nut 4A39/2 and screw 4A39/3 to

holder, 4A39/1. Install assembly to pinion

flange using two suitable bolts and nuts. While

holding 4A39/1, tighten screw 4A39/3 to

remove pinion flange.

Figure 4B-114

13. Pry pinion oil seal out of carrier bore using

Tool No. 56750 or a suitable seal extraction

tool.

Figure 4B-115

14. Remove pinion by tapping on front end with a

soft faced hammer and withdrawing it through

rear of carrier. Remove pinion front bearing

from carrier bore. Remove and discard pinion

bearing spacer.

Figure 4B-116

15. If pinion bearings are to be replaced, remove

bearing cups using Tool No. E9293. As shown

in Figure 4B-123, Tool No. E9271 is used for

installing new bearing cups.

Figures 4B-122 and 4B-123 illustrate both the

removal and installation of bearing cups.

Figure 4B-117

NOTE:

It is essential to only replace one bearing cup at a

time, as Tool No. E9271 relies on the remaining

bearing cup as a guide.

Figure 4B-118

16. To remove rear bearing from pinion, remove

legs from the ring of Tool No. E1673MT.

Place ring on suitable press plates. Install

pinion and adaptors E1673A15 into ring. Pr ess

pinion from bearing.

Figure 4B-119

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 differential for V8 and V6 supercharged

engined vehicles is unique and parts are not

interchangeable with the V6 engined unit. The

general overhaul procedures however, remain the

same for both types. The unique components for

the V8 and V6 super charged, are; dif ferential c ase,

differential pinions, side gears and thrust block.

1. Before disas s embling dif f er ential ca se, ins pec t

differential side bearings for any signs of

damage.

NOTE:

Both side bearings and their cups are matched

pairs. If either bearing is to be replaced, its

matching cup must also be replaced.

2. If necessar y, us e Tool No. E1673MT , adaptors

E1673N15 and stepped plug E1673B16 to

remove side bearings from differential case, as

shown.

Discard side bearings once they are removed.

To remove side bearing cups, refer to

3.3 REMOVED FINAL DRIVE ASSEMBLY -

DISASSEMBLE step 10.

Figure 4B-120

3. Grip the differential case in a vice with soft

jaws.

4. Remove ring gear attaching bolts.

NOTE:

Ring gear attaching bolts use a left hand thread and

are identified by an 'L' on the bolt head.

5. Remove differential case from vice.

Figure 4B-121

6. Using a soft faced hammer, remove ring gear

from differential case by hitting down on ring

gear. Support ring gear during this operation

so that it does not strik e bench top as it com es

free of case.

NOTE:

Do not use a screwdriver to pry between ring gear

and case.

Figure 4B-122

7. Drive out differ ential pinion gear long shaf t and

short shafts retaining pins from differential

case, using a suitable size pin punch and

hammer.

Figure 4B-123

8. Re-mount the differential case in vice with soft

jaws. Using a brass drift and hammer, drive

out pinion long shaft from differential case.

Figure 4B-124

9. Remove differential case from vice. Using a

brass drift and hammer, separate two

differential case halves by driving against

thrust block.

NOTE:

Do not use a screwdriver to prise the differential

case halves apart.

Figure 4B-125

10. Using a brass drift and hammer, drive out

pinion gear short shafts from differential case.

Figure 4B-126

11. Lift out pinion gears, thrust washers and thr ust

block from differential case.

Remove differential side gears and thrust

washers from differential case halves.

NOTE 1:

When removing the thrust block from a V8 or V6

supercharged differential, note that the pinion

shafts are angled at 96° and not 90° as is usual.

NOTE 2:

Keep the gears with their r espective thrust washers

in pairs so they can be reinstalled in their original

position. Figure 4B-127

INSPECT

All components should be thoroughly cleaned and

dried, then inspected.

Differential Case

Check case for general soundness and pay

particular attention to the following points;

1. If differential case side bearings have been

rem oved, check case j ournals f or damage and

that bearing seating surf ac es ar e f r ee f rom dir t

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 ex am ined f or exces sive

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 splines should be

checked for excessive wear. W ear 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 in rear axle assembly when

vehicle is driven at low speeds.

5. Inspect differential pinion bores and thrust

surfaces for scoring. Also check differential

pinion gear 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.

Ring Gear and Pinion

1. Inspect gear teeth for scoring or damage.

Scoring of gear teeth is usually caused by

excessive shock loading, use of incorrect

lubricant or ins uf ficient "run in" bef or e towing a

heavy load. (Refer VT Series Owner's

Handbook). Scored gears must be replaced.

2. The ring gear bore and back face should be

clean and free from burrs.

3. The rear bearing seating s urf ace on the pinion

should 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 appears on both the pinion and ring

gear, as shown.

7. On ring gear bolts, clean Durlok serrations

under bolt flange.

Figure 4B-128

Bearings

1. Bearing cups should have an even wear

pattern and must be free from flaking or

pitting. Ensure that seating surf aces are clean

and free from burrs or raised metal.

2. The bearing assemblies 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 show no evidence of flaking

or pitting.

Refer to 4.4 FINAL DRIVE BEARING

DIAGNOSIS in this Section, for identification

of bearing failures.

Differential Carrier

1. Check casting all over for general soundness.

2. Examine oil passages and ensure they are

free from obstructions and loose particles.

3. The bore f or 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.

Screw Adjusters and Inner Axle Shafts

1. Inspect inner ax le s haf t needle bearings ins ide

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 shaf t

seals, as detailed in steps 6 and 7 of

3.3 REMOVED FINAL DRIVE ASSEMBLY -

DISASSEMBLE.

Remove screw adjusters from carrier and

position each onto a block of wood. Then,

using a 1.25 inch socket and bar or a 73 mm

diameter tube, press the bearing from each of

the screw adjusters.

3. Remove and discard O-rings from screw

adjusters.

4. Examine adjuster seal bores for burrs, nicks or

other damage. Examine oil passages and

ensure they are free from obstructions and

loose particles.

Adjuster thread and bearing bores should be

clean and free from burrs or other damage. Figure 4B-129

5. To ins tall new screw adjuster needle bearings,

place screw adjuster onto Tool No. AU409 and

press needle bearing into adjuster using Tool

No. AU411. Repeat procedure for opposite

screw adjuster.

NOTE 1:

Side bearing cups must be installed into screw

adjusters before installing needle bearings. This is

to ensure that needle bearings ar e located c or rec tly

into screw adjuster bores.

NOTE 2:

To install side bearing cups, refer to step 1,

Differential Case Side Bearing Pre-Load Setting in

this Section.

Figure 4B-130

6. Examine seal surface of inner axle shafts and

carefully remove any nicks or burrs.

Should this surface be irreparable on either

axle shaft, a new axle shaft must be fitted.

7. Check spring clip in end of inner ax le shaf ts to

ensure that they are not damaged and move

freely in grooves. Replace spring clips if

necessary, by expanding ends of each clip

and removing from inner axle shafts. Expand

ends of new clips sufficiently to allow

installation into axle 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 clean and free of

obstructions.

REASSEMBLE

Differential Case

1. Lubricate all differ ential gears, bearings, thrus t

washers and differential pinion gear shafts

with the recommended rear axle lubricant

before assembly.

2. Position differential side gears with their thrust

washers into differential case halves.

Figure 4B-131

3. Using a soft faced hammer, install pinion gear

short shafts and long shaft into differential

case, j ust enough to allow a pinion gear thrust

washer to sit on the end of each shaft.

NOTE:

Ensure that the retaining pin holes in the dif ferential

case and pinion gear shafts are in alignment and

with the cham fered edge of the holes in each shaft

facing up.

Figure 4B-132

4. Install one of the pinion gear thrust washers

over inside end of one of the short shafts.

5. Position appropriate pinion gear next to thrust

washer and knock short shaft in until it com es

through centre of the gear.

6. Carry out steps 4 and 5 for sec ond pinion gear

short shaft.

Figure 4B-133

7. Install thrust block 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

differential case.

Figure 4B-134

8. Install pinion gear thrust washer and gear to

long shaft. Knock cross shaft through gear and

thrust block.

Figure 4B-135

9. Install remaining pinion gear and thrust

washer. Knock long shaft through pinion gear,

ensuring that thrust washer aligns with cross

shaft. Knock cross shaft into differential case

until retaining pin hole in shaft aligns with hole

in differential case.

Figure 4B-136

10. Install pinion gear long shaft and short shaft

retaining pins. Ensure that ends of retaining

pins protrude 6 mm from differential case cap

to cover mating surface. This is necessary to

provide a positive location for the differential

case cover to case cap.

Figure 4B-137

11. Holding differential side gear in position with a

finger through differential case cover bore as

shown, push the two differential case halves

together, locating on the protruding retaining

pins.

Figure 4B-138

12. Place ring gear into position on differential

case cap and install ring gear attaching bolts.

NOTE 1:

For ease of assem bly, it m ay 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.

NOTE 2:

On no account must a flame be used to heat the

ring gear.

NOTE 3:

Use left hand threaded guide pins to pilot the ring

gear over the differential case spigot.

13. Install and gradually tighten NEW ring gear

attaching bolts evenly, until gear face is flush

with differential cas e s pigot. T ighten all bolts to

the correct torque specification.

DIFFERENTIAL RING GEAR 125 - 150

BOLTS TORQUE SPECIFICATION Nm

NOTE:

Ring gear attaching bolts use a left hand thread

and are identified by an 'L' on the bolt head.

Figure 4B-139

14. If installing new side bearings, use Tool No.

E9277 to press on side bearings to differential

case journals.

Figure 4B-140

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

press new cup into place. Repeat procedure

for remaining screw adjuster.

NOTE 1:

Ensure that bearing side and cup matching is

maintained.

NOTE 2:

The screw adjuster used on the V8 and V6

supercharged engine final drives is 1.9 mm deeper

than the one used for V6. The deeper screw

adjuster can be identified by a groove on the inner

edge.

This depth change is necessary to accommodate

the greater side bearing span used with the V8 and

V6 supercharged axle assemblies. Figure 4B-141

2. Install new O-rings to screw adjusters and

apply a lubricant such as rubber grease to

each.

3. Holding differential case in carrier, fit screw

adjusters to both sides of carrier. Continue

tightening adjusters until case assembly is

supported by side bearings.

4. Rotate differential case several times to

ensure that side bearings are correctly seated.

5. W r ap a piece of st ring around diff erential case

flange and check side bearing pre-load by

pulling on end of string with a spring balance.

Spring balance reading must be within

specification.

Tighten or loosen one of the screw adjusters

until the correct pre-load is obtained.

SIDE BEARING

PRE-LOAD 15 - 35 N (New Bearings)

SPECIFICATION 8 - 18 N (Used Bearings)

Figure 4B-142

6. Using Tool No. AU407 and a torque wrench,

measure tightening torque of each screw

adjuster (usually within the range of 50-60 Nm)

and record.

These torque readings will be used to set

bearing pre-load on final assembly.

7. Using Tool No. AU407, loosen and remove

screw adjusters, remove differential case

assembly.

Figure 4B-143

Hypoid Pinion Positioning Shim Selection

The pinion positioning shim is located between

pinion rear bearing cup and carrier housing.

If the ring gear and pinion or the pinion rear bearing

assembly are replaced, pinion depth must be

rechecked with pinion setting gauge, Tool No.

E9300A (previously released as E9300) and

dummy arbor Tool No. AU408.

The gauge and arbor provide a nominal or 'zero'

pinion as a gauging reference.

NOTE 1:

If a new gear set is to be installed, ensure that the

sam e matc hing number appear s on both the pinion

and the ring gear.

NOTE 2:

The V6 and V8/V6 supercharged pinions have

different mounting distances (94.49 and 102.50

mm respectively). Also, as the V6 and V8/V6

superchar ged assem blies have dif f erent rear pinion

bearings, gear set sizes, differential case

assemblies and screw adjusters, none of these

parts are to be mixed. Figure 4B-144

1. Inspect pinion bearing cups/cones for nicks

and burrs. Replace if damaged (refer to Step

16 of 3.3 REMOVED FINAL DRIVE

ASSEMBLY - DISASSEMBLE).

2. Lubricate pinion front and rear bearings with

the recom mended dif ferential car rier lubricant.

Do not use engine or other oils, as a

misleading rotating torque can be obtained.

V6 Vehicles with the 3.08:1 Ratio Axle

Assembly:

3a. Install the rear bearing onto dummy pinion

after first installing the distance spacer Tool

No. E9300-1 (part of Tool No. E9300A).

NOTE:

The spacer is not required when using E9300.

V8/V6 Supercharged Vehicles with the 3.07:1

Ratio Axle Assembly:

3b. Install the rear pinion bearing onto the dum my

pinion, supplied as part of E9300A.

4. Install dummy pinion and rear bearing into

carrier housing. Fit front bearing to dummy

pinion and then install dummy pinion thrust

collar and nut.

NOTE:

Ensure that the rear pinion bearing that will be used

for final reassembly of the pinion is used on the

dummy pinion.

5. Tighten nut on end of dummy pinion until

specified rotational torque is obtained.

DUMMY PINION, 1.4 - 2.0 Nm

ROTATIONAL (New Bearings)

TORQUE 0.7 - 1.0 Nm

SPECIFICATION (Used Bearings)

6. Rotate dummy pinion back and forth during

tightening to ensure that bearings settle in

their cups.

NOTE 1:

Pinion bearing pre-load is very important bec ause it

retains pinion in its correct relationship to ring gear.

NOTE 2:

Bearings that are installed with insufficient or no

pre-load, will, after a comparatively short period of

running, develop end play, causing noisy operation

on overrun and could be r esponsible for s cuffing of

ring gear and pinion teeth.

NOTE 3:

Bearings that have too much pre-load, may

become pitted or flaked and result in ultimate

failure.

NOTE 4:

It is therefore essential to ensure that bearings are

pre-loaded to specified torque specification.

NOTE 5:

Rotate dummy pinion back and forth during

tightening to ensure bearings settle.

Figure 4B-145

7. Position arbor Tool No. AU408 in carrier

assem bly and install screw adjusters with side

bearing cups. Adjust screw adjusters to lightly

clamp arbor, using Tool No. AU407.

NOTE:

Ensure that arbor is free of bur rs that may damage

bearing cups.

Figure 4B-146

8. Check clearance between arbor and head of

dummy pinion with a feeler gauge. Record this

dimension.

Figure 4B-147

9. On the end of the pinion, a drive pinion

installation marking figure is etched. A zero

marking ('0') indicates that shim size equal to

the dimension measured in Step 7 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 7, refer to the

following chart.

A negative marking, e.g. -3, means that a

thickness measurement equivalent to this

num erical m ar king mus t be added to the shim

size measured in Step 7. Refer to the f o llowing

chart for specific details.

PINION SHIM THICKNE S S

MARKING REQUIRED

–4 Add 0.10 mm t o measurement of step 7.

–3 Add 0.075 mm t o measurement of step 7.

–2 Add 0.050 mm t o measurement of step 7.

–1 Add 0.025 mm t o measurement of step 7.

0 Size as measured in s tep 7.

+1 Subtract 0. 025 mm from measurement of s tep 7.

+2 Subtract 0. 050 mm from measurement of s tep 7.

+3 Subtract 0. 075 mm from measurement of s tep 7.

+4 Subtract 0. 10 mm from measurement of s tep 7.

NOTE:

Pinion positioning shims are serviced in

thicknesses of 0.2 - to 0.75 mm in 0.25 mm

increments. They are also dimensioned differently,

depending on the pinion bearing used.

Figure 4B-148

10. Remove dummy pinion and arbor from carrier

assembly.

Pinion Installation

1. Select pinion positioning shim stack as

determined in the Operation, Hypoid Pinion

Positioning Shim Selection, in this Section.

2. Remove pinion rear bearing cup, using Tool

No. E9293.

Figure 4B-149

3. Install pinion positioning s him/s into pinion r ear

bearing cup bore.

Figure 4B-150

4. Reinstall pinion rear bearing cup using Tool

No. E9271. Ensure that cup is seated squar ely

in bore.

Figure 4B-151

5. Press rear bearing inner race against the

shoulder of the pinion, using Tool No.

E3C10AER.

NOTE 1:

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.

NOTE 2:

Locate bearing inner race squarely on the pinion

and press only on inner race surface.

NOTE 3:

Only lubricate the bearing with the recommended

differential carrier lubricant.

Figure 4B-152

6. Place the pinion in the carrier.

7. Lubricate pinion front bearing with the

recom mended dif ferential carr ier lubricant and

assemble the collapsible pinion bearing

spacer and front bearing onto pinion, while

supporting pinion head.

8. Install pinion flange and the original pinion

flange retaining nut.

9. Using Tool No. J 8614-10 to hold pinion flange,

tighten retaining nut until pinion front bearing

starts on pinion shaft.

10. Remove pinion flange retaining nut and, using

the three components of Tool No. J8614-01,

assembled as shown, remove pinion flange.

Figure 4B-153

11. Lubricate pinion oil seal lips with differential

carrier lubricant. Lightly c oat differential c arrier

seal bore with differential carrier lubricant to

assist in seal installation. Install oil seal into

carrier bore using Tool No. 17-010A. Seal fits

flush to 0.25 mm below carrier housing

surface.

Figure 4B-154

12. Reinstall pinion flange and f it a NEW retaining

nut. Hold pinion flange using Tool No. J8614-

10 and gradually tighten retaining nut while

rotating pinion in both directions to seat

bearings.

13. Check bearing pre-load frequently by

removing flange holding tool and installing a

pulley to pinion flange. Refer to

7 SPECIAL TOOLS at the end of this Section

for pulley details.

14. Using a spring scale, measure rotational

torque.

15. Tighten nut until specified torque is achieved.

PINION BEARING 1.4 - 2.4 Nm (New Bearings)

PRE-LOAD

SPECIFICATION 0.7 - 1.2 Nm (Used Bearings)

The torque figure is calculated by multiplying the

radius of the pulley by the spring balance reading.

EXAMPLE:

If the pulley diameter is 152 mm, the radius is 76

mm which equals 0.076 m. The spring balance

reading is 25 N. Therefore, the pre-load equals

0.076 m x 25 N = 1.9 Nm.

Figure 4B-155

CAUTION:

Should the retaining nut be overtightened 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.

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 as sem blies to both sides

of carrier. Using Tool No. AU407, continue

tightening adjusters until case assembly is

supported by side bearings.

3. Rotate differential case several times, to

ensure that side bearings are correctly seated.

4. Tighten screw adjusters to the torque setting

recorded in step 6, ‘Differential Case Side

Bearing - Pre-load Setting’, in this Section.

Figure 4B-156

5. Mount a dial indicator on carrier and check

gear backlash between the ring gear and

pinion. Back lash should be within the following

specification.

Check readings at four equally spaced

positions around ring gear.

NOTE:

Position the dial indicator so that the indicator

stylus is perpendicular to the ring gear tooth and in

line with gear rotation.

BACKLASH 0.10 - 0.18 mm at the

SPECIFICATION tightest point

6. 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 and tighten both as per step 4.

7. With backlash correctly set, check gear

contact pattern as detailed in the following

instructions.

Figure 4B-157

Ring Gear and Pinion Contact Pattern

1. Thoroughly clean 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 while lightly loading gear set.

To load gear set, use a suitable bar to lever

between ring gear outer 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 by above

procedure.

5. After a satisfactory contact pattern is

produced, clean the ring gear and pinion gear

teeth and pour a liberal quantity of the correct

rear axle lubricant onto the gears and

bearings. Turn the gear set to work the

lubricant into all surfaces.

Tooth marking Nomenclature

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 4B-158 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 'B', it indicates not enough backlash. To

correct, move the ring gear away from the pinion by

increasing the s ize of the shim on the pinion s ide of

the ring gear and decreasing the ring gear side

shim by an equal amount.

If the pattern shows a heel contact 'C', it indicates

too muc h backlash. T o correct, m ove the ring gear

towards the pinion by increasing the size of the

shim on the ring gear side and decreasing the size

of the shim on the pinion side of the ring gear by an

equal amount.

NOTE:

Make adjustment, increasing and decreasing shim

thickness by 0.04 mm at a time. Check contact with

gear marking compound and continue adjustment

until tooth contact appears as in 'A'. Back lash m ust

remain within specified limits.

To correct a pattern such as 'D', it will be necessary

to install a thicker pinion positioning shim as

described under HYPOID PINION POSITIONING

SHIM SELECTION in this Section. A 0.025 mm

thicker shim 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 contact pattern.

Moving the pinion 'IN' reduces backlash and

moving pinion 'OUT' increases backlash.

Figure 4B-158

IDEAL CONTACT

Figure 4B-159

Drive Side

A central toe contact marking, lengthwise in position and slightly low contact in the profile position.

Total length approximately 5/8 ths of the gear face width.

There should be clearance of about 1 mm between the contact marking and the toe and along the top face angle

line.

Coast Side

A centrally located marking, lengthwise in position and slightly high in the profile position.

Total length approximately 5/8 ths of the gear face width.

There should be clearance between the contact and the face angle line of the gear.

ACCEPTABLE HEEL CONTACTS

Figure 4B-160

Drive Side

A central face contact marking, lengthwise in position, is shown in Figure 4B-160. 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 shown and is acceptable, although low contact marking is preferred.

Coast Side

The centre of the contact marking is located at 5/8 ths of the face width from the toe and it does not approach the

heel end by less than 5 mm.

A high contact marking, as shown in Figure 4B-160, is preferred for coast side contacts which tend to be toward the

heel.

A central profile marking position is acceptable, providing the pinion face angle edge lines do not appear low on the

gear.

ACCEPTABLE TOE CONTACTS

Figure 4B-161

Drive Side

The contact markings begin almost at the toe end face and extend in length by approximately half the face width.

A slightly low contact marking is shown in Figure 4B-161. 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 shown in Figure 4B-161. A

square end is equally acceptable.

The total length of the contact marking is approximately 1/2 of the face width.

A high profile marking position is desirable, although a central profile is acceptable.

3.4 LIMITED SLIP DIFFE RE NTIAL

The overhaul procedures, ring gear and pinion

positioning and tooth markings for the limited slip

diff erential ar e the same as f or the s tandar d type of

rear axle assembly, except for the servicing of the

internal components of the limited slip differential

assembly.

NOTE:

The differential for V8 and V6 supercharged

engined vehicles is unique and parts are not

interchangeable with the V6 engined unit. The

general overhaul procedures however, remain the

same for both types. The unique components for

the V8 and V6 super charged, are; dif ferential c ase,

differential pinions, side gears and thrust block.

DISASSEMBLE

1. Before disas s embling dif f er ential ca se, ins pec t

differential side bearings for any signs of

damage.

NOTE:

Both side bearings and their cups are matched

parts. If either bearing is to be replaced, its

matching cup must also be replaced.

2. If replacing side bearings, use Tool No.

E1673MT, adaptors E1673N15 and stepped

plug E1673B16 to remove side bearings from

differential case.

Discard side bearings once they are removed.

To remove side bearing cups, refer to

3.3 REMOVED FINAL DRIVE ASSEMBLY -

DISASSEMBLE, step 10 in this Section.

Figure 4B-162

3. Grip differential case in a vice with soft jaws.

4. Remove ring gear attaching bolts.

NOTE:

Ring gear attaching bolts use a left hand thread

and are identified by an 'L' on the bolt head.

5. Remove differential case from vice.

Figure 4B-163

Techline

6. Using a soft faced hammer, remove ring gear

from differential case by hitting down on ring

gear. Support ring gear during this operation

so that it does not str ik e benc h top as it c omes

free of case.

NOTE:

Do not use a screwdriver to pry between ring gear

and case.

7. Place differential case in a vice equipped with

soft jaws.

Figure 4B-164

8. Loosen and remove differential case cap to

cover attac hing bolts evenly. Lift of f dif ferential

case cover. If necessary, remove clutch cup

from cover (some-times the cone will remain

inside the cover).

Figure 4B-165

9. Remove clutch cone, shim (if fitted), side gear

and thrust spring plate from pinion cross shaft.

NOTE:

V8 and V6 supercharged vehicle clutch cone and

side gears are an integral unit and must stay

assembled to each other.

Figure 4B-166

NOTE:

To ensure that the clutch cones are not

interchanged during reassembly, mark the cone

and corres ponding side of the diff erential case with

a daub of paint. If shims are present, they must

also be marked so that they can be reassembled

into the correct case half.

Figure 4B-167

10. Remove three concentric differential pre-load

springs from centre of pinion cross shaft.

Figure 4B-168

11. Lift pinion cross shaft, pinion gears and thrust

washers from case. Rem ove 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.

12. Remove remaining thrust spring plate, side

gear, shim (if fitted) and clutch cone from

differential case cap.

Figure 4B-169

INSPECT

All components should be thoroughly cleaned and

dried, then inspected.

Differential Case

Check the case for general soundness and pay

particular attention to the following points:

1. If differential case side bearings have been

rem oved, check case j ournals f or 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 differential pinions

should be examined for excessive wear.

5. The clutch cone seats in two housing halves

should be smooth and free from any

excessive scoring. Slight grooves and

scratches are permissible and normal.

The land surface of the heavy spirals on clutch

cones will duplicate the housing surface

condition. Excessive wear or damage on

clutch cone sur face will neces sitate renewal of

both clutch cones (V6 only) or the clutch

cone/side gear assemblies (V8 and V6

supercharged models) and the housing

6. Inspect axle splines of the clutch cones for

excessive wear.

7. Check thrust spring plates for excessive wear

or damage.

8. If fitted, inspect side gear shims for damage.

9. Inspect pinion gear cross shaft bores for

ovality.

Differential Side Gears and Pinion Gear s

1. Examine all gear teeth for cracks or hard

contact marks.

2. The differential side gear splines should be

checked for excessive wear. W ear 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

excessive shock loading, use of the incorrect

lubricant or ins uf ficient "run in" bef or e towing a

heavy load. (Refer VT Series Owner's

Handbook). Scored gears must be replaced.

2. If on reassembly, a new gear set is to be

installed, ensure that the same matching

number appears on both the pinion and ring

gear.

Figure 4B-170

3. On ring gear bolts, clean Durlok serrations

under bolt flange.

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 assemblies should feel smooth

when turned in the cups.

3. The assembly should be free from loose

particles.

4. There should be no cracks present in the

roller cages and the bores should show no

evidence of flaking or pitting.

Refer to 4.4 FINAL DRIVE BEARING

DIAGNOSIS 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 before assembly.

2. With V6 engined models, install respective

clutch cones and shims (if fitted) into

differential case halves.

To check if shims are required:

a. Measure the distance from the case

mating surface to the flat surface of the

tightly seated clutch cone. Record this

dimension.

b. This measurement will indicate what size

side gear positioning shim is required.

Each case half and clutch cone must be

measured for its own respective shim.

c. With the measurement from "a", above,

select the correct shim size as indicated

by the following chart.

DISTANCE MEASURED SHIM SIZE REQUIRED

32.0 - 31.84 mm No shim required

32.14 - 32.04 mm 0.13 mm shim required

32.27 - 32.17 mm 0.25 mm shim required

Figure 4B-171

3. Remove clutch cones and shims from

differential case halves.

NOTE:

With V8 and V6 supercharged models, shimming is

not required, as the side gear and cone are an

integrated, single assembly.

4. If available, use an axle shaft from a VS

Series vehicle, 5 link rear axle assembly and

clamp it in a vice using soft jaws, allowing

approximately 85 mm to extend above vice

jaws.

Figure 4B-172

If an axle shaft from a VS Series vehic le, 5 link

rear axle assembly is not available, clamp the

left hand inner axle shaft in a vice equipped

with soft jaws.

NOTE:

The axle shaft (or inner axle shaft) is used as a

mounting tool with V6 differentials, to ensure

correc t side gear and clutch cone s pline alignment.

Failure to follow this procedure will prevent

installation of the inner axle shafts at final

assembly.

Figure 4B-173

5. Place differential case cap over axle shaft

mounted in vice with interior of the housing

facing upwards.

6. Paint a mixture of Molybdenum Disulphide

grease and the recommended differential

carrier lubricant onto faces of side gears and

clutch cone surfaces.

Figure 4B-174

7. For V6 differentials, install clutch cone over

axle splines, seating it in position in housing

followed by a shim (if required, refer Step 2)

and side gear.

With V8 and V6 supercharged differentials,

install the clutch cone/side gear assembly to

the housing.

Figure 4B-175

8. Place a thrust spr ing plate, stepped side up on

side gear.

9. Assemble the four pinions and thrust washers

onto pinion cross shaft.

10. Install pinions and cross shaft assembly to

case cap, ensuring that pinions m es h with side

gear.

Figure 4B-176

11. Install three new concentric differential pre-

load springs into centre of the pinion cross

shaft.

NOTE:

NEW pre-load springs must always be installed on

reassembly, DO NOT RE-USE OLD SPRINGS.

Figure 4B-177

12. Assemble second thrust spring plate, stepped

side onto pre-load springs.

Figure 4B-178

13. For V6 diff er entials , inst all clutc h c one, s him (if

required) and side gear to case cover.

With V8 and V6 supercharged differentials,

install the clutch cone/side gear assembly to

the housing.

Figure 4B-179

14. Install case cover onto case cap.

NOTE:

Ensure that the cut out on each side of the case

cover and cap align.

Figure 4B-180

15. Install two NEW differential case cap-to-cover

attaching bolts in opposite bolt holes and

finger tighten.

16. Install other axle shaft 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 evenly

to the correct torque specification.

DIFFERENTIAL CASE CAP

TO COVER ATTACHING BOLT 35 - 45 Nm

TORQUE SPECIFICATION

17. With V6 engined models, remove axle shafts

from differential case assembly.

NOTE 1:

If the shafts bind on the clutch cone and side gear

splines, a light tap with a soft metal hammer may

be necessary to remove the axle shafts.

NOTE 2:

At no time mus t the side gear s and c lutc h cones be

rotated until the inner axle shafts are fully installed.

Failure to observe this condition will result in side

gear and clutch cone spline misalignment, thus

preventing inner axle shaft installation.

Should splines become misaligned, loosen case

cap to cover bolts and repeat steps 4, 5, 15 and 16

of REASSEMBLE procedure.

Figure 4B-181

18. Place ring gear into position on differential

case cap and install ring gear attaching bolts.

NOTE:

For ease of assem bly, it m ay 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.

NOTE

On no account must a flame be used to heat the

ring gear.

NOTE:

Use left hand threaded guide pins to pilot ring gear

over differential case spigot.

19. Install NEW ring gear attaching bolts evenly

until gear face is flush with differential case

spigot.

Tighten bolts to the correct torque

specification.

DIFFERENTIAL RING GEAR 125 - 150

BOLTS TORQUE SPECIFICATION Nm

NOTE:

Ring gear attaching bolts use a left hand thread

and are identified by an 'L' on the bolt head.

Figure 4B-182

20. If installing new side bearings, use Tool No.

E9277 to press on side bearings to differential

case journals.

Figure 4B-183

21. Continue rear axle assembly, proceeding from

'Differential Case Side Bearing Pre-Load

Setting', refer Figure 4B-141, in this Section.

3.5 REAR AXLE

Reassemble

1. Apply a 1.5 - 2.0 mm diameter continuous

bead of sealant, such as Loctite 587 (‘Ultra

Blue’) or equivalent (Holden's Specification

HN1973) to inside edge of r ear cover and bolt

holes and completely around drain plug hole.

2. Install rear c over to dif f er ential c ar rier housing.

Fit screw adjuster lock plates to rear cover,

ensuring that lock plates fit over ribs or

between ribs on screw adjusters.

If equipped with ABS, install both sensors,

ensuring that sensor wiring is securely held in

the harness clip and that no chafing of the

wire is possible. Install and tighten rear cover

attaching bolts to the correct torque

specification.

REAR COVER ATTACHING 23 - 31

BOLT TORQUE SPECIFICATION Nm

3. 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

4. Install inner axle shafts, aligning splines with

clutch cones (if a V6 and equipped with an

LSD) and side gears.

NOTE 1:

To avoid premature seal failure, ensure axle shaft

splines or s ecuring c lip do not scor e or dam age the

seal lips during installation.

NOTE 2:

With V6, LSD type differential assemblies, ensure

that both inner axle shafts are installed fully before

rotating either shaft. If rotation of one shaft occurs

before both are fully installed, misalignment of

opposite side gear and clutch cone will occur, thus

preventing assembly of remaining shaft.

NOTE 3:

For vehicles equipped with ABS, the inner axle

shafts are unique for this application.

5. Lightly hit on end of each shaft flange with a

soft faced hammer to compress spring clip on

shaft into clutch cup and side gear splines.

Fully engage both shafts until clips snap into

side gear grooves.

6. Reinstall dif ferential carr ier assem bly. Ref er to

3.2 FINAL DRIVE ASSEMBLY in this Section.

Figure 4B-184

4. DIAGNOSIS

4.1 GENERAL INFORMATION

Very often, final drive assemblies are considered as noisy, when in reality, the noise is emanating from some other

source, such as tyres, front wheel bearings, rear wheel bearings, manual transmission 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 type of body construction, load

and tyre pressure.

Noise which emanates from any one of these can quite easily be confused with a final drive assembly noise and

unless a series of elimination tests are carried out to definitely 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 by 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 speeds at which

they occur. Release the accelerator and without using the brakes, allow 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 eliminated 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.

NOTE:

Only drive at high speeds when it is legal and safe to do so.

Tyre Noise

Tyre noise can easily be mistaken for final drive assembly noise even though the noisy tyres 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 tyre 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, chipped or incorrectly adjusted front wheel bearings will cause a noise, 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. This noise does not 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.

Techline

Transmission Rear Bearing (Manual Transmission)

A rough or pitted rear transmission bearing, 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 constant 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 acceleration and deceleration may be caused by worn differential pinion shafts, excessive

clearance between inner axle shaft and side gear splines, drive shaft companion flange and wheel spindle flange

splines, excessive clearance between side gear hub and counterbore in case, worn pinion and side gear teeth, worn

thrust washers and excessive drive pinion and ring gear backlash. Remove worn parts and replace as required,

selecting close fitting parts when possible. Adjust pinion and 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 2.10 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 engine, transmission or muffler are occasionally confused with final drive assembly

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 vehicles with manual transmission), run the engine up and down slowly through

the engine speeds that correspond to the vehicle speeds at which the noise was prominent and observe whether

there is any similarity to a final drive assembly noise.

For vehicles with manual transmission: With transmission still in neutral, again run the engine at similar speed while

slowly letting the clutch engage, and listen for noises from the transmission.

Muffler noises are usually readily identified, possibly an exception being when a muffler emits a high-pitched

periodic whistling noise, which could be confused with a bearing noise.

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 generally shows up as a 'drive noise', 'coast

noise', or 'float noise'.

1. Drive noise is most pronounced on constant 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 teeth 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 usually

appears as a sharp metallic sound when shifting from reverse to first gear.

BEARING RELATED NOISE

Differential Pinion Gear Bear ings

Worn, rough or loose bearings will tend to aggravate and magnify drive, float and coast noise, and result in heavy,

irregular drive noise on constant acceleration and float, and also an irregular noise on deceleration.

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 bearings, even from natural wear, which permits the pinion to feed back into the ring gear, will

cause a noise on over-run.

Drive Shaft Bearings

Drive shaft bearings that are rough or pitted 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 eccentric form. It can also be

intermittent as the noise may fade for a short period.

To confirm the diagnosis of a drive shaft bearing noise:

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, speed engine up to a fast idle.

3. If a stethoscope is available, it is ideal to compare the noise of one 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 drive shaft bearings can also be discerned by placing a steel-shafted

screwdriver to the ear and in close proximity to each bearing in turn.

With practice, a noticeable difference in noise can, at most times, be observed between a good and not so good

bearing.

Differential Si de Bearings

Side bearings will produce a constant grinding noise of a slower nature than pinion bearings (side bearing noise

cannot be determined by the diagnosis 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 abutment faces during assembly.

4.3 LSD NOISE

If LSD stick-slip chatter is diagnosed, the differential carrier lubricant should be drained 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 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 DIFFERENTIAL in this

Section.

Techline

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 FOLLOWING ILLUSTRATIONS.

3. DETERMINE THE CAUSE.

4. MAKE ALL REPAIRS FOLLOWING RECOMMENDED PROCEDURES.

ABRASIVE ROLLER WEAR

PATT E RN ON RACES A ND ROLLE RS

CAUSED BY FINE ABRASIVES.

CLEAN ALL PARTS AND HOUSINGS.

CHECK SEALS AND BEARINGS,

REPLACING IF LEAKING, ROUGH OR

NOISY.

GALLING

METAL SMEARS ON ROLLER ENDS

DUE TO OVERHEATING, LUBRICANT

FAILURE OR OVERLOAD.

REPLACE BEARING. CHECK SEALS

AND CHECK F OR PROPER

LUBRICATION.

BENT CAGE

CAGE DAMAGE DUE TO IMPROPER

HANDLING OR TOOL USE .

REPLACE BEARING.

ABRASIVE STEP WEAR

PATT E RN ON ROLLER ENDS CAUSED

BY FINE ABRASIVES.

CLEAN ALL PARTS AND HOUSING.

CHECK SEALS AND BEARINGS AND

REPLACE IF LEAKING, ROUGH OR

NOISY.

ETCHING

BEARING SURFACES APPEAR GREY

OR GREYISH BLACK IN COLOUR WITH

RELATE D E T CHING AWAY OF

MATERIA L , USUALLY AT ROLLER

SPACING.

REPLACE BEARINGS. CHECK SEALS

AND CHECK F OR PROPER

LUBRICATION.

BENT CAGE

CAGE DAMAGE DUE TO IMPROPER

HANDLING OR TOOL USE .

REPLACE BEARING.

INDENTATIONS

SURFACE DEPRESSIONS ON RACE

AND ROLLERS CAUSED B Y HARD

PARTI CLES OF FORE IGN MATERI AL.

CLEAN ALL PARTS AND HOUSING.

CHECK SEALS AND REPLACE

BEARI NGS IF ROUGH AND NOIS Y.

CAGE WEAR

W E AR AROUND OUTSIDE DI AMETER

OF CAGE A ND ROLLE R POCKETS

CAUSED BY ABRASIVE MATERIALS

AND INEFFICIENT LUBRICATION.

REPLACE BEARINGS. CHECK SEALS

AND CHECK F OR PROPER

LUBRICATION.

MISALIGNMENT

OUTER RACE MI SALIGNME NT DUE TO

FOREIG N OB JECT.

CLEAN RELATED PARTS AND REPLACE

BEARING. MAKE SURE RACES ARE

PROPERLY SEATED.

Figure 4B-185

CRACKED INNER RACE

RACE CRACKED DUE TO IMPROPER

FIT, COCKI NG OR POOR B EARING

SEATS.

REPLACE BEARING AND CORRECT

BEARING SEATS.

FATIGUE SPALLING

FLAKING OF SURFACE METAL

RESULTING FROM FATIGUE.

REPLACE BEARING, CLEAN ALL

RELATE D PARTS.

BRINELLING

SURFACE INDENTATIONS IN RACEWAY

CAUSED BY ROLLERS E ITHER UNDER

IMPACT, LOADING OR VIBRATION

W HILE THE BEARING IS NOT

ROTATING.

REPLACE BEARING IF ROUGH OR

NOISY

FRETTAGE

CORROSION S E T UP BY RELATIVE

MOVEMENT OF PARTS WITH NO

LUBRICATION.

REPLACE BEARING. CLEAN RELATED

PARTS. CHECK SEALS AND CHECK

FOR PROPER LUBRICATION.

STAIN DISCOLOURATION

DISCOLOURAT ION CAN RANGE F ROM

LIGHT BROW N 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.

CHECK SEALS AND RELATED PARTS

FOR DAMAGE.

HEAT DISCOLOURATION

HEAT DI SCOLOURATION CAN RANGE

FROM FAINT YELLOW TO DARK BLUE,

RESULTING FROM OVERLOAD OR

IMPROPER LUBRICANT.

EXCESSIVE HEAT CAN CAUSE

SOFTE NI NG 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 W ILL GRAB

AND CUT METAL, WHEREAS A FILE

DRAWN OVER A HARD PART WILL

GLIDE READILY WITH NO METAL

CUTTING ACTION.

REPLACE BEARING IF OVERHEATING

DAMAGE I S INDICATED. CHECK SEALS

AND OTHER P ARTS.

SMEARS

SMEARING OF METAL DUE TO

SLIPPAGE THAT CAN BE CAUSED BY

POOR FITS, LUBRICATION,

OVERHEATING, OVERLOADS OR

HANDLING DAMAGE.

REPLACE BEARINGS. CLEAN RELATED

PARTS AND CHECK FO R PROPER FI T

AND LUBRICATION.Figure 4B-186

5. SPECIFICATIONS

V6 Engine V8 & V6

Supercharged

Engine

GENERAL

Rear Axle Assembly BTRE - 76 Series BTRE - 80 Series

Axle Type Independent Housing

STANDARD AND LSD AXLES

Gear Type Hypoid

Gear Ratio 3.08:1. 3.07:1

See I.D. tag attached to the carrier

No. of Teeth:

Ring Gear 37 43

Drive Pinion Gear 12 14

LUBRICANT

Capacity 1.65 litres

Type:

With/Without LSD Mineral Hypoid Gear

Oil to Holden's

Specification

HN1561. Refer

2.1 CHECKING

DIFFERENTIAL

CARRIER

LUBRICANT LEVEL

for recommendations

Synthetic Hypoid Gear

Oil to Holden's

Specification HN2040.

Refer

2.1 CHECKING

DIFFERENTIAL

CARRIER

LUBRICANT LEVEL

for recommendations

NOTE:

Use Synthetic Hypoid Gear Oil to Holden’s

Specification HN2040 for V6 Wagon with

Manual Transmission, refer 2.1 CHECKING

DIFFERENTIAL CARRIER LUBRICANT

LEVEL

DIFFERENTIAL GEARS

Type Straight Bevel

No. Teeth: Pinion Gears 10 10

Side Gears 16 15

FINAL DRIVE PINION GEAR BEARINGS

Bearing Type Adjustable Taper Roller

Bearing Adjustment Collapsible Spacer

Bearing Pre-Load:

Dummy pinion - New bearings 1.4 - 2.0 Nm

Dummy pinion - Used bearings 0.7 - 1.0 Nm

New with oil seal 1.4 - 2.4 Nm

New without oil seal 1.4 - 2.0 Nm

Used with oil seal 0.7 - 1.2 Nm

Used without oil seal 0.7 - 1.2 Nm

DIFFERENTIAL CARRIER SIDE

BEARINGS

Type Adjustable Taper Roller

Adjustment Screw adjusters on each side of the carrier.

Bearing Pre-Load

New Bearings 15 - 35 N Torque measured at the differential

case, without inner axle shafts

Used Bearings 8 - 18 N or final drive pinion installed.

RUN-OUT SPECIFICATIONS

Trunnion Assembly Hub 0.060 mm Total Indicated Run-out

Case Assembly (without ring gear

attached) 0.05 mm (maximum)

Ring Gear Rear Face (assembled

onto case assembly) 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 Specification 45 Nm (minimum)

ABS SENSOR

Air Gap (non-adjustable) 0.4 - 1.5 mm

SEALANTS

Drive Shaft Dust Caps/Shield RTV 732 Sealant, to Holden’s Specification

HN1373

Rear Cover to Carrier Housing Loctite 587 (‘Ultra Blue’) or equivalent, to

Holden’s Specification HN1973

As Required Loctite 242 or equivalent, to Holden’s

Specification HN1256, Class 2, Type 1

LUBRICANTS

As Specified in Text Molybond HE50 or equivalent, to Holden’s

Specification HN1326

As Specified in Text Lithium Soap Based Grease to Holden’s

Specification HN1147

6. TORQUE WRENCH SPECIFICATIONS

Rear cover attaching bolts 23 - 31

Filler plug 23 - 31

Drain plug 23 - 31

Final drive ring gear bolts 125 - 150

LSD case cap to cover attaching bolts 35 - 45

Collar nut to trunnion assembly 295 - 305

Drive shaft constant velocity joint to trunnion

flange/inner axle shaft flange bolts 50 Nm, then

60 ° - 75° turn angle

Road wheel attaching nut 110 - 140

Brake caliper anchor plate to trailing arm bolts 70 - 100

Rear disc brake shield to trailing arm. Upper bolts 70 - 80

Lower bolts 85 - 90

!Differential carrier to rear crossmember

attaching bolts 90 Nm, then

30° - 45° turn angle

!Rear mount to vehicle underbody attaching bolts 30 Nm, then

60° turn angle

!Rear mount to differential carrier rear cover

attaching bolts 85 - 105

Shock absorber lower mounting bolt 105 - 125

Crossmember front mounting brace to

underbody bolts 60 - 70

Crossmember front mounting bolt 125 Nm, then

30° - 45° turn angle

Intermediate exhaust pipe to catalytic converter

attaching bolts 40 - 50

!New bolts and/or nuts MUST be used on

reassembly.

7. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

E1673MT BASIC PULLER PREVIOUSLY RELEASED

FOR "V" CAR.

E1673A15 ADAPTOR PREVIOUSLY RELEASED

FOR "V" CAR.

USED WITH E1673MT.

E1673N15 ADAPTOR PREVIOUSLY RELEASED

FOR "V" CAR.

USED WITH E1673MT.

E9277 SIDE BEARING INSTALLER PREVIOUSLY RELEASED

FOR "V" CAR.

E1673B16 STEPPED PLUG PREVIOUSLY RELEASED

FOR "V" CAR.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

17-010A PINION OIL SEAL INSTALLER PREVIOUSLY RELEASED

FOR "V" CAR.

E3C10AER PINION REAR BEARING CONE

REPLACER PREVIOUSLY RELEASED

FOR "V" CAR.

E9300A PINION HEIGHT SETTING GAUGE SET PREVIOUSLY RELEASED AS

E9300, FOR "V" CAR.

THIS SET NOW HAS AN

ADDITIONAL SPACER FOR

THE DRIVE PINION USED ON

THE V8 AND V6

SUPERCHARGED FINAL

DRIVE ASSEMBLIES.

AU408 DUMMY ARBOR USED WITH DUMMY PINION

FROM E9300A

PINION FLANGE PULLEY DETAILS DEALER FABRICATED:

1. MADE FROM A 13 MM

THICK PIECE OF WOOD.

2. DRILL A SMALL HOLE AT

'A' AND ATTACH A ONE

METRE LENGTH OF

STRING AT THIS POINT.

3. DRILL TWO 10 MM

HOLES AS SHOWN IN

THE FIGURE.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

7208 REAR AXLE REMOVAL ADAPTOR PREVIOUSLY RELEASED

FOR "V" CAR.

USED WITH E6662B FOR LSD

TORQUE CHECK.

E6662B TORQUE WRENCH ADAPTOR PREVIOUSLY RELEASED

FOR "V" CAR.

USED WITH 7208

J8614-01 PINION FLANGE HOLDER AND REMOVER PREVIOUSLY RELEASED

FOR "V" CAR.

E9293 PINION BEARING CUP REMOVER PREVIOUSLY RELEASED

FOR "V" CAR.

E9271 PINION BEARING CUP INSTALLER PREVIOUSLY RELEASED

FOR "V" CAR.

AU407 SCREW ADJUSTER SOCKET USED FOR CHECKING AND

ADJUSTING SCREW

ADJUSTERS.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

AU409 PRESS FIXTURE USED FOR INSTALLING

NEEDLE BEARINGS AND

SIDE BEARING CUP INTO

SCREW ADJUSTERS.

USED WITH AU411

AU411 BEARING AND CUP REMOVER AS ABOVE.

AU410 SEAL INSTALLER USED FOR INSTALLING SEAL

INTO SCREW ADJUSTERS.

1150 PULLER USED WITH FORCING

SCREW E6661S AND

ADAPTOR AU412 TO

REMOVE SIDE BEARING

CUPS FROM SCREW

ADJUSTERS.

E6661S FORCING SCREW PREVIOUSLY RELEASED.

AU412 ADAPTOR PREVIOUSLY RELEASED.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

KM480 HOLDING FIXTURE PREVIOUSLY RELEASED

FOR THM 125 AUTOMATIC

TRANSAXLE.

MODIFY BY DRILLING TWO

14 MM HOLES AS SHOWN IN

THE ILLUSTRATION.

USED FOR HOLDING

DIFFERENTIAL CARRIER

ASSEMBLY.

N/A DIFFERENTIAL CARRIER HOLDING FIXTURE IF KM480 IS NOT AVAILABLE,

FABRICATE A HOLDING

FIXTURE AS SHOWN

J3289-20 HOLDING FIXTURE BASE PREVIOUSLY RELEASED

FOR "V" AND "J" CARS.

KM468 HOLDING BAR PREVIOUSLY RELEASED

FOR "J" CAR.

USED TO HOLD TRUNNION

ASSEMBLY FROM

ROTATING.

AU416 TORX BIT USED TO REMOVE AND

INSTALL REAR BRAKE

BACKING PLATE TO

TRAILING ARM ATTACHING

BOLTS.

AJ24292-C PRESS TOOL USED FOR REMOVING REAR

WHEEL STUDS FROM

TRUNNION ASSEMBLY

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

E1896 CLAMP PLIERS PREVIOUSLY RELEASED

FOR "J" CAR.

USED FOR SECURING DRIVE

SHAFT CONSTANT

VELOCITY JOINT BOOT

CLAMPS.

56750 SEAL REMOVER PREVIOUSLY RELEASED

FOR "V" CAR.

KM620-A REMOVER/INSTALLER PREVIOUSLY RELEASED

FOR "VQ".

USED FOR REMOVING AND

INSTALLING TRUNNION

FLANGE, REAR WHEEL

BEARING AND TRUNNION

ASSEMBLY.

E1312 PRESS PLATES PREVIOUSLY RELEASED.

E7115 ANGLE WRENCH PREVIOUSLY RELEASED

FOR "J" AND "V" CARS AS

TOOL NO. 394.

USED TO TIGHTEN

COMPONENT FASTENERS

WHEN ANGLE TORQUE IS

REQUIRED.

09520-32012 SLIDE HAMMER PREVIOUSLY RELEASED

FOR "JK" APOLLO.

USED TO REMOVE INNER

AXLE SHAFTS FROM THE

FINAL DRIVE ASSEMBLY.