SECTION 4B – FINAL DRIVE AND DRIVE SHAFTS
CAUTION:
This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either
seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front
passenger's air b ags or seat belt pre- tensioners, driv er’s and front passenger’s air bag and left and right
hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M, Supplemental Restraint System of
this Service Information CD before performing any service operation on, or around any SRS
components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could
result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.
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,
VT Series I Service Information (V6) or VT Series II Service Information (GEN III V8).
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 and then draining the LPG
service lin es, b efo re any serv ice work is carried o ut on th e v ehi cle. Refer t o t he L PG leaf let in clud ed with
the Owner's Handbook for details or the appropriate Section of this Service Information CD for more
specific servicing information.
1. GENERAL INFORMATION
A local sourc e of rear suspens ion trailing arm s is to be f itted to VT Ser ies II vehicles f rom an antic ipated break point
in late January, 2000.
As the new trailing arm requires new special tools to service the trunnion and/or bearing, should work be required
on these components, then correct identification of the trailing arm will be required. Refer to
2.2 TRAI LING ARM IDENTIFICATION, in this Section for details.
Service operations relating to the removal and reinstallation procedures for the final drive assembly have been
included, that reflect revised procedures, some torque specification revisions and upgraded illustrations.
Apart from this change, all other service operations remain as detailed in 4B FINAL DRIVE AND DRIVESHAFTS
of the VT Series I Service Information.
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2. SERVICE OPERATIONS
2.1 SERVICE NOTES
IMPORTANT SERVICE REQUIREMENTS
1. Whenever a road wheel and/or brake disc is
removed from the vehicle, the relationship of
the road wheel to the hub and the disc to the
hub MUST be marked with a felt tipped pen or
similar, in order for those parts to be reinstalled
in their original positions. This is critical to
maintain the brake disc and road wheel runout
dimension to a minimum.
2. When reinstalling road wheels, do not use an
impact gun to tighten wheel nuts, unless it is
fitted with a torque limiter socket (Tool No
AU534). Failure to correctly tighten wheel nuts
to the correct torque specification and in the
correct order, may result in a distorted brake
disc, that may lead to the development of
brake shudder.
ROAD WHEEL ATTACHING NUT
TORQUE SPECIFICATION 110 – 140 Nm
For a complete description of the method used to
measure both brake disc and trunnion assembly
runout and correction, refer to
2.2 REAR BRAKE DISC, Brake Disc and Hub
Indexing Procedure, in 5A STANDARD BRAKES,
of the VT Series II Service Information.
Figure 4B-1
3. All rear suspension fasteners are important
attaching parts because they affect the
performance of vital components and/or could
result in major repair expense. Where
specified in this Section, fasteners MUST be
replaced with ones of the s ame par t number or
with an equivalent part. Do not use a
replacem ent part of inf erior quality or substitute
design.
4. Torque values must be used as specified
during reassembly to ensure proper retention
of all rear suspension components.
2.2 TRAILING ARM IDENTIFICATION
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 &
ABS/ETC, VT Series I Service Information
(V6 engine) or Section 12L ABS & ABS/ETC, VT
Series II Service Information (GEN III V8
engine).
As the introduction of the changed source of
trailing arm manufacturer has been on a ‘staged’
basis over a period of tim e, identific ation of the two
types is necessary if service work is to be carried
out on the trunnion and/or bearing.
The most effective way of identifying the locally
sourced trailing arm is a visual inspection, that can
be achieved by the following procedure.
1. Using a floor jack under centre of differential
carrier, jack up rear of vehicle and place saf ety
stands under body rear jack ing points. Ref er to
Section 0A GENERAL INFORMATION of the
VT Series I Service Information for location of
jacking points.
2. Remove wheel cover (steel wheels) or centre
cap ( alloy wheels) from the requir ed side of the
vehicle.
3. Mark relationship of road wheel to hub (e.g.
end of wheel stud), with a felt tipped pen or
similar. Loosen then remove road wheel
attaching nuts. Remove the road wheel.
4. Remove brake caliper anchor plate to trailing
arm attaching bolts (1) and remove caliper (2)
from disc. Support the brake caliper with tie
wire secured to the vehicle underbody. THE
CALIPER IS NOT TO HANG BY THE BRAKE
HOSE.
Figure 4B-2
5. Visually observe the protrusions from the rear
of the trunnion housing. If the two inner
protrusions (B and C) are higher than the outer
two (A) and each are of differing heights to
each other (as shown in Fig. 4B-3), then the
trailing arm is of local manufacture.
The service operations relating to the trunnion
and/or bearing are included in this Section.
Should the protrusions all be of the same
height, then the trailing arm is of the earlier
design. For service operations on this
trunnion/bearing assembly, refer to
2.5 TRAILING ARM, in Section 4B FINAL
DRIVE AND DRIVESHAFTS, of the VT Series
I Service Information.
NOTE: The view shown does not include the brake
backing plate, trunnion or inner trunnion flange, to
more clearly show the protrusion differences.
Figure 4B-3
6. Reinstall the brake caliper (3) to the trailing
arm, reinstall brake caliper anchor plate to
trailing arm attaching bolts (4) and tighten to
the correct torque specification.
BRAKE CALIPER ANCHOR PLATE
TO TRAILING ARM ATTACHING 70 - 100 Nm
BOLT TORQUE SPECIFICATION
7. Reinstall road wheel, aligning marks made
before removal and reinstall attaching nuts.
8. Lower vehicle to the ground and tighten road
wheel attaching nuts to the correct torque
specification, working in a ‘star’ pattern. Refer
2.1 SERVICE NOTES in this Section for more
details.
ROAD WHEEL ATTACHING NUT
TORQUE SPECIFICATION 110 - 140 Nm
9. Refit wheel cover/centre cap.
Figure 4B-4
3. MAJOR SERVICE OPERATIONS
3.1 TRAI LING ARM TRUNNION FLANGE, TRUNNION ASSEMBLY AND/OR
WHEEL BEARING
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 – Early
Production Trailing Arms or Section 4A REAR
SUSPENSION – Local Production T railing Arms of
the VT Series II Service Information, involving the
trailing arm removed from the vehicle.
For this operation, a new lock plate and collar nut
must be used on reassembly.
NOTE: The rear wheel bearing should only be
rem oved if it is faulty, or if the trunnion ass embly is
to be removed.
Trunnion Assembly – Sectioned View
Legend
1. Collar Nut Lock Plate.
2. Collar Nut.
3. Trunnion Flange.
4. Trailing Arm.
5. Brake Backing Plate.
6. Brake Disc.
7. Brake Caliper.
8. Rear Wheel Bearing.
9. Trunnion Assembly.
10. Rear Wheel Bearing Retaining Ring.
Figure 4B-5
REMOVE
1. Using a floor jack under centre of differential
carrier, jack up rear of vehicle and place saf ety
stands under body rear jack ing points. Ref er to
Section 0A GENERAL INFORMATION of the
VT Series I Service Information for location of
jacking points.
2. On the side of the vehicle where the trailing
arm is to be removed, mark relationship of
road wheel to hub (e.g. end of wheel stud),
with a felt tipped pen or similar. Loosen then
remove road wheel attaching nuts. Remove
the road wheel.
3. Remove brake hose retaining clip (1) from
brake backing plate bracket (2). Disconnect
rear caliper brake hose (3) from brake pipe (4)
and disconnect pipe f rom bac k ing plate bracket
(2).
Plug open ends of brake pipe (4) and hose (3)
to prevent fluid loss and foreign matter entry.
Figure 4B-6
4. Remove brake caliper anchor plate to trailing
arm attaching bolts (1) and remove caliper (2)
from disc.
Important: If the brake pipe to hose is not
disconnected, the br ak e caliper m ust be s ecured to
the vehicle underbody. THE CALIPER IS NOT TO
HANG BY THE BRAKE HOSE.
5. Remove brake disc from the wheel bearing
hub.
NOTE 1: While the brake disc to hub location is
marked in production, ensure that the disc to hub
position is carefully marked (e.g. disc to end of
wheel stud), with a felt tipped pen or s im ilar. T his is
necess ary to overcome the pos sibility of inducing a
brake shudder condition after reassembly.
NOTE 2: Should it be necessary to adjust the park
brake shoe to allow the brake disc to be removed,
refer to 5A STANDARD BRAKES, of the VT
Series I Service Information, for the necessary
procedure.
Figure 4B-7
6. Position floor jack with a block of wood under
the trailing arm (2). Raise jack slightly to take
spring load off trailing arm.
7. Disconnect rear shock absorber lower
mounting bolt ( 1) f rom trailing ar m (2), then pull
the lower end of shock absorber (3) from
trailing arm (2).
‘A’ – Sedan
‘B’ – Station Wagon
NOTE: Leave the supporting jack and wooden
block in position.
Figure 4B-8
8. Using holding bar, Tool No. KM468 over the
wheel studs to hold trunnion assembly from
rotating, loosen and remove the six drive shaft
(1) constant velocity joint to trunnion flange
attaching bolts (2) and plates, using an 8 mm
Allen key socket and suitable socket
equipment (3).
Figure 4B-9
9. Separate drive shaft from flange and lift
upward. While keeping the outer constant
velocity joint (1) in the same plane as the
driveshaft, use a piece of wire (2) and tie up
the drive shaft assembly to lower end of shock
absorber upper mounting.
NOTE: Bruising to the inside of the drive shaft
constant velocity joint boots will occur if the trailing
arm is lowered. This will lead to premature failure
of the boot and eventual failure of the joint if left
unchecked.
10. The supporting jack may now be lowered and
the wooden block removed.
Figure 4B-10
11. Using T orx bit s ocket, T ool No. AU416, remove
brake backing plate to trailing arm, two upper
attaching bolts. Then, using suitable socket
equipment, remove the two longer, hexagonal
headed, lower bolts.
Figure 4B-11
12. Secure flange holding tool, KM620-1-A and
trunnion flange ring tool KM620-2 to trunnion
flange (1) with three of the removed drive s haft
constant velocity joint to trunnion flange
attaching bolts (2).
NOTE: Align holes marked ‘B' on the flange
holding tool KM620-1-A and KM620-2 with holes in
the trunnion flange before installing and tightening
bolts.
Figure 4B-12
13. Install a suitable length and diam eter steel tube
over handle of KM620-1-A to stop it from
rotating, then use suitable socket equipment
(1) to loosen and remove the collar nut and
lock plate.
NOTE: Once collar nut and lock plate have been
removed, they must be discarded as they are only
to be used once.
Figure 4B-13
14. Lubricate the threads of forcing screw KM620-
3, then install to adaptor KM620-4-A. Apply
grease to ball end of plunger, T ool No. KM620-
5-B, then install that, into the end of forcing
screw KM620-3.
15. Install the whole sub-assembly through the
central opening of flange holding tool KM620-
1-A. Secure the adaptor KM620-4-A to the
flange holding tool KM620-1-A, using three
suitable bolts (1).
NOTE: Adjust the position of the forcing screw
KM620-3 in the adaptor KM620-4-A, to allow
adaptor to be in full contact with the flange holding
tool KM620-1-A.
Figure 4B-14
16. 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-15
17. Preparatory to removing the trunnion assembly
and rear wheel bearing from the trailing arm,
use a commercially available M10 x 1.25
bottoming tap and clean the four backing plate
to trailing arm bolt threads, using a suitable
lubricant and working from the trunnion
assembly side.
NOTE: This step is necessary to clear any dried
mud, dirt etc, from the exposed portion of the
threads on the inboard side of the trailing arm.
Also, the deepest thread (position ‘C’) may not be
completely formed through to the inboard side.
18. Install two supports KM620-7-A in positions ‘A’
and two KM620-7-AUS to ‘B’ and ‘C’ in the
trailing arm, as indicated.
As a guide, the two longest supports (KM620-
7-A) are to be installed at the brake caliper
mounting side (position ‘A’). The longer of
KM620-7-AUS supports is installed at position
‘B’ and the shorter is installed at position ‘C’.
19. After installing all four supports in the correct
positions, tighten with a set spanner.
Figure 4B-16
20. Install flange holding tool KM620-1-A over the
four supports, KM620-7-A (2 places) and
KM620-7-AUS (2 places), install four suitable
nuts (1) and tighten to secure.
21. Pre-assemble lubricated forcing screw KM620-
3 to adaptor KM620-4-A. Apply grease to ball
end of plunger KM620-5-B, then install that,
into the end of forcing screw KM620-3.
22. Install this sub-assembly through the central
opening of holding tool KM620-1-A. Secure the
adaptor KM620-4-A to the flange holding tool
KM620-1-A, using three suitable bolts (2).
NOTE: Adjust the position of the forcing screw
KM620-3 into the adaptor KM620-4-A, to allow full
contact of the adaptor to the flange holding tool
KM620-1-A.
Figure 4B-17
23. Insert a suitable length of tube over the handle
of holding tool KM620-1-A to stop it from
rotating and turn the forcing screw KM620-3 to
press trunnion from rear wheel bearing.
24. W hen the trunnion has been removed, remove
nuts (1) holding KM620-1-A assembly to the
distance pieces, KM620-7-A and KM620-7-
AUS. Remove KM620-1-A, and remove
KM620-5-B from KM620-3.
25. Unscrew the forcing screw (KM620-3), as this
same arrangement is used to press the rear
wheel bearing from the trailing arm.
NOTE: The rear wheel bearing inner cone will
separate from the bearing assembly and be
retained on the trunnion assembly.
26. Remove the brake backing plate and park
brak e assem bly from the trailing ar m and set to
one side.
Figure 4B-18
27. If the trunnion assem bly (1 ) is to be reinstalled,
then the outer half of the inner rear wheel
bearing cone (2) will need to be removed from
the trunnion assembly (1).
a. Install press plates J22912-01 over the
bearing cone (2) and tighten the press
plate bolts to grip the bearing cone.
b. Press the trunnion assembly (1) from the
bearing cone (2) and discard bearing cone.
NOTE 1: If the trunnion is to be r eplaced, then step
26 will not be required.
NOTE 2: A new trunnion assembly is supplied with
wheel studs already installed.
Figure 4B-19
28. Remove wheel bearing retaining ring (1) from
trailing arm (2), using suitable circlip pliers (3).
Figure 4B-20
29. With the tool components set up in the same
arrangement as for step 20 (and as shown in
Fig. 4B-21), install rear axle bearing removing
plate KM620-6 to rear of the axle bearing.
Reposition the forcing screw KM620-3 to hold
the removing plate KM620-6 in place.
30. Insert a suitable length of tube over the handle
of holding tool KM620-1-A to stop it from
rotating, then turn the forcing screw KM620-3
to press the wheel bearing from the trailing
arm.
31. If installing a replacement trailing arm without
bushes, install new bushes. Refer to
2.6, TRAILING ARM BUSHES in 4A REAR
SUSPENSION of the VT Series I Service
Information.
Figure 4B-21
REINSTALL
To Install a 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 such as
Molybond HE50, or equivalent (to Holden's
Specification HN1326).
3. Remove bolts securing adaptor KM620-4-A to
the holding tool KM620-1-A, then remove the
adaptor and forcing screw KM620-3 from the
holding tool KM620-1-A.
4. Lubricate the thrust ball bearing race (1) (part
of KM620-A) with lubricant such as Molybond
HB50, or equivalent (to Holden's Specification
HN1326), then assemble the bearing onto the
flanged end of adaptor KM620-4-A.
5. Reinstall the f orcing sc rew and adaptor/bearing
assembly to the flange holding tool KM620-1-
A. Do not reinstall the adaptor (KM620-4-A) to
holding tool (KM620-1-A) attaching bolts.
6. Install bearing installer KM620-8-A into a new
bearing (2) and install both into the trailing arm
(3).
7. Join the forcing screw (KM620-3), and bearing
installer (KM620-8-A) by engaging the screw
thread of the forcing screw (KM620-3) with
installer (KM620-8-B) and tightening the f orc ing
screw to engage at least eight full threads.
8. While holding the forcing screw (KM620-3)
from turning by using suitable socket
equipment (4), rotate the adaptor KM620-4-A
in a clockwise direction, using a suitable 40
mm wrench to draw the new bearing (2) fully
into position.
Figure 4B-22
9. When the bearing is fully installed, separate
installer KM620-8-A from the forcing screw
KM620-3, then rem ove the installer and for cing
screw (KM620-3), adaptor (KM620-4-A) and
bearing, from the holding tool (KM620-1-A).
Leave remaining tools installed.
10. Using suitable circlip pliers, install a new
bearing retaining ring into trailing arm,
ensuring that the ring is seated correctly.
11. Install rear disc brake shield to trailing arm
bolts and tighten to the correct torque
specification.
REAR DISC BRAKE SHIELD TO Upper: 70 - 80 Nm
TRAILING ARM ATTACHING
BOLT TORQUE SPECIFICATION Lower: 85 - 90 Nm
NOTE 1: The two upper bolts have washers that
are to be 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-23
To Reinstall Trunnion:
1. Remove KM620-1-A from distance pieces,
KM620-7-A and KM620-7-AUS. Install KM620-
9-A over KM620-3, with the stepped shoulder
facing away from the trunnion bearing.
Reinstall KM620-1-A to KM620-7-A and
KM620-7-AUS, tightening the attaching nuts.
2. Screw the threaded end of the trunnion into
KM620-3. While holding KM620-3 f rom turning,
rotate KM620-4-A to draw trunnion into wheel
bearing.
3. Unscrew f orcing s crew KM620-3 from trunnion,
then remove the nuts holding tool KM620-1-A
to the distance pieces KM620-7-A and KM620-
7-AUS.
4. Remove the distance pieces KM620-7-A and
KM620-7-AUS from the trailing arm.
Figure 4B-24
5. Assemble KM620-2 and KM620-1-A to
trunnion flange using thr ee drive shaft cons tant
velocity joint to flange bolts.
6. Lubricate trunnion flange splines and trunnion
threads with the recommended differential
carrier lubricant.
7. With KM620-4-A, thrust ball bearing race (2)
and KM620-3 assem bled to KM620-1-A, screw
the internal thread of KM620-3 onto the
trunnion assembly.
Figure 4B-25
8. While holding the forcing screw (KM620-3)
from turning with suitable socket equipment
(1), use a suitable 40 mm wrench to rotate the
adaptor KM620-4-A in the direction shown, to
install the trunnion flange onto trunnion.
9. Unscrew KM620-3 from the trunnion, then
remove it and adaptor KM620-4-A from the
holding tool KM620-1-A. Leave the holding tool
KM620-1-A and trunnion flange ring tool
KM620-2 installed to the trunnion flange.
Figure 4B-26
10. Inst all NEW collar nut to the trunnion assem bly
and, using a suitable length and sized pipe
over the handle of KM620-1-A to hold trunnion
assembly from turning, tighten collar nut to the
correct torque specification.
COLLAR NUT TO TRUNNION
ASSY TORQUE SPECIFICATION 295 - 305 Nm
11. Remove the holding tool KM620-1-A and
trunnion flange ring tool KM620-2 from the
trunnion flange.
Figure 4B-27
12. Using a 1.25 inch socket (1), 150 mm socket
bar (2) and a soft faced hammer, install new
lock plate over collar nut.
Figure 4B2-28
13. Assemble driveshaft outer constant velocity
joint to trunnion flange, aligning bolt holes.
14. Reinstall attaching bolts with plates and tighten
bolts to the correct torque specification.
DRIVESHAFT CONSTANT
VELOCITY JOINT TO TRUNNION 50 Nm, then
FLANGE ATTACHING BOLT 60° - 75 turn angle
TORQUE SPECIFICATION
Figure 4B-29
15. Reinstall brake disc (1) to trunnion, aligning the
marks made before removal.
NOTE: If the trunnion has been replaced, then
runout checks must be carried out on the trunnion
flange and the installed brake disc (1). Refer to
5A STANDARD BRAKES, of the VT Series II
Service Information for important information
regarding these checks.
16. Reinstall the brake caliper (3) to the trailing
arm, reinstall brake caliper anchor plate to
trailing arm attaching bolts (4) and tighten to
the correct torque specification.
BRAKE CALIPER ANCHOR PLATE
TO TRAILING ARM ATTACHING 70 - 100 Nm
BOLT TORQUE SPECIFICATION
17. After reconnecting the brake line to the caliper
hose and installing the brake hose retaining
clip, bleed the rear brakes and check for leaks.
For the recommended procedure, refer to
5A STANDARD BRAKES, of the VT Series I
Service Information.
Figure 4B-30
18. Support the trailing arm with a floor jack and
wooden block, sufficient to enable the shock
absorber to be reinstalled.
19. Reinstall shock absorber to trailing arm, install
the lower mounting bolt but do not torque to
specification at this stage.
20. Install road wheel, aligning marks made before
removal and reinstall attaching nuts.
21. Remove safety stands and lower vehicle to the
ground and bounce the rear of the vehicle
several times to settle the suspension
components.
22. Tighten the lower shock absorber 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.
23. Tighten road wheel attaching nuts to the
correct torque specification, working in a ‘star’
pattern. Refer 2.1 SERVICE NOTES in this
Section for more details.
ROAD WHEEL ATTACHING NUT
TORQUE SPECIFICATION 110 - 140 Nm
24. Refit wheel cover/centre cap.
Figure 4B-31
3.2 FINAL DRIVE ASSEMBLY
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 &
ABS/ETC, VT Series I Service Information
(V6 engine) or Section 12L ABS & ABS/ETC, VT
Series II Service Information (GEN III V8
engine).
Important: Before disturbing the rear suspension
crossmember mounting bolts, an alignment
procedure is required on reinstallation and a
special tool is required for this purpose. If this tool
is not available, then the crossmember cannot be
correctly aligned and steering and/or handling
abnormalities will result.
NOTE: Fo r this s ervice operation, new trailing ar m -
to-crossmember lock nuts, rear crossmember rear
mount-to-vehicle underbody attaching bolts,
differential carrier-to-rear crossmember attaching
bolts and intermediate muffler support retainers
must be used on reassembly.
REMOVE
1. Using a floor jack under centre of differential
carrier, jack up rear of vehicle and place saf ety
stands under body rear jack ing points. Ref er to
Section 0A GENERAL INFORMATION of the
VT Series I Service Information for location of
jacking points.
2. Remove wheel covers (steel wheels) or centre
caps (alloy wheels).
3. Mark relationship of road wheels to hubs (e.g.
end of wheel stud), with a felt tipped pen or
similar. Loosen then remove road wheel
attaching nuts. Remove the road wheel.
4. Disconnect exhaust system from rear of
catalytic converte r/s:
V6 Engined Vehicles (A):
a. Remove both flange bolts (1) and springs
(2). After separation remove the retaining
ring (3).
V6 Supercharged and GEN III V8 Engined
Vehicles (B):
b. Remove both flange bolts (1), then the
sealing gasket (2).
NOTE: Only one side of the V6
Supercharged/GEN III V8 engine arrangement is
shown.
Figure 4A-32
5. Remove the two retainers (1) from the top
posts and discard. Disconnect exhaust system
support rings (2) from rear hanger of rear
muffler assembly. Both V6 and GEN III V8
engine arrangements are similar.
Figure 4A-33
6. Remove muffler support to rear crossmember
hanger retainers (1).
NOTE: There are two retainers for V6 engined
vehicles (as shown) and four retainers for V6
Supercharged and GEN III V8 engined vehicles.
7. Support intermediate section of exhaust
system and remove support rings (2) from
muffler and crossmember hangers.
8. Remove intermediate and rear sections of
exhaust system from vehicle.
Figure 4A-34
9. Remove propeller shaft, refer to
Section 4C PROPELLER SHAFT AND
UNIVERSAL JOINTS VT Series I Service
Information (V6 engines) or
Section 4C PROPELLER SHAFT AND
UNIVERSAL JOINTS VT Series II Service
Information (GEN III V8 engine).
10. Set park brake in fully released position, then
release each of the underbody to park brake
cable (1) retaining clips (2) and free cables (1).
Figure 4A-35
11. Remove park brake outer cable retaining
bracket bolt (underbody bracket and bolt are
not shown) from the vehicle underbody.
12. Pull each park brake inner cable forward and
up, (1) out of the cable retainer to release each
cable.
13. Pull the outer cable rearward (2) to remove
from the underbody retainer.
Figure 4A-36
14. Disconnect brake pipe (3) from brake hose (4)
at trailing arm bracket (2) and remove the
brake hose retaining clip (1).
Plug the open ends of both pipes and hoses to
prevent unnecessary fluid loss and/or dirt
entry.
15. Repeat for the other side.
Figure 4A-37
16. Pull out differential carrier breather hose (1)
from vehicle underbody crossmember hole (2).
Figure 4A-38
17. If vehicle is fitted with ABS, pull both sensor
lead connectors from the underbody retaining
clips (1). Separate the sensor connectors from
the body harness connectors by levering with a
screwdriver.
Figure 4A-39
18. Using a scriber, m ark rear m ount (1) to vehicle
under body location (A). This will assist in rear
crossmember alignment on reinstallation.
19. Support weight of differential carrier with floor
jack.
Figure 4A-40
20. Remove rear mount (1) to vehicle underbody
attaching bolts (2) and discard removed bolts.
Lower differential carrier and rear
crossmember assembly by at least 60 mm.
Figure 4A-41
21. Position floor jack with a block of wood under
trailing arm. Raise jack slightly to take spring
load off trailing arm. Disconnect rear shock
absorber lower mounting bolt (1) from trailing
arm (2), then pull the lower end of shock
absorber (3) from trailing arm (2).
‘A’ – Sedan
‘B’ – Station Wagon
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. Bruising of the boot will lead to
prem ature f ailure of the boot and eventual failure of
the joint if left unchecked.
Figure 4A-42
22. Remove rear springs and insulators from
vehicle underbody and trailing arms.
23. Raise differential c arrier and rear cr ossm em ber
on floor jack until rear mount contacts
underbody.
Figure 4A-43
24. If replacing differential carrier assembly, rear
cover or rear mount, loosen and remove rear
mount to r ear cover attac hing bolts (1), rem ove
rear mount (2) and discard attaching bolts (1).
Figure 4A-44
25. Use a floor jack and block of wood to support
differential carrier and crossmember assembly.
26. Remove brace to underbody bolts (1) (3
places) and crossmember to vehicle
underbody attaching bolt (2) from each side.
27. Remove the braces (3) from the vehicle.
28. With an assistant supporting front end of rear
crossmember, lower assembly on jack and
remove from beneath vehicle.
NOTE: If the vehicle is fitted with the GEN III V8
engine and manual transmission, take care not to
lose the is olating r ubbers (4 ) loc ated on top of eac h
front crossmember bush.
Figure 4A-45
29. Using an 8 m m Allen key socket, remove drive
shaft inner constant velocity joint (1) to inner
axle shaft (2) attaching bolts (3) and plates (4).
Disconnect joints from inner axle shafts.
NOTE: Support drive shafts with suitable tie wire
so that they do not hang on one end. Drive shaft
joint def lection should be kept to within the angular
movement of an installed drive shaft.
Figure 4B-46
30. Remove differential carrier (3) to rear
crossmember (2) attaching bolts (1), remove
rear crossmember assembly from differential
carrier and discard attaching bolts(1).
31. If not carried out in step 24, rem ove rear m ount
to rear cover attaching bolts, remove mount
and discard attaching bolts.
Figure 4B-47
REINSTALL
Installation is the reverse of removal procedure
except for the following items:
1. If necessary, install rear mount (1) to rear
cover using NEW bolts but leave bolts finger
tight at this stage.
2. Line up mounting holes in differential
carrier (2) and rear crossmember (3). Install
NEW attaching bolts (4) (four places) and
tighten to the correct torque specification.
DIFFERENTIAL CARRIER TO REAR 90 Nm, then
CROSSMEMBER ATTACHING BOLT 30° - 45°
TORQUE SPECIFICATION turn angle
Figure 4B-48
3. Inspect drive shaft constant velocity joint boots
for damage, replace as necessary.
4. Tighten drive shaft inner constant velocity joint
to inner axle shaf t 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-49
5. With the aid of two assistants, place the
differential carrier and rear crossmember
assembly onto a floor jack.
6. Position assem bly under vehicle, raise with the
jack and, with the aid of the assistants, guide
the crossmember front mounting points into
position.
NOTE 1: When raising the assembly take car e that
the rear mount does not foul on the fuel tank or
fuel hoses.
NOTE 2: During this operation, ensure that trailing
arms are also supported on safety stands, to keep
the drive shafts as near to horizontal as possible.
Otherwise, bruising to the insides of the constant
velocity joint boots will result, leading to boots
splitting and eventually joint failure, if left
unchecked.
7. If the vehicle is fitted with the GEN III V8
engine and manual transmission, an isolating
rubber (4) must be fitted at the top of each
crossmember front bush as shown, before
raising the assembly into place.
8. Install crossm ember front mounting braces (3),
attaching bolts (‘1’ - three places) and rear
crossmember, front mounting bolt (4) but do
not fully tighten any of these bolts at this
stage.
Figure 4A-50
9. Lower rear of the final drive assembly to gain
access to the rear mount to cover attaching
bolts. Tighten attaching bolts to the correct
torque specification. At the same time, ensure
that mount does not twist, as the mount to
vehicle underbody mating surface should be
parallel to the rear crossmember, to within 1
mm (‘X’).
REAR MOUNT TO REAR COVER
ATTACHING BOLT 85 – 105 Nm
TORQUE SPECIFICATION
NOTE: Use a spirit level on rear mount to
underbody surface and top surface of
crossmember to ensure that both surfaces are
parallel. Dimension ‘A’ is to be 56.7 mm.
Figure 4A-51
10. Lower differential carrier and rear
crossmember assembly on floor jack and
safety stands. Install rear springs (1) and the
two insulators, (2 and 3).
NOTE: During this operation, the differential c arrier
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 4A-52
11. After installing springs and insulators, use a
second floor jack to raise each trailing arm (2)
up far enough to allow shock absorber (3)
lower mounting to be installed to the trailing
arm (2).
12. Install washers and bolts (1) to the shock
absorber lower mount and tighten bolts to the
correct torque specification. Repeat for the
other side.
SHOCK ABSORBER LOWER
MOUNTING BOLT 105 – 125 Nm
TORQUE SPECIFICATION
NOTE 1: The torque specification for Sedan (A)
and Station Wagon (B) are the same.
NOTE 2: vehicle m ust be at curb weight and on all
four wheels before this torque is applied.
Figure 4A-53
13. Raise assembly until rear mount contacts
vehicle underbody.
14. Align rear mount (1) with marks on underbody,
made on disassembly, then loosely install new
attaching bolts (2) but do not fully tighten at
this stage.
15. The rear crossmember MUST now be aligned
to the vehicle centreline, using the special tool
and procedure as detailed in
Section 1A2 BODY DIMENSIONS of the VT
Series I Service Information.
CAUTION: Failure to correctly align the rear
crossmember to the centreline of the vehicle
will result in steering abnormalities and uneven
tyre wear!
Figure 4A-54
16. Tighten all cros smember mounting f ast eners to
the correct torque specification.
REAR MOUNT TO VEHICLE 30 – 40 Nm, plus
UNDERBODY ATTACHING BOLT 55° – 65 °
TORQUE SPECIFICATION turn angle
REAR CROSSMEMBER FRONT 125 Nm, plus
MOUNTING BOLT 30° – 40°
TORQUE SPECIFICATION turn angle
REAR CROSSMEMBER FRONT
MOUNTING BRACE BOLT 60 – 85 Nm
TORQUE SPECIFICATION
17. Install differential carrier breather hose into
vehicle underbody crossmember hole. Ensure
that end of hose is pushed into hole
approximately 25 mm.
Figure 4B-55
18. If equipped with ABS, reconnect wheel sensor
wiring harness connectors. Reinstall into the
retaining clips.
19. 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.
20. Check and fill dif ferential c arrier to co rrect level
with specified lubricant, refer to
2.1 CHECKING DIFFERENTIAL CARRIER
LUBRICANT LEVEL in 4B FINAL DRIVE AND
DRIVE SHAFTS, of the VT Series I Service
Information.
21. Check park brake adjustment and bleed brake
hydraulic system, refer to
Section 5A STANDARD BRAKES of the VT
Series I Service Information.
22. Reinstall propeller shaft. Refer to
Section 4C PROPELLER SHAFT AND
UNIVERSAL JOINTS VT Series I Service
Information (V6 Engines) or
Section 4C PROPELLER SHAFT AND
UNIVERSAL JOINTS VT Series II Service
Information (GEN III V8 Engine).
23. Reinstall exhaust system, by first installing the
front of the intermediate pipe to the catalytic
converter (V6 engine) or converters (V6
Supercharged and GEN III V8 engines). Use
new gaskets at the flanges on V6
Supercharged and GEN III V8 converters.
24. While supporting the exhaust system, install
the exhaust hanger rubbers to the rear of the
intermediate muffler/s and secure with new
retainers
25. Install rear muffler support rings to the rear of
the rear muffler and secure with new retainers.
26. Tighten intermediate exhaust pipe to catalytic
converter bolts to the correct torque
specification.
Figure 4B-56
INTERMEDIATE EXHAUST PIPE TO All Engines
CATALYTIC CONVERTER B OL T 40 – 50 Nm
TORQUE SPECIFICATION
27. Check exhaust clearances as detailed in
Section 8B EXHAUST SYSTEM VT Series I
Service Information (V6 engines) or
Section 8B EXHAUST SYSTEM VT Series II
Service Information (GEN III V8 engine).
28. Reinstall road wheel/s, aligning the marks
made prior to removal and secure with the
attaching nuts.
29. Remove safety stands and lower vehicle.
30. Bounce the rear of the vehicle several times to
settle suspension then, tighten road wheel
attaching nuts to correct torque specification,
working in a ‘star’ pattern, as indicated in Fig.
4B-1, in this Section.
ROAD WHEEL ATTACHING NUT
TORQUE SPECIFICATION 110 – 140 Nm
31. Refit wheel cover/centre cap.
32. Start vehicle and check for exhaust leaks.
Repair as necessary.
4. TORQUE WRENCH SPECIFICATIONS
NOTE: Only those torque wrench specifications relative to the service procedures contained in this Section are
detailed here. For all remaining torque specifications, refer to 4B FINAL DRIVE AND DRIVESHAFTS of the VT
Series I Service Information.
Nm
Brake Caliper Anchor Plate to Trailing Arm Attaching Bolt .................... 70 – 100
Collar Nut to Trunnion Assembly............................................................ 295 – 305
Differential Carrier to Rear Crossmember Attaching Bolt ...................... 90, then
30° – 45° turn angle
Driveshaft Constant Velocity Joint to Trunnion Flange Attaching Bolt ... 50, then
60° – 75° turn angle
Intermediate Exhaust Pipe to Catalytic Converter Bolt (All Engines) ..... 40 – 50
Rear Crossmember Front Mounting Bolt ............................................... 125, then
30° – 40° turn angle
Rear Crossmember Front Mounting Brace Bolt..................................... 60 – 85
Rear Mount to Rear Cover Attaching Bolt .............................................. 85 - 105
Rear Mount to Vehicle Underbody Attaching Bolt .................................. 30 – 40, then
55° – 65° turn angle
Rear Disc Brake Shield to Trailing Arm Attaching Bolt - Upper ............ 70 – 80
- Lower ............ 85 – 90
Road Wheel Attaching Nut..................................................................... 110 – 140
Shock Absorber Lower Mounting Bolt.................................................... 105 - 125
5. SPECIAL TOOLS
NOTE: Only those special tools relative to the service procedures contained in this Section are detailed here. For
all remaining special tools, refer to 4B FINAL DRIVE AND DRIVESHAFTS of the VT Series I Service Information.
TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS
AU416 TORX BIT
Previously released.
Used to loosen/tighten the two
upper rear brake disc shield
bolts to the trailing arm.
AU534 TORQUE LIMITING SOCKET
New release.
Used in conjunction with an
impact gun to tighten wheel
nuts.
This is a mandatory tool.
E7115 ANGLE WRENCH
Previously released.
Used to tighten any fastener
where a torque angle is
specified in addition to and
initial torque specification.
J22912-01 PRESS PLATES Previously released.
Used for various pressing
support operations.
KM468 HOLDING BAR
Previously released.
Used to hold trunnion assembly
hub from rotating.
TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS
KM620-A REMOVER/INSTALLER
Previously released.
Used to remove and install
trunnion flange, rear wheel
bearing and trunnion assembly.
KM620-7-AUS SUPPORTS
New release.
The two revised length supports
are required when undertaking
any of the following service
operations on the locally
sourced trailing arm assembly:
• Rear trunnion flange
• Rear wheel bearing
• Rear trunnion assembly
• Rear brake disc shield.