SECTION 4B - FINAL DRIVE AND DRIVE SHAFTS

IMPORTANT

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

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL DESCRIPTION

1.1 FINAL DRIVE ASSEMBLY IDENTIFICATION

1.2 FINAL DRIVE ASSEMBLY MAINTENANCE

MAINTENANCE

LIMITED SLIP DIFFERENTIAL

PRECAUTIONS

LUBRICATION

2. MINOR SERVICE OPERATIONS

2.1 GENERAL

IMPORTANT SERVICE REQUIREMENTS

2.2 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL

2.3 CHANGING/FLUSHING REAR AXLE

LUBRICANT LEVEL

2.4 TRAILING ARM TRUNNION ASSEMBLY HUB

CHECK FOR RUN-OUT

2.5 TRAILING ARM TRUNNION ASSEMBLY

HUB STUDS

REPLACE

2.6 LIMITED SLIP DIFFERENTIAL

TORQUE CHECK

2.7 DRIVE SHAFT ASSEMBLY

REMOVE

REINSTALL

2.8 DRIVE SHAFT AND/OR CONSTANT

VELOCITY JOINTS

DISASSEMBLE

INSPECT

REASSEMBLE

2.9 INNER AXLE SHAFT SEAL

REPLACE

2.10 PINION OIL SEAL

REPLACE

2.11 PINION FLANGE

REPLACE [USING OLD OIL SEAL]

REPLACE [USING NEW OIL SEAL]

3. MAJOR SERVICE OPERATIONS

3.1 TRAILING ARM TRUNNION FLANGE,

TRUNNION ASSEMBLY AND/OR

WHEEL BEARING

REMOVE

REINSTALL

3.2 FINAL DRIVE ASSEMBLY

REMOVE

REINSTALL

3.3 REMOVED FINAL DRIVE ASSEMBLY

DISASSEMBLE

INSPECT

REASSEMBLE

3.4 LIMITED SLIP DIFFERENTIAL

DISASSEMBLE

INSPECT

REASSEMBLE

3.5 REAR AXLE

REASSEMBLE

4. DIAGNOSIS

4.1 GENERAL INFORMATION

4.2 FINAL DRIVE ASSEMBLY NOISE

GEAR RELATED NOISE

BEARING RELATED NOISE

4.3 LSD NOISE

4.4 FINAL DRIVE BEARING DIAGNOSIS

5. SPECIFICATIONS

6. TORQUE WRENCH SPECIFICATIONS

7. SPECIAL TOOLS

Techline

1. GENERAL DESCRIPTION

Independent rear suspension is fitted as standard equipment on all MY2003 VY Series vehicles and all are fitted

with a f inal dr i ve ass embly that h as a f our -pin ion type rear dif f er entia l as sembl y. The rin g ge ar di ameter varie s f r om

190.5 m m to 203.2 mm and 205 mm . Applicat ion of each r atio is pro vided in a s ummar y of usage in table form on

page 4B-5.

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

availab le on a ll models. While the m aj orit y of illust rations shown in th is Sec ti on rel ate to v eh ic les f itted with th e AB S

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

noted.

The final dr ive assem bly is mounted directl y to a crossm em ber which is rubber mounted to th e vehicle un derbod y.

The differential case and drive p inion are m ounted in opposed taper roller bearings in the carrier. Differentia l case

side beari ng pre- load adj us tm ent is provi ded b y screw adjusters in the s ides of the cas e. Pinion b earing pr e- load is

provided by a collapsible spacer. Torque is transferred from the propeller shaft to the final drive assem bly 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 t wo co ne t ype clutc hes b ehind the s ide gears t hat, wit h V6 m odels, ar e sp lined to the inner axl e shaf ts 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 Differential has three pre-load springs enclosed in the centre of the pinion cross shaft. The Limited

Slip Diff erential dir ects the m ajor drivin g forc e to the wheel with the gr eater am ount of trac tion, but will not inter fere

with steer ing char acteristic s or dif ferentia l action. T he partia l lock ing action, due t o the sprin g load on th e cones , is

automatic ally incr eased by the i nherent separa ting f orces bet ween the side gear s and pinions , which pro gressive ly

increases the resistance in the differential as applied torque is increased.

W hen the rear wh eels are under ex trem ely unbalanc ed condit ions, s uch as a wheel on a dr y road and t he other in

mud or ice, with the standa rd differential, wheel spin eas ily occ urs if over-ac celeration is attem pted. Howeve r, with

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

drivin g force to the non-s pinning wheel. In the event o f continu ed spin ning, a whirring so und fr om the ov er-runnin g

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

The f inal dri ve as sembl y shoul d be r emoved f rom the vehicl e f or all s ervice oper at i ons other than for the remova l 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 velocit y joint is bolted to the inner axle shaft flange at the differential ca rrier, with the outer joint bolted to

the trunnion flange at the rear trailing arm.

Figure 4B-1

Legend

1. Drive Shaft

2. Rear Suspension Stabiliser Bar

3. Final Drive Assembly

4. Constant Velocity Joints

5. Trailing Arm

6. Rear Suspension Crossmember

7. Rear Stabiliser Bar to Trailing Arm Link

Legend

1. LH Inner Axle Shaft

2. Pinion Flange

3. RH Inner Axle Shaft

4. Identification Label

5. Drain Plug

6. Rear Cover

7. Breather

8. Filler Plug

9. Lubrication Tag

Figure 4B-2

1. 1 FINAL DRIVE ASSEMBLY IDENTIFICATION

The type of differential fitted to this final drive

assembly can be identified by referring to the

identification label (1) attached to the RHS of the

carrier housing and the lubrication tag (2) under the

filler plug (3) on the rear cover.

The locations of the identification label and

lubrication tag are as shown in Figure 4B-3.

The identification label (1) carries the final drive

assembly part number for the 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.

Usage Ratio Type I.D. Code

GEN III V8 or Standard FB

V6 Engined Ut il ity LSD FA

with 3.46:1 ABS (Std) FT

Manual LSD & ABS FC

Transmission

GEN III V8 &V6 Standard FD

Superc harge d with LSD FE

Automatic Trans. / 3.07:1 ABS (Std) FF

V6 Statio n Wagon LSD & ABS FH

with Manual Tr ans .

All V6 Engined Standard FJ

Sedans, Utility and LSD FK

Station Wagon 3.08:1 ABS (Std) FL

with Aut omatic LSD & ABS FM

Transmission

When fitted, the information on the lubrication tag

(2) under the filler plug (‘3’ in Figure 4B-3), will be:

Figure 4B-3

• With V6 and LSD; “SPIN RESISTANT DIFF. USE APPROVED LUBRICANT ONLY”

• With GEN III V8, V6 Supercharged (with Automatic Transmission), V6 Station Wagon and V6 Utility (with

Manual Transmission), fitted with the conventional differential; “HIGH PERFORMANCE. USE APPROVED

LUBRICANT ONLY”

• With GEN III V8, V6 Supercharged (with Automatic Transmission), V6 Station Wagon and V6 Utility (with

Manual Transmission), fitted with LSD; “LSD - HIGH PERFORMANCE. USE APPROVED LUBRICANT AND

FRICTION MODIFIER”

1.2 FIN AL 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

2.7 DRIVE SHAFT ASSEMBLY and to

2.8 DRIVE SHAFT AND/OR CONSTANT

VELOCITY JOINTS in this Section.

Differential Carrier Assembly

Check for lubricant leaks at every maintenance

service. If there is evidence of leakage, c orrect the

leak and add lubricant as necessary. (Refer to

2 MINOR SERVICE OPERATIONS in this

Section).

At the tim e or distance interval specified in the MY

2003 VY and V2 Ser ies Owner's Handbook , check

to ensur e that the lubr icant le vel is to the bottom of

the filler plug hole when the differential carrier

assembly is COLD.

Final Drive Assembly Breather

The breath er hose ( 1) shou ld be check ed regular ly

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 (2).

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 wheel raised. The 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 bal ancer ma y be used b y rem oving the road wheel opposit e to the one bein g spun, the veh icle raised

and supported on safety stands. Refit wheel nuts, reversed, to retain brake disc.

LUBRICATION

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

MY2003 V Y Series Owner' s Handbook with the differ ential carr ier COLD ; refer to 2.2 C HECKING DIFF ERENT IAL

CARRIER LUBRICANT LEVEL in this Sec t ion . At th is temperatur e, th e l ubr ica n t s hould be le ve l with the bott om of

the filler plug hole. Operation 2.2 also details the recommended lubricants for all final drives fitted to MY2003 VY

Series vehicles.

NEVER USE ANY OTHER THAN THE STATED AND RECOMMENDED LUBRICANT.

NOTE 1: The lubricant for vehicles with the 3.08:1 ratio assembly, with either the standard or Limited Slip

Differential (LSD) differential, is an approved mineral, LSD compatible lubricant and 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 3.08:1 ratio assembly, oil seal deterioration

with the possibility of lubricant leakage may occur.

NOTE 2: T he lubr icant used i n the r ear ax les of al l 3.0 7 and 3.46:1 rat io as sem bli es, is a s ynthetic pr oduc t. The oil

seals of the 3.07 and 3.46 :1 ratio as semblies ha ve been speci ally form ulated to tolerat e this lubr icant. It mus t also

be noted that, using a m ineral t ype lubricant in any final drive f itted to a 3.07 or 3.46:1 ratio assem bly, may cause

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

NOTE 3: With rear axles of 3.07 and 3.46:1 ratio assemblies, with LSD, an approved additive such as Sturaco

7098 MUST also be used, in conjunction with a synthetic hypoid gear oil.

NOTE 4: If the incorrect lubricant is accidentally used in the rear axle of any MY2003 VY Series vehicle, 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 2.3 CHANGING/FLUSHING REAR AXLE LUBRICANT, in this

Section.

2. MINOR SERVICE OPERATIONS

2.1 GENERAL

IMPORTANT SERVICE REQUIREMENTS

1. Whenever a road wheel and/or brak e disc is removed from the vehicle, the relationship of the road wheel and

the disc to th e hub MUST be mark ed with a felt ti ppe d pen or similar, in or d er f or those parts to be re ins ta ll ed in

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

minimum.

2. When reinstalling road wheels, do not use an

impact gun to tighten wheel nuts unless the

impact gun is fitted with a torque limiter socket

(Tool No. AU534 or a commercial equivalent).

Failure to correctly tighten wheel nuts to the

correct torque specification and in the correct

order, may result in a distorted brake disc,

leading to the development of brake shudder.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 – 140 Nm

For a complete description of the method

used to measure both brake disc and

trunnion assembly runout and correction, refer to

3.5 REAR BRAKE DISC, Brake Disc and Hub

Indexing Procedure, in Section 5A SERVICE AND

PARK BRAKING SYSTEMS in the MY 2003 VY

and V2 Series Ser v ice Infor mation

Figure 4B-5

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

replace d with ones of the s am e par t num ber or

with an equivalent part. Do not use a

replacement part of inf erior qua lity or substitute

design.

4. Torque values must be used as specified

during reassembly to ensure proper retention

of all rear suspension components.

2.2 CHECKING DIFFERENTIAL CARRIER LUBRICANT LEVEL

1. Ensure ve hic l e is le vel.

2. Clean area around filler plug (1).

3. Remove filler plug (1) from rear cover (3) (do

not lose the lubrication tag (2) from the plug, if

fitted).

4. The lubricant level is to be maintained at the

bottom edge of the filler plug hole, WHEN

COLD. Use only the recommended lubricant,

detailed as follows:

Figure 4B-6

ENGINE & AXLE TYPE RECOMMENDED LUBRICANT

ALL V6 Sedan with Manual or Automatic

Transmission,

V6 Station Wagon or Utility with Automatic

Transmission

Mineral Hypoid Gear Oil SAE 90 LSD such as;

AMPOL Gear Lube LSD 90,

CASTROL LSX90,

SHELL Helix Limited Slip Diff. Oil

VALVOLINE HP Gear Oil LS90

ALL NON-LSD AXLES ALL LSD AXLES

ALL GEN III V8 V6 Supercharged and V6 Station

Wagon or Utility with Manual Transmission Synthetic Hypoid Gear Oil, SAE

80W-140 such as;

MOBIL Mobilube SHC ID or

CASTROL SAF-XA Only

Synthetic Hypoid Gear Oil, SAE

80W-140 such as;

MOBIL Mobilube SHC ID,

CASTROL SAF-XA

With LSD (G80), also add;

0.1 litre of Sturaco 7098 Oil

Additive

5. Inspect filler plug (1) for damage, if OK,

reinstall to the rear cover (3) (including the

lubrication tag (2). If damaged, replace plug.

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

specification.

FILLER PLUG

TORQUE SPECIFICATION 23 - 31 Nm

2.3 CHANGING/FLUSHING REAR AXLE LUBRICANT

1. To drain lubrican t from diff er entia l c arr ier as s embly, re move filler ( 1) and dr ai n p lu gs (4 ) ( refer Figur e 4B-6) a nd

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

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

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

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

REAR AXLE DRAIN PLUG

TORQUE SPECIFICATION 23 - 31 Nm

4. Fill the f in al dr iv e as sembl y with eith er 1.6 litr es of the r ec om m ended l ubric an t or 1.5 litr es of the r ec om mended

lubricant plus 0.1 litre of Sturaco 7098 oil additive. Install the filler plug (1) and lubrication tag (2) (if fitted) and

tighten to the correct torque specification.

REAR AXLE FILLER PLUG

TORQUE SPECIFICATION 23 - 31 Nm

2.4 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 wheel nut covers (alloy wheels) on that side of the vehicle where

the trunnion is to be checked.

3. Mark relationship of wheel to mounting flange. Remove road wheel attaching nuts and remove wheel.

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

absorber (3) from trailing arm.

NOTE: View ‘A’ i n Figure 4B-7 s hows the sedan, lower s hock absorber m ounting, whil e view ‘B’ sho ws the station

wagon arrangement.

Figure 4B-7

5. Remove brake caliper anchor plate to trailing

arm attac hing bo lts ( 1), rem ove c aliper (2) fr om

disc.

Figure 4B-8

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

of shock absorber upper mounting. DO NOT

ALLOW CALIPER TO HANG BY BRAKE

HOSE.

7. Mark the brake disc position to trunnion

assembly, using a felt tipped pen or similar,

then remove the brake disc from the trunnion

assembly (Shown already removed in

Figure 4B-9).

Figure 4B-9

8. Clean the rear trunnion face by rubbing lightly

with fine emery paper.

9. Mount the pre-fabricated mounting plate (refer

7. SPECI AL TOOLS in th is Section f or details )

to the brake caliper mounting points on the rear

trailing arm, using the caliper mounting bolts.

10. Mount a magnetic based dial indicator stand,

install a dial in dicat or, posit ioning the pointer at

a distance of 5 mm in from the outer edge (‘A’).

11. Using the wheel studs , carefull y rotate trunn ion

assembly hub, noting the points of maximum

and minimum lateral run-out. The difference

between these two dimensions is the total

indicated runout.

MAXIMUM TRUNNION ASSEMBLY HUB,

TOTAL INDICATED RUN-OUT 0.060 mm

Figure 4B-10

If Run-out is Within Specification:

12. Reinstall brake disc over the trunnion wheel

studs, ensur ing that th e ali gnm ent marks made

prior to disassembly, are aligned.

13. Reinstall brake caliper (2) anchor plate to

trailing arm attaching bolts (1) and tighten to

the correct torque specification.

BRAKE CALIPER ANCHOR

PLATE TO TRAILING

ARM ATTACHING BOLT

TORQUE SPECIFICATION 70 – 100 Nm

Figure 4B-11

14. 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

TORQUE SPECIFICATION 105 - 125 Nm

NOTE 1: Vehic le m ust be at c urb we ight an d on al l

four wheels before this torque is applied.

NOTE 2: View ‘A’ in Figure 4B-12 shows the

sedan, lower shock absorber mounting, while view

‘B’ shows the station wagon arrangement.

Figure 4B-12

15. Reinstall road wheel, aligning marks made

prior to removal, install and tighten attaching

nuts.

16. Remove safety stand and lower vehicle.

17. Tighten road wheel attaching nuts to the

correct torque specification and in the correct

sequence (refer ‘IMPORTANT SERVICE

REQUIREMENTS’ in 2.1 GENERAL, in this

Section).

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

18. Refit wheel cover/ whe el nut caps.

If the Run-out Check, Exceeds Specification:

19. The tr unnion assem bly mus t be replace d, refer

to 3.1 TRAILING ARM TRUNNION FLANGE,

TRUNNION ASSEMBLY AND/OR WHEEL

BEARING in this Sect ion.

2.5 TRAILING ARM TRUNNION ASSEMBLY HUB STUDS

LT Section No: E006500 / E006600

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. Rem ove rear wheel cover (steel whee ls) or whee l nut caps (alloy whee ls) on that side of the veh icle where th e

stud/s are to be replaced.

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

road wheel.

4. Loosen and disconnec t rear shock absorber lo wer mounting bolt ( 1) from trailing arm (2) and pull lo wer end of

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

NOTE: View ‘A ’ in Figure 4 B-13 s h o ws th e s eda n, lower shoc k absor ber mountin g, whil e vie w ‘ B’ s ho ws t he s tatio n

wagon arrangement.

Figure 4B-13

5. Loosen and remove brake caliper anchor plate

to trailing arm attaching bolts (1) and remove

caliper (2) from disc.

Figure 4B-14

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

lower end of shock absorber upper mounting.

DO NOT ALLOW CALIPER TO HANG BY

BRAKE HOSE.

7. Mark the brake disc position to trunnion

assembly, using a felt tipped pen or similar,

then remove the brake disc from the trunnion

assembly (Shown already removed in Figure

4B-15).

Figure 4B-15

8. Using Tool No. J24292-C or equivalent, press

stud/s from hub.

Figure 4B-16

9. Install Tool No. K M-46 8-B hol ding bar, with tw o

wheel nuts to t he trun nion assem bly 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.

10. Install any remaining studs in the same

manner.

11. Remove Tool No. KM468-B.

Figure 4B-17

12. Reinst all br ak e disc ( 1) over the trunnion wheel

studs, ensuring that the marks made prior to

disassembly, are aligned.

Reinstall brake caliper (3) anchor plate to

trailing arm attaching bolts (2) and tighten to

the correct torque specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING

BOLT TORQUE SPECIFICATION 70 – 100 Nm

Figure 4B-18

13. Reinstall 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

TORQUE SPECIFICATION 105 - 125 Nm

NOTE 1: Vehic le m ust be at c urb we ight an d on al l

four wheels before this torque is applied.

NOTE 2: View ‘A’ in Figure 4B-19 shows the

sedan, lower shock absorber mounting, while view

‘B’ shows the station wagon arrangement.

14. Install road wheel, aligning marks made prior to removal, install and tighten attaching nuts.

15. Remove safety stand and lower vehicle.

16. Tighten road wheel attaching nuts to the correct torque specification and in the correct sequence (refer

‘IMPORTANT SERVICE REQUIREMENTS’ in 2.1 GENERAL, in this Sec ti on).

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

17. Refit wheel cover/wheel nut caps.

Figure 4B-19

2.6 LIMITED SLIP DIFFERENTIAL

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. Rem ove rear wheel cover (steel whee ls) or whee l nut caps (alloy whee ls) on that side of the veh icle where th e

stud/s are to be replaced.

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

road wheel.

5. Loosen and disconnect rear shock absorber lower mounting bolt from trailing ar m and pull lower end of shock

absorber from trailing arm.

NOTE: View ‘A ’ in Figure 4 B-20 s h o ws th e s eda n, lower shoc k absor ber mountin g, whil e vie w ‘ B’ s ho ws t he s tatio n

wagon arrangement.

Figure 4B-20

6. Loosen and remove brake caliper anchor plate

to trailing arm attaching bolts (1) and remove

caliper (2) from disc.

Figure 4B-21

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

lower end of shock absorber upper mounting.

DO NOT ALLOW CALIPER TO HANG BY

BRAKE HOSE.

8. Mark the brake disc position to trunnion

assembly, using a felt tipped pen or similar,

then remove the brake disc from the trunnion

assembly (Shown already removed in

Figure 4B-2 2).

Figure 4B-22

9. Using a torque wrench in conjunction with

adaptor, Tool No. 7208, and torque wrench

adaptor E6662B, rotate trunnion assem bly in a

forward direction. If the unit is operating

satisf ac toril y, a torque rea di ng of appr ox imately

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-23

10. Reinst all br ak e disc ( 1) over the trunnion wheel

studs, ensuring that the marks made prior to

disassembly, are aligned.

Reinstall brake caliper (3) anchor plate to

trailing arm attaching bolts (2) and tighten to

the correct torque specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING

BOLT TORQUE SPECIFICATION 70 – 100 Nm

Figure 4B-24

11. Reinstall 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

TORQUE SPECIFICATION 105 - 125 Nm

NOTE 1: Vehicle must be at curb weight and on all four wheels before this torque is applied.

NOTE 2: View ‘A’ in Figure 4B-25 shows the sedan, lower shock absorber mounting, while view ‘B’ shows the

station wagon ar rangem ent.

Figure 4B-25

12. Install road wheel, aligning marks made prior to removal, install and tighten attaching nuts.

13. Remove safety stand and lower vehicle.

14. Tighten road wheel attaching nuts to the correct torque specification and in the correct sequence (refer

‘IMPORTANT SERVICE REQUIREMENTS’ in 2.1 GENERAL, in this Sec ti on).

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

15. Refit wheel cover/wheel nut caps.

2.7 DRIVE SHAFT ASSEMBLY

LT Reference No: F50400 / F504100 / F504200

NOTE: The following fasteners MUST be replaced when

performing this operation:

 Drive shaft constant velocity joint to trunnion flange and

inner axle shaft attaching bolt.

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 mm Allen key socket, remove drive

shaft inner constant velocity joint to inner axle

shaft and outer constant velocity joint to

trunnion flange attaching bolts (2) (six places)

and plates, remove drive shaft (1).

NOTE 1: As it is only the inner, constant velocity

joint that is a plunge joint, it is important that the

drive shaft orientation 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-26

REINSTALL

Reinstallation of the drive shaft is reversal of the

removal procedure, noting the following points.

NOTE: A label is attached to each drive shaft, to

indicate which joint faces outward. The outer CV joint

is also marked with a groove, while the inner, plunge

joint has none. 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 FLANGE AND

INNER AXLE SHAFT ATTACHING

BOLT TORQUE SPECIFICATION 50 Nm, then

90° turn angle

Techline

2.8 DRIVE SHAFT AND/OR CONSTANT VELOCITY JOINTS

There are four repair kits available for drive shaft constant velocity joint repairs.

1. A ‘BOOT KIT’, which consists of a boot, boot clamps, snap ring and two tubes of grease.

2. A ‘CONSTANT VELOCITY JOINT KIT’, which contains the same items as the BOOT KIT plus the inner,

constant ve locity joint.

3. A ‘CONSTANT VELOCITY JOINT KIT’, which contains the same items as the BOOT KIT plus the outer,

constant ve locity joint.

4. A ‘DUST CAP REPAIR KIT’, which is common to both the inner and outer constant velocity joints.

DISASSEMBLE

1. Remove drive shaft assembly, refer to

2.7 DRIVE SHAFT ASSEMBLY in this Section.

2. Clean outside of assembly with a suitable

solvent before disassembling.

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

fitted with soft metal jaws.

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

boot clamps (2) in raised crimped area and

remove clamps.

Figure 4B-27

5. Using a suitable dr ift (1) a nd hamm er, tap dust

shields (2) and caps (3) from both sides of

constant velocity joints.

Figure 4B-28

6. Using suitable snap ring pliers (1), remove the

snap ring (2) from each end of drive shaft and

discard.

NOTE: Do not use s na p rin gs once they have be en

removed. Always use new snap rings on

reassembly.

7. Remove assembly from vice. Slide dust shield

and boots towards centre of shaft.

Figure 4B-29

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

E1312), supporting inner race, press drive

shaft from constant velocity joint.

9. Repeat process to remove remaining constant

velocity joint.

10. Remove boots and dust shields from drive

shaft, ensuring boots are not damaged on

edges of shaft.

Figure 4B-30

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: As the interc onnecting shaft is not serv iced

separately, if the interconnecting shaft is found to

be defective, then the driveshaft 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.

2. If ins pection reveals that the joint h as not been

contaminated, clean joint by soaking in a

suitable cleaning solvent.

3. Once grease has been removed, inspect

internal c ompone nts by tilti ng inner race to one

side to expose each ball.

4. 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-31

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 (1) and cage (2),

together with the individual balls (3), should be

maintained in their original locations to minimise

the creation of a noisy joint.

NOTE 3: Und er no circum stances 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.

With the inner joint, note the single identification

groove (4) on the outer race (5) and the

identification step (6) on the inner race.

Conversely, the outer joint has two grooves (6) on

the outer race, a chamfer (5) on the cage and a

recess (4) on the inner race (1).

Figure 4B-32

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

position centrally.

Figure 4B-33

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

into the outer race (1). Make sure that the

identification groove (1) and step (2) are on

opposite sides of the assembly, as shown.

Figure 4B-34

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

with the narrow ones (2) on the inner race.

Figure 4B-35

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

one ball.

Repeat this process for the remaining five

balls.

Figure 4B-36

5. When assembly of the CV joint is complete,

check for plunge movement of the inner

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

movement can be achieved, then the

constant velocity joint has been incorrectly

assembled.

If suc h a situation occurs, t he CV joint m ust 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-37

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 (2) and place boot over dust shield (1). Using Tool No. J22610,

securely crimp boot clamp, ensuring the crimp is positioned mid-way between two bolt holes (3, in view ‘A’).

3. Apply a 2 mm diameter bead (4) of commercially available RTV 732 sealant to dust caps/shields 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-38

6. Only for the inner constant velocity joint (1),

reinsta ll the joi nt (1) onto s haft with step (3) on

the inner race (2) facing toward the shoulder

(4) on the shaft.

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 a NEW circlip at each end.

NOTE: When pressing joints onto shaft, ensure

that the joint inner races (2) take the press load.

Figure 4B-39

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 hammer, tap caps

and shields into place.

Figure 4B-40

11. Locate small ends of boots into boot grooves

on drive shafts, ensuring that boots are not

twisted.

W ith both j oin t, pr y up s mall ends of b oots f rom

shaft (1) to equalise air pressure inside and

outside of boots and work out any dimples

before applying new small clamps.

IMPORTANT: The location distance ’A’, ONLY

applies to the inner, plunge joint and should be set

at 81 mm before applying the small clamp.

Figure 4B-41

12. Position small clamps over ends of boots and

using Tool No. J22610, crimp ends of clamps.

13. Reinstall drive shaft, refer 2.7 DRIVE SHAFT

ASSEMBLY - REINSTALL in this Section.

Figure 4B-42

2.9 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. Remove drive shaft from side of vehicle

which seal is to be replaced, refer to

2.7 DRIVE SHAFT ASSEMBLY – REMOVE,

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 s haft j oint def lection sho uld be k ept

to a minimum.

3. Remove inner axle shaft (1) by installing a slide

hammer, Tool No. 7 374 with three suit abl e s i ze

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 a 3.08:1 ratio final drive 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, dismant ling and realigning g ear and cone

splines.

NOTE: The above ‘Caution’ does not apply to

either the 3.07:1 or 3.46:1 ratio 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 scr ew adjust er.

Figure 4B-43

5. Using a suitable screwdriver (1) and a block of

wood (2), lever seal (3) from screw adjuster

bore (4).

NOTE: Take care not to damage the screw

adjuster's aluminium housing (4) with the

screwdriver blade (1), as this could cause oil leaks

to occur, after a new oil seal was fitted.

Figure 4B-44

6. Before installation of new seal, examine seal

surface of inner axle shaft and remove any

nick s or bur rs. Shoul d th is i ns pection sho w that

the surface is marked, a new inner axle shaft

should be fitted.

NOTE 1: The left hand in n er ax le sh aft is shor ter in

length than the right hand shaft.

NOTE 2: If veh icle is e quipped with AB S, the inner

axle shafts are unique for this application.

NOTE 3: Check spring clip in end of axle shaft to

ensure that it is not damaged and moves freely in

groove. Replace spring clip if necessary, by

expanding ends of clip and removing from shaft.

Only expand the ends of a new clip 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. Insta ll seal usin g Tool No.

AU410, until seal bottoms in bore.

Figure 4B-45

9. Reinstall inner axle shaft (1), aligning splines

with clutch cone (if fitted with a Limited Slip

Diff erential) and side ge ar .

NOTE: To avoid premature seal failure, ensure

axle shaft splines or securing clip do not score or

damage the seal lips during installation.

10. Lightl y hit on end of axle shaf t flange (1) with a

soft faced hammer (2) to compress spring clip

on shaft in to cl utch con e and s ide g ear splin es.

Fully engage shaft (1) until clip snaps in to side

gear groove.

Figure 4B-46

11. Reinstall drive shaft, refer to

2.7 DRIVE SHAFT ASSEMBLY in this

Section.

12. Remove safety stands and lower vehicle.

13. Check and f il l dif f er entia l carrier to c orr ec t le vel

with specified lubricant. Refer to

2.2 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

2.10 PINION OIL SEAL

LT Reference No: F502100

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 coupling to

pinion flange, using a felt tipped pen or similar.

3. Remove propeller shaft, refer to 4C PROPELLER

SHAFT AND UNIVERSAL JOINTS in the MY 2003 VY

and V2 Series Service Information. This operation may

also require partial exhaust system removal.

4. Lightly centre-punch alignment marks (A) on the

pinion flange (1), flange nut (2) and pinion end (3) as

an aid for reassembly.

By reassembling to the original position, the flange

run-out will be minimised and the pinion bearing

preload will be maintained.

Figure 4B-47

5. Attach Tool No. KM620-1A to the pinion flange,

using three suitable bolts to hold pinion flange.

NOTE 1: If not previously done so, drill out holes

stamped ‘B’ on Tool No. KM620-1A to 12.5 mm.

NOTE 2: Use either the rear coupling to pinion flange

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

installed first or use three bolts M12 x 1.5 x 40, with the

thread extending to w ithin 12 mm of the head.

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

the installed tool for leverage, then remove the

pinion flange retaining nut, using a commercially

available, 30 mm deep socket and socket bar (2).

7. Remove Tool No. KM620-1A from the pinion flange.

Figure 4B-48

8. Place drain tray beneath differential carrier.

9. Install extractor, Tool No. KM628-A to the

pinion flange using the same three bolts used

to secure the flange holding tool, KM620-1A

(refer Figure 4B-48).

NOTE: If not previo us l y done s o, dr ill out the flan ge

holes on Tool No. KM628-A to 12.5 mm.

IMPORTANT: If using the original propeller shaft

coupling bolts, they must have a 25 mm spacer

fitted to each, so the tool is clamped to the pinion

flange. If this is not done, the screw thread on the

extractor Tool No. KM628-A will not be long

enough to fully remove the pinion flange.

10. While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening

the forcing screw in the direction indicated.

Figure 4B-49

11. Prise pinion oil seal from carrier bore using

Tool No. E308 or a universal seal removing

tool.

Figure 4B-50

12. Lubricate a new pinion oil seal lips and the

outer diameter with the recommended rear

axle lubr ic ant.

13. Start oil seal into differential carrier housing

and dri ve seal squ arel y into pos ition usin g T ool

No. E9055. Seal fits flush to 0.25 mm below

carrier housing surface.

14. Ensure that pinion shaft is free from burrs and

that flange oil seal surface is free from

damage.

Figure 4B-51

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

16. Coat splines and s eal s urface of pinion f lan ge with dif f er enti al g ear lubricant , and ins ta ll flange ont o pi nio n shaft

splines. Ensure that centre-punch marks are aligned.

17. Reinstall holding tool KM620-1A to the pinion flange.

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

nut, then reinstall the nut.

19. Tighten the flange retaining nut until all centre-punch marks align. Then carefully tighten the nut to a position

not more than 5° past the aligned setting.

NOTE: The pinion flange is an interference fit on pinion shaft splines and should only be pulled into place by

tightening the retaining nut. DO NOT, UNDER ANY CIRCUMSTANCES, USE FORCE OR HAMMER THE

FLANGE DURING INSTALLATION ONTO PINION FLANGE.

CAUTION: Should the retaining nut be over-tightened and pre-load exceeded, it will be necessary to

remove the pinion from the carrier and install a new collapsible spacer. Under no circumstances must the

retaining nut be backed off to decrease the pre-load reading.

20. Reinstall propeller shaft rear coupling to the pinion flange, refer Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS in the MY 2003 VY and V2 Series Service Information.

21. 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.

22. Remove safety stands and lower vehicle.

23. Check lubricant le vel and t op up as necessar y. Refer 2.2 CH ECKING D IFFER ENTIAL CARRIER LUBRICANT

LEVEL in this Section

24. Start vehicle and check for exhaust leaks.

2.11 PINION FLANGE

LT Reference No: F501100

REPLACE (USING OLD OIL SEAL)

NOTE: Due to production tolerances in the length of the pinion flange, it is essential that the following method be used when

installing a new pinion flange. .

1. 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 2.1 PROPELLER SHAFT in 4C PROPELLER SHAFT AND UNIVERSAL JOINTS in the

MY 2003 VY and V2 Series Service Information.

3. Remove both drive shafts, refer 2.7 DRIVE SHAFTS in this Section.

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

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

suitable bolts and attach a cord around pulley

and to a spring scale (2).

NOTE 1: Use either the rear coupling to pinion

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

flat washers) installed first or use three bolts

M12 x 1.5 x 40, with the thread extending to

within 12 mm of the head.

NOTE 2: For details of the fabricated pulley,

refer 7 Special Tools at end of this Section.

b. Start rotation of pulley and whilst in motion

(approximately 50-60 rpm) note and record

reading of spring balance.

This pre-load reading includes pinion bearings,

side bearings, meshing effect of gear set and

pinion oil seal.

To determine pre-load, multiply reading on

spring balance by radius of pulley.

EXAMPLE: With a pulley diameter of 152 mm, the radius

is 76 mm, which equals 0.076 m. With a spring balance

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

1.9 Nm.

5. Remove pulley from pinion flange.

Figure 4B-52

6. Attach Tool No. KM620-1A to the pinion flange,

using three suitable bolts to hold pinion flange.

NOTE 1: If not previously done so, drill out holes

stamped ‘B’ on Tool No. KM620-1A to 12.5 mm.

NOTE 2: Use either the rear coupling to pinion

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

washers) installed first or use three bolts M12 x 1.5

x 40, with the thread extending to within 12 mm of

the head.

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

the installed tool for leverage, then remove the

pinion flange retaining nut, using a commercially

available, 30 mm deep socket and socket bar (2).

8. Remove Tool No. KM620-1A from the pinion flange.

Figure 4B-53

9. Place drain tray beneath differential carrier.

10. Install extractor, Tool No. KM628-A to the

pinion flange using the same three bolts used

in step 6.

NOTE: If not previo us l y done s o, dr ill out the flan ge

holes on Tool No. KM628-A to 12.5 mm.

IMPORTANT: If using the original bolts, they must

have the 25 mm spacers fitted so the tool is

clam ped to the pinion f lang e. If this is not don e, the

screw thread on the extractor Tool No. KM628-A

will not be long enough to fully remove the pinion

flange.

11. While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening

the forcing screw in the direction shown.

Figure 4B-54

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

pinion flange with the recommended rear axle lubricant.

13. Install the new pinion flange and a new 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 INSTALLATION ONTO PINION FLANGE.

14. Tighten flange retaining nut gradually until pinion shaft end play is reduced to approximately 0.50 mm.

15. Attach pull ey to the ne w pi nion flange and using sprin g balance, chec k pre-load . Continue ti ghtening nut while

alternatively turning pinion to seat bearings, until the pre-load figure recorded previousl y (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 over-tightened and the pre-load exceeded, it will be necessary to

remove the differential carrier assembly and install a new collapsible spacer. Under no circumstances

must the retaining nut be backed off to decrease the pre-load setting.

16. Reinstall drive shafts, refer to 2.7 DRIVE SHAFTS in this Section.

17. Reinstall pro peller s haf t, ref er to Se ction 4C P ROP EL LER SHAFT AND UNIVERS AL JOINT S in th e M Y 20 03

VY and V2 Series Service Information.

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

3.2 FINAL DRIVE ASSEMBLY, in this Section, for details.

19. Remove safety stands and lower vehicle.

20. Check lubricant level and top up as necessary with the recommended lubricant, refer to

2.2 CHECKING DIFFERENTIAL CARRIER LUBRICANT LEVEL in this Section.

21. Start vehicle and check for exhaust leaks.

REPLACE (USING NEW OIL SEAL)

1. 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 4C PROPELLER SHAFT AND UNIVERSAL JOINTS in the MY 2003 VY and V2

Series Service Information.

3. Remove both drive shafts, refer to 2.7 DRIVE SHAFTS in this Section.

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

follows:

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

suitable bolts and attach a cord around pulley

and to a spring balance (2).

NOTE 1: Use either the rear coupling to pinion

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

flat washers) installed first or use three bolts

M12 x 1.5 x 40, with the thread extending to

within 12 mm of the head.

NOTE 2: For fabricated pulley details, refer to

7. Special Tools at the 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, meshing effect of gear set and

pinion oil seal.

To determine pre-load, multiply reading on

spring balance by radius of pulley.

EXAMPLE: With a pulley diameter of 152 mm, the radius

is 76 mm 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-55

6. Attach Tool No. KM620-1A to the pinion flange,

using three suitable bolts to hold pinion flange.

NOTE 1: If not previously done so, drill out holes

stamped ‘B’ on Tool No. KM620-1A to 12.5 mm.

NOTE 2: Use either the rear coupling to pinion flange

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

installed first or use three bolts M12 x 1.5 x 40, with the

thread extending to w ithin 12 mm of the head.

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

the installed tool for leverage, then loosen the pinion

flange retaining nut, using a commercially available,

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

can be felt in the pinion shaft.

8. Check the oil seal and differential side bearing pre-

load using the spring scale and pulley, as detailed in

steps 4a and 4b, Record oil seal and side bearing

pre-load for later use.

9. Remove Tool No. KM620-1A from the pinion flange.

Figure 4B-56

10. Place drain tray beneath differential carrier.

11. Install extractor, Tool No. KM628-A to the

pinion flange using the same three bolts used

previously.

NOTE: If not previo us l y done s o, dr ill out the flan ge

holes on Tool No. KM628-A to 12.5 mm.

IMPORTANT: If using the original bolts, they must

have the 25 mm spacers fitted so the tool is

clam ped to the pinion f lang e. If this is not don e, the

screw thread on the extractor Tool No. KM628-A

will not be long enough to fully remove the pinion

flange.

12. While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening

the forcing screw in the direction shown.

Figure 4B-57

13. Prise pinion oil seal from carrier bore using

Tool No. E308 or a universal seal removing

tool.

Figure 4B-58

14. Lubricate a new pinion oil seal lips and the

outer diameter with the recommended rear

axle lubr ic ant.

15. Start oil seal into differential carrier housing

and dri ve seal squ arel y into pos ition usin g T ool

No. E9055. Seal fits flush to 0.25 mm below

carrier housing surface.

16. Ensur e that pin ion shaf t is free f rom burrs , then

clean the threads of the pinion shaft, removing

any oil, dirt or grease.

17. Coat splines and seal surface of pinion flange

with differential gear lubricant, then reinstall

flange to the pinion shaft splines.

18. Install a new flange retaining nut, then tighten

to draw the pinion flange onto the pinion shaft

splines.

NOTE: The ne w flang e will be an int er f er enc e f it 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.

19. Continue to tighten the flange retaining nut

gradually until pinion shaft end play is reduced

to approximately 0.5 mm.

20. 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.

Figure 4B-59

21. The pre-load reading for differential assembly

obtained in step 8, is subtracted from pre-load

reading obtained in step 20. 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 steps 8 and 20 must

be added to pre-load reading obtained in step

4b to obtain a total pre-load reading.

THEORETI CAL EXAMPLE

STEP 20 NEW OIL SEAL AND SIDE

BEARIN G PR E- L OAD

SETTING

1.47 Nm

STEP 8 OLD OIL SE AL AND SIDE

BEARING

PRE-LOAD READING

1.02 Nm

SUBTR AC T STEP 8

FROM STEP 20

0.45 Nm

STEP 4b COMPLETE

DIFFER EN TIAL ASSEM BLY

PRE-LOAD READING

1.47 Nm

THE PRE-L O AD READIN G

COMBINATION WILL BE

THE SUM OF:-

1.47 Nm

plus

0.45 Nm

WHICH GI VE S A TO TAL

PRE-LOAD READING OF:-

1.92 Nm

22. Continue tightening retaining nut while

alternately turning pinion to seat bearings until

total pre-load figure obtained in step 21 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.

CAUTION: Should the retaining nut be over-tightened and the pre-load exceeded, it will be necessary to

remove the differential carrier assembly and install a new collapsible spacer. Under no circumstances

must the retaining nut be backed off to decrease the pre-load setting.

NOTE: It must be realised that the pre-load readings in the example are only theoretical. In practice, the figures

could differ greatly, so the readings obtained when performing the actual operations, are the ones to use.

23. Reinstall drive shafts, refer to 2.7 DRIVE SHAFTS in this Section.

24. Reinstal l propeller shaf t, refer to Sect ion 4C PROPELL ER SH AFT AND UNIVER SAL JOINT S in the MY2003

VY and V2 Series Service Information.

25. 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.

26. Remove safety stands and lower vehicle.

27. Check lubricant level and top up as necessary, refer to 2.2 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

28. Start vehicle and check for exhaust leaks.

3. MAJOR SERVICE OPERATIONS

3.1 TRAILING ARM TRUNNION FLANGE, TRUNNION ASSEMBLY

AND/OR WHEEL BEARING

LT Reference No: F201350 / F201450 / F701100 / F701200 / F201300 / F21400

NOTE: The following fastener MUST be replaced when

performing this operation:

 Collar nut to trunnion assembly.

 Drive shaft constant velocity joint to trunnion flange and

inner axle shaft attaching bolt.

NOTE 1: The following procedure involves the removal of the trunnion flange, trunnion and/or wheel bearing with

the trailing arm installed in the vehicle. A similar procedure is included in Section 4A REAR SUSPENSION in

the MY2003 VY Series Service Information, when the trailing arm is rem oved from the vehicle.

NOTE 2: The rear wheel bearin g should only be removed if it is faulty, or if the trunnion assembly is to be removed.

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 Retai ning Ring.

Figure 4B-60

REMOVE

1. Using a floor jack under centre of differential carrier, jack up rear of vehicle and place safety stands under body

rear jacking points. Refer to Section 0A GENERAL INFORMATION in the MY2003 VY Series Service

Information for location of jacking points.

2. On the side of the vehicle where the trailing arm is to be removed, remove the wheel trim or wheel nut covers,

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

remove road wheel attaching nuts. Remove the 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 disc on nec t p ipe from bac king plate brack et

(2).

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

to prevent fluid loss and foreign matter entry.

Figure 4B-61

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

disconn ected, t he brak e caliper mus t be secur ed to

the vehicle underbody. THE CALIPER IS NOT TO

HANG BY THE BRAK E 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 f elt ti pp ed p en or similar. This is

necessar y to overcom e the possibil ity of inducin g a

brake shudder condition after reassembly.

Figure 4B-62

NOTE 2: Should it be necessar y to adjust the park

brake shoe to allow the brake disc to be removed,

the following method should be adopted.

6. Remove one of the access hole plugs (1) from

either of the two access holes provided in the

disc. Using a suitable lever such as a

screwdriver, loosen the par k brake shoe screw

adjuster, until the disc is freed.

7. After disc removal, reinstall the access hole

plug to prevent loss.

Figure 5A-63

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

trailing arm.

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

absorber (3) from trailing arm. Leave the supporting jack and wooden block in position.

NOTE: View ‘A ’ in Figure 4 B-65 s h o ws th e s eda n, lower shoc k absor ber mountin g, whil e vie w ‘ B’ s ho ws t he s tatio n

wagon arrangement.

Figure 4B-64

10. 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-65

11. 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 velocit y 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.

12. The supporting jack may now be lowered and

the wooden block removed.

Figure 4B-66

13. Remove park brake shoe by grasping each

end as shown. Push up on one end of the

shoe, dislodging the end from the actuator pin

and the shoe from the retaining clip.

Figure 5A-67

14. Using a scre wing motion, rotate t he park brak e

shoe around the trunnion flange to remove it

from the vehicle.

15. Rem ove the park brak e s hoe spring retai ner b y

prising from the rear disc shield, with a

screwdriver or similar lever.

16. Using suitable socket equipment, loosen then

remove the two lower bolts securing the park

brake adjuster and brake backing plate to the

trailing arm.

17. Using Tool No. AU416 and suitable socket

equipment, loosen then remove the two upper

brak e backing plate to the trail ing arm , Tor x bit

headed bolts

Figure 5A-68

18. Secure flange holding tool, KM620-1A and

trunnion flange ring tool KM620-2 to trunnion

flange (1) with thr ee of the rem oved drive shaf t

constant velocity joint to trunnion flange

attaching bo lts (2).

NOTE: Align holes marked ‘B' on the flange

holding tool KM620-1A and KM620-2 with holes in

the trunnion flange before installing and tightening

bolts.

Figure 4B-69

19. Install a su ita ble le ngth and diameter s teel tub e

over handle of KM620-1A to stop it from

rotating, then use suitable socket equipment

(1) to loosen and remove the collar nut and

lock plate.

NOTE: Once collar nut and lock plate have been

removed, they must be discarded as they are only

to be used once.

Figure 4B-70

20. Lubricate the threads of forcing screw KM620-

3, then install to adaptor KM620-4-A. Apply

grease to ball end of plung er, T ool No. KM 620-

5B, then install that, into the end of forcing

screw KM620-3.

21. Install the whole sub-assembly through the

central opening of flange holding tool KM620-

1-A. Secure the adaptor KM620-4A to the

flange holding tool KM620-1A, using three

suitable bo lts (1) .

NOTE: Adjust the position of the forcing screw

KM620-3 in the adaptor KM620-4A, to allow

adaptor to be in full contact with the flange holding

tool KM620-1A.

Figure 4B-71

22. While hold ing KM 620-1A f rom r otating, tur n the

screw KM620-3, forcing the flange free from

the trunnion.

Separate tool components from flange once it

has been removed.

Figure 4B-72

23. Prepara tory to rem oving th e trunni on assem bly

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.

24. Install two supports KM620-7A in positions ‘A’

and two KM620-7AUS to ‘B’ and ‘C’ in the

trailing arm, as indicated.

As a guide, the two longest supports (KM620-

7A) are to be installed at the brake caliper

mounting side (position ‘A’). The longer of

KM620-7AUS supports is installed at position

‘B’ and the shorter is installed at position ‘C’.

25. After installing all four supports in the correct

positions, tighten with a set spanner.

Figure 4B-73

26. Install flange holding tool KM620-1A over the

four supports, KM620-7A (2 places) and

KM620-7AUS (2 places), install four suitable

nuts (1) and tighten to secure.

27. Pre-assem ble lubricated forcing screw KM620-

3 to adaptor KM620-4A. Apply grease to ball

end of plunger KM6 20-5B, then i nstall th at, into

the end of forcing screw KM620-3.

28. Install this sub-assembly through the central

opening of holding tool KM620-1A. Secure the

adaptor KM620-4A to the flange holding tool

KM620-1A, using three suitable bolts (2).

NOTE: Adjust the position of the forcing screw

KM620-3 into the adaptor KM620-4A, to allow full

contact of the adaptor to the flange holding tool

KM620-1A.

Figure 4B-74

29. Insert a s uitable le ngth of tube over the handle

of holding tool KM620-1A to stop it from

rotating and turn the forcin g screw KM620-3 to

press trunnion from rear wheel bearing.

30. W hen the trunnion has be en removed, rem ove

nuts (1) holding KM620-1A assembly to the

distance pieces, KM620-7A and KM620-7-

AUS. Rem ove KM620-1A, and r emove KM620-

5B from the end of KM620-3.

31. 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.

32. Remove the brake backing plate and park

brak e assem bly from the trailin g arm and s et to

one side.

Figure 4B-75

33. If the trunnio n assem bly (1) is to be reins talled,

then the outer half of the inner rear wheel

bearing cone (2) will need to be removed from

the trunnion assembly (1).

a. Ins tall press plates J2291 2-01 over the b earing

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 tru nn ion is t o be r ep laced , th en s t ep

27 will not be required.

NOTE 2: A new trunnio n assem bly is supplied with

wheel studs already installed.

Figure 4B-76

34. Remove wheel bearing retaining ring (1) from

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

Figure 4B-77

35. With the tool components set up in the same

arrangement as for step 20 (and as shown in

Figure 4B-73), install rear axle bearing

removing plate KM620-6 to rear of the axle

bearing. Reposition the for cing scre w KM620-3

to hold the removi ng pl ate KM6 20-6 in pl ac e.

36. Insert a s uitable le ngth of tube over the handle

of holding tool KM620-1A to stop it from

rotating, then turn the forcing screw KM620-3

to press the wheel bearing from the trailing

arm.

37. If installing a replacement trailing arm without

bushes, install new bushes. Refer to

2.7, TRAILING ARM BUSHES in Section 4A

REAR SUSPENSION in MY2003 VY and V2

Series Service Information.

Figure 4B-78

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 diam eter of ne w wheel bear ing an d bor e of traili ng arm with lubric a nt such as M ol ybond HE50 , or

equivalent.

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

the holding tool KM620-1A, then remove the

adaptor and forcing screw KM620-3 from the

holding tool KM620-1A.

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

of KM620-A) with lubricant such as Molybond

HB50, or equivalent, then assemble the

bearing onto the flanged end of adaptor

KM620-4A.

5. Reinstal l t he f or c in g s cr e w and ad aptor / bearing

assem bly to t he flange ho lding tool KM620-1A.

Do not reinstall the adaptor (KM620-4A) to

holding tool (KM620-1A) attaching bolts.

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

bearing (2) and install both into the trailing

arm (3).

7. Join the forcing screw (KM620-3), and bearing

installer (KM620-8A) by engaging the screw

thread of the forcing screw (KM620-3) with

installer (KM620-8A) and tightening the forcing

screw to engage at least eight full threads.

Figure 4B-79

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

adaptor KM620-4A in a clockwise direction, using a suitable 40 mm wrench to draw the new bearing (2) fully

into position.

9. W hen the bearing is f ully installed, separ ate instal ler KM620-8A f rom the forcing s crew KM620-3, the n remove

the instal ler and f orc ing scre w (KM620- 3), adap tor (K M620- 4A) and be arin g, from the holdin g tool (KM 620- 1A).

Leave remaining tools installed.

10. Using s uitab le circ lip pl iers, ins tall a new bear ing ret ainin g ring into tra iling arm , ensuring t hat the r ing is s eat ed

correctly.

11. Install rear disc brake shield to trailing arm but

do not inst all fastener s (‘1’ and ‘2’) at this tim e,

as the s upports, K M620-7A and KM620- 7-AUS

could not be fully installed in the threaded

holes on the opposite side.

Figure 4B-80

To Reinstall Trunnion:

1. Remove KM620-1A from distance pieces,

KM620-7A and KM620-7AUS. Install sleeve

KM620-9A over KM620-3, with the stepped

shoulder facing away from the trunnion

bearing. Reinstall KM620- 1A to K M620-7A a nd

KM620-7AUS, tightening the attaching nuts.

2. Screw the threaded end of the trunnion into

KM620-3. W hile ho ld ing K M620-3 f rom tur ning,

rotate KM620-4A to draw trunnion into wheel

bearing.

3. Unscrew for cing sc rew KM620-3 fr om trunni on,

then rem ove t he nuts h old i ng to ol KM 620- 1 A t o

the distance pieces KM620-7A and KM620-

7AUS.

4. Remove the distance pieces KM620-7A and

KM620-7AUS from the trailing arm.

Figure 4B-81

5. Assem ble KM620-2 and KM620-1A to trunnion

flange using three drive shaft constant velocity

joint to flange bolts.

6. Lubricate trunnion flange splines and trunnion

threads with the recommended differential

carrier lubricant.

7. With KM620-4A, thrust ball bearing race (2)

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

the internal thread of KM620-3 onto the

trunnion ass embly.

Figure 4B-82

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 KM620-4A in the direction shown, to

install the trunnion flange onto trunnion.

9. Unscrew KM620-3 from the trunnion, then

remove it and adaptor KM620-4A from the

holding tool KM620-1A. Leave the holding tool

KM620-1A and trunnion flange ring tool

KM620-2 installed to the trunnion flange.

Figure 4B-83

10. Install N EW c ollar nut to t he trunnio n assem bly

and, using a suitable length and sized pipe

over the handle of KM620-1A to hold trunnion

assembly from turning, tighten collar nut to the

correct torque specification.

COLLAR NUT TO

TRUNNION ASSEMBLY

TORQUE SPECIFICATION 295 – 305 Nm

11. Remove the holding tool KM620-1A and

trunnion flange ring tool KM620-2 from the

trunnion flange.

Figure 4B-84

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 4B2-85

13. Assem ble driveshaft ( 1) outer c onstant veloc ity

joint to trunnion flange, aligning bolt holes.

14. Reinstall six attaching bolts (2) with plates and

tighten bo lts to the c orrect torque specific ation,

using suitable socket equipment (3).

DRIVESHAFT CONSTANT

VEL O CI T Y JO I NT TO TRUNNIO N

FLANGE ATTACHING BOLT

TORQUE SPECIFICATION 50 Nm, then

90° turn angle

Figure 4B-86

15. Reinst all t he f our br ak e back ing plat e t o trail ing

arm bolts (‘1’ a nd ‘2’) and tighte n to the c orrect

torque specification.

REAR DISC BRAKE SHIELD TO

TRAILING ARM UPPER BOLT (‘1’)

TORQUE SPECIFICATION 70 - 80 Nm

REAR DISC BRAKE SHIELD TO

TRAILING ARM LOWER BOLT (‘2’)

TORQUE SPECIFICATION 85 - 90 Nm

NOTE 1: The upper Torx headed bolts have

washers with cut-outs that are to be installed with

the cut-o ut ed ge f ac ing ar o und t he trailing arm hub,

outer surface.

NOTE 2: Apply Loctite 242 thread sealant or

equivalent (to GM Specification 998 5283) to the

threads of the two longer, lower hexagon headed

bolts, befor e instal lat io n.

Figure 4B-87

16. Reinst all br ak e disc ( 1) to trunnion, align ing 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

2.4 TRAILING ARM TRUNNION ASSEMBLY, in

this Section for important information regarding

these checks.

17. Reinstall the brake caliper (3) to the trailing

arm, reinstall brake caliper anchor plate to

trailing ar m attac hing bolts (2 and tig hten to the

correct torque specification.

BRAKE CALIPER ANCHOR

PLATE TO TRAILING ARM

ATTACHING BOLT

TORQUE SPECIFICATION 70 – 100 Nm

18. After reconnecting the brake line to the caliper

hose and installing the brake hose retaining

clip, bl eed the rear brak es and ch eck f or leaks.

For the recommended procedure, refer to

Section 5A SERVICE AND PARK BRAKING

SYSTEMS, in the MY 2003 VY and V2 Series

Service Information.

Figure 4B-88

19. Support the trailing arm with a floor jack and wooden block, sufficient to enable the shock absorber to be

reinstalled.

20. Reinstall shock absorber (3) to trailing arm (2), install the lower mounting bolt (1) but do not torque to

specification at this stage.

NOTE 1: View ‘A’ in Figure 4B-89 shows the sedan, lower shock absorber mounting, while view ‘B’ shows the

station wagon ar r ang ement.

Figure 4B-89

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

22. Remove safety stands and lower vehicle to the ground and bounce the rear of the vehicle several times to

settle the suspension components.

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

SHOCK ABSORBER LOWER

MOUNTING BOL T

TORQUE SPECIFICATION 105 - 125 Nm

NOTE: Vehicle must be at curb weight and on all four wheels before this torque is applied.

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

Service Notes in 2.1 GENERAL in this Section for more details.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

25. Refit wheel cover/wheel nut decorative caps.

3.2 FINAL DRIVE ASSEMBLY

LT Reference No: F650100 / F504150

NOTE: The following fasteners MUST be replaced when

performing this operation:

 Final drive assembly to crossmember attach ing bolts.

 Drive shaft constant velocity joint to trunnion flange

and inner axle shaft attaching bolt.

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 5B ABS & ABS/TCS, in the MY2003 VY and V2 Series

Service Information.

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 han dling abnormalities will result.

NOTE: For this service ope ration, ne w intermediate muffler support retainers must be used on reassem bly.

REMOVE

1. Using a floor jack under centre of differential carrier, jack up rear of vehicle and place safety stands under body

rear jacking points. Refer to Section 0A GENERAL INFORMATION in MY2003 VY Series Service Information

for location of jacking points.

2. Remove wheel covers (steel wheels) or whe el nut 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 converter/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 1: Only one side of the V6 Supercharged/GEN III V8 engine arrangement is shown.

NOTE 2: Both Views ‘A’ and ‘B’ (Figure 4B-91) show a catalytic converter fitted to the exhaust system, which may

not be applicable for all vehicle spe cifications.

Figure 4B-90

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/V6

Supercharged engine arrangements are

similar.

Figure 4B-91

6. Remove muffler support to rear crossmember

hanger retainers (1).

NOTE: There are two retainers for V6 engined

vehicles and four retainers for GEN III V8 and V6

Supercharged engine 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 4B-92

9. Remove propeller shaft, refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS in the MY2003 VY and

V2 Series Service Information.

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 4B-93

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 cabl e reta iner to re lease eac h

cable.

13. Pull the outer cable rearward (2) to remove

from the underbody retainer.

Figure 4B-94

14. Disconnect brake pipe (3) from brake hose (4)

at trailing arm bracket (2) and remove the

brake hose retaining clip (1).

Plug t he op en ends of both pipes and hoses to

prevent unnecessary fluid loss and/or dirt

entry.

15. Repeat for the other side.

Figure 4B-95

16. Pull out differential carrier breather hose (1)

from vehicle underbody crossmember hole (2).

Figure 4B-96

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 har ness c onnecto rs by levering with a

screwdriver.

Figure 4B-97

18. Using a scriber, m ark rear mount (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 4B-98

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 4B-99

21. Position floor jack with a block of wood under

trailing arm. Raise jack slightly to take spring

load off trailing arm.

22. Disconnect rear shock absorber lower

mounting bo lt (1) from trailing arm (2) , and pull

lower end of shock absorber (3) from trailing

arm.

NOTE 1: View ‘A’ in Figure 4B-98 shows the

sedan, lower shock absorber mounting, while view

‘B’ shows the station wagon arrangement.

Figure 4B-100

NOTE 2: 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 leas t 60 m m . Bruisin g of t he boo t wil l le ad to pr em ature f ailure of t he boot and event ual f ailur e of the

joint, if left unchecked.

23. Remove rear springs and insulators from

vehicle underbody and trailing arms.

24. Raise dif f erential c arrier and rear cros sm ember

on floor jack until rear mount contacts

underbody.

Figure 4B-101

25. If replacing differential carrier assembly, rear

cover or rear mount, loosen and remove rear

mount to r ear cover attachi ng bol ts (1) , rem ove

rear mount (2) and discard attaching bolts (1).

Figure 4B-102

26. Use a floor jack and block of wood to support

differential carrier and crossmember assembly.

27. Remove brace to underbody bolts (1) (3

places) and crossmember to vehicle

underbody attaching bolt (2) from each side.

28. Remove the braces (3) from the vehicle.

29. 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 isolating rubbers

(4) locate d on top of each f ront c r ossmem ber bus h,

remove and set to one side.

Figure 4B-103

30. Using an 8 mm Allen key s ocket, rem ove 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 shou ld be kept to within t he angular

movement of an installed drive shaft.

Figure 4B-104

31. Remove differential carrier (3) to rear

crossmember (2) attaching bolts (1), remove

rear crossmember assembly from differential

carrier and discard attaching bolts(1).

32. If not carrie d out in s tep 25, r emove rear mount

to rear cover attaching bolts, remove mount

and discard attac h ing bo lts .

Figure 4B-105

REINSTALL

Installation is the reverse of removal procedure

except for the following items:

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

cover using NEW bolts but leave bolts finger

tight at this stage.

2. Line up mounting holes in 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

CROSSMEMBER ATTACHING BOLT

TORQUE SPECIFICATION 90 Nm, then

30° - 45°

turn angle

Figure 4B-106

3. Inspect drive shaft constant velocity joint boots

for damage, replace as necessary.

4. Tighten drive shaft inner constant velocity joint

to inner axle shaft attaching bolts to the correct

torque specification.

 DRIVE SHAFT CONSTANT VELOCITY

JOINT TO TRUNNION FLANGE

ATTACHING BOLT

TORQUE SPECIFICATION 50 Nm, then

90° turn angle

Figure 4B-107

5. With the aid of two assistants, place the

differential carrier and rear crossmember

assembly onto a floor jack.

6. Position assembly 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 care

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 an isolating rubber

(4) on each side, it must be fitted at the top of

each crossmember front bush as shown,

before raising the assembly into place.

8. Install crossm ember front m ounting 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 4B-108

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.

IMPORTANT: At t he s ame tim e, ens ure that m ount

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

TORQUE SPECIFICATION 85 – 105 Nm

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 4B-109

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 operatio n, the diff erential c arrier

and rear crossmember assembly rear mount must

be lowered at least 60 mm from the vehicle

underbody. Otherwise damage to the drive shaft

constant velocity joint boots will occur.

Figure 4B-110

11. Reinstall shock absorber to trailing arm, fit

washer to the lower mounting bolt, install bolt

but do not fully tighten at this time, as the

vehicle must be at curb weight before final

tightening is undertaken.

NOTE: View ‘A’ in Figure 4B-109 shows the sedan,

lower shock absorber mounting, while view ‘B’

shows the station wagon arrangement.

Figure 4B-111

12. Raise assembly until rear mount contacts

vehicle underbody.

13. Align r ear mount (1) with m arks on underbod y,

made on disassem bly, then loosely install new

attaching bolts (2) but do not fully tighten at

this stage.

14. The rear crossmember MUST now be

aligned to the vehicle centreline, using the

special tool and procedure as detailed in

Section 1A2 BODY DIMENSIONS in the

MY2003 VY and V2 Series Service

Information.

CAUTION: Failure to correctly align the rear

crossmember to the centreline of the vehicle

will result in steering abn ormalities and unev en

tyre wear!

Figure 4B-112

15. Tighten all cr os smem ber mount ing f as ten er s to

the correct torque specification.

REAR MOUNT TO VEHICLE

UNDERBODY ATTACHING BOLT

TORQUE SPECIFICATION 30 – 40 Nm, plus

55° – 65° turn angle

REAR CROSSMEMBER FRONT

MOUNTING BOLT

TORQUE SPECIFICATION 125 Nm, plus

30° – 40° turn angle

REAR CROSSMEMBER FRONT

MOUNTING BRACE BOLT

TORQUE SPECIFICATION 60 – 85 Nm

16. Install differential carrier breather hose into

vehicle underbody crossmember hole. Ensure

that end of hose is pushed into hole

approximately 25 mm.

Figure 4B-113

17. If equipped with ABS, reconnect wheel sensor

wiring harness connectors. Reinstall into the

retaining clips (1).

18. 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.

19. Check and f ill diff erentia l c arrier to cor rect le vel

with specified lubricant, refer to

2.2 CHECKING DIFFERENTIAL CARRIER

LUBRICANT LEVEL in this Section.

20. Check park brake adjustment and bleed

brake hydraulic system, refer to

Section 5A SERVICE AND PARK BRAKING

SYSTEMS in the MY 2003 VY and V2 Series

Service Information.

21. Reinstall propeller shaft. Refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS in the MY2003 VY and

V2 Series Service Information.

22. 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.

23. While supporting the exhaust system, install

the exhaust hanger rubbers to the rear of the

intermediate muffler/s and secure with new

retainers.

Figure 4B-114

24. Install rear muffler support rings to the rear of

the rear muffler and secure with new retainers.

25. Tighten intermediate exhaust pipe to catalytic

converter bolts to the correct torque

specification.

INTERMEDIATE EXHAUST PIPE TO

CATALYTIC CONVERTER B OL T

TORQUE SPECIFICATION 40 – 50 Nm

(All Engines)

26. Check exhaust clearances, Refer to Section 8B EXHA UST SYSTEM in the MY2003 VY and V2 Series Service

Information.

27. Reinstall road wheel/s, aligning the marks made prior to removal and secure with attaching nuts.

28. Remove safety stands and lower vehicle.

29. 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-5, in this Section.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 – 125 Nm

30. Refit wheel cover/wheel nut decorative caps.

31. Tighten lower shock absorber lower mounting bolts to the correct toque specification.

SHOCK ABSORBER LOWER

MOUNTING BOLT

TORQUE SPECIFICATION 105 - 125 Nm

32. Start vehicle and check for exhaust leaks. Repair as necessary.

3.3 REMOVED FINAL DRIVE ASSEMBLY

NOTE: The following fasteners MUST be replaced

when performing this operation:

n Final drive ring gear bolts.

Figure 4B-115

Legend

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

6. SHIM – 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 ASSE MBLY – 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

44. BOLT – Case cap to cover

41. CARRIER

42. TAG – Lubrication

‘A’ V6 Engine – Non-Limited Slip Differential

‘B’ V6 Engine – Limited Slip Differential

‘C’ V6 Supercharged and GEN III V8 Engine – Limited

Slip Differential

DISASSEMBLE

1. Remove differential carrier assembly. Refer to

3.2 FINAL DRIVE ASSEMBLY in this Section.

2. Secure holding tool (1) that is either fabricated

or Tool No. KM480, to the differential carrier

using tw o of the d iscarded differ ential 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-116

4. Remove rear cover to differential carrier

attaching bolts and screw adjuster lock plates.

Using a soft faced hammer, tap rear cover at

rear mount area to break rear cover to

differential carrier seal. Remove rear cover,

rotate the assembly and drain residual

differential lubricant into a suitable container.

Figure 4B-117

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. Chec k the tor que of th e rin g gear bolts and t he

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, the n r otate the diff erentia l

case through several turns to measure ring

gear run-out.

RING GEAR FACE

RUN-OUT SPECIFICATION 0.13 mm maximum

d. Leave the dial indicator set up and push the

ring gear har d one wa y, then hard the oppos ite

way to measure 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-118

e. Set up the dial indicator to measure ring gear

backlash at three equally spaced positions.

BACKLASH SPECIFICATION 0.10 - 0.18 mm, at

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 Sectio n.

Figure 4B-119

6. Remove inner axle shafts (1) by installing a

slide hammer, Tool No. 7374 and three

suitable size bo lts to each axle flange . Use the

slide hammer to release axle shaft spring clips.

NOTE: The left hand inner axle shaft is shorter in

length than the right hand shaft.

Figure 4B-120

7. If new screw adjuster seals are to be installed,

use a suita ble scre wdriver and a b lock 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 th is c ou ld ca us e oil l eaks to occ ur , af ter a

new oil seal is fitted.

Figure 4B-121

8. Remove screw adjusters from housing using

Tool No. 205-463 (also released as AU407).

9. Remove dif ferential c ase a ss embl y from car rier

housing.

Figure 4B-122

10. To remove side bearing cups from screw

adjusters, install screw adjusters, reversed,

into dif ferential c arrier. Inst all ada ptor, Tool No.

AU412 onto screw adjuster. Using puller, Tool

No. 1150, a nd forc ing screw T ool No. E6 661S,

pull side bearing cups from screw adjusters

and discard.

NOTE: Side bear i ng cups a r e only to be removed if

side bearing assemblies are to be replaced.

Figure 4B-123

11. Install Tool No. KM620-1A to the pinion flange

using three suitable bolts.

NOTE 1: Use either the rear coupling to pinion

flange r eta in ing bo lts with a 25 m m spac er (e.g. f lat

washers) insta lled firs t or u se three b olts M 12 x 1.5

x 40,with the thread extending to within 12 mm of

the head.

NOTE 2: If not previously done so, drill out holes

stamped ‘B’ on Tool No. KM620-1A, to 12.5 mm.

12. W hile holding KM620- 1A with a suitable length

of pipe (1) over the tang, loosen and remove

pinion flange retaining nut, using a

commercially available deep socket and

bar (2).

Remove flange holding tool KM620-1A from

pinion flange.

Figure 4B-124

13. Install extractor, Tool No. nut KM628-A to the

pinion flange, using the same three bolts used

in step 11.

NOTE: If not previously done so, dr ill out the three

flange holes on Tool No. KM628-A, to 12.5 mm.

14. W hile holding KM6 28-A with a set spann er (1),

use suitable socket equipment (2) to withdraw

the pinion flange by tightening the forcing

screw in the direction indicated.

Figure 4B-125

15. Pry pinion oi l s eal out of c arr ier bor e us ing Tool

No. E308 or a suitable seal extraction tool.

Figure 4B-126

16. Remove pinion (1) by tapping on front end with a

soft faced hammer (2) to withdraw it through rear of

carrier. Remove pinion front bearing from carrier

bore. Remove and discard pinion bearing spacer.

Figure 4B-127

17. If pinion bearings are to be replaced, remove

bearing cups using Tool No. E9293.

NOTE 1: View ‘A’ shows the tool arrangement to

remove the front (outer) pinion bearing cup, while view

‘B’ shows the arrangement to remove the rear (inner)

bearing cup.

NOTE 2: When removing the rear (inner) pinion bearing

cup from 3.07 and 3.46 assemblies, the adaptor 'B' to

be used with E9293, is DT-47695.

NOTE 3: As the installation tool (E9271) relies on an

installed bearing cup for alignment, it is essential that

only one bearing cup is replaced at the one time. Use of

installer E9271 is shown in Fig. 4B-129.

Figure 4B-128

18. To install a new, rear (inner) pinion bearing cup,

use installer Tool No. E9271 with adaptor E9271/B,

as shown. The same arrangement is used to install

a new front (outer) pinion bearing cup, using

adaptor E9271/A (or 205-552-1).

NOTE: When installing the rear (inner) pinion bearing

cup to 3.07 and 3.46 assemblies, the adaptor to be

used with E9271, is 205-552-2.

Figure 4B-129

19. To remove rear (inner) bearing from pinion, remove

legs from the ring of Tool No. E1673MT.

20. Place ring on suitable press plates. Install pinion

and adaptors E1673A15 (3.08:1 assembly) or

E1673S15 (3.07/3.46:1 assembly) into the ring.

Press pinion from bearing .

NOTE: With the larger pinion head size on the

3.07/3.46:1 assemblies, the ring must be placed over

the bearing first, then the adaptors manoeuvred into

place under the bearing cone.

21. Discard the removed bearing.

Figure 4B-130

Differential Case

The following procedures describe the standard type differential

case assembly. For Limited Slip Differential case assembly, refer

to 3.4 LIMITED SLIP DIFFERENTIAL in this Section.

NOTE: The 3.07:1 and 3.46:1 ratio differentials are unique and

parts are not interchangeable with the 3.08:1 ratio unit. The

general overhaul procedures however, remain the same for both

types. The unique components for the 3.07:1 and 3.46:1 ratio

differentials are; differential case, differential pinions, side gears

and thrust block.

1. Before disassembling the differential case, inspect differential

side bearings for any signs of damage.

IMPORTANT: The side bearings can be manufactured by either

one of two manufacturers; Timken or Koyo. When replacing the

differential side bearings, the two bearings and cups must be of

the same brand. The pinion bearings may be of a different

manufacture but again, they must be a matched pair. The reason

for matched pairs of bearings is that a different preload

specification is required for each brand.

2. If necessary, use 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 FINAL DRIVE

ASSEMBLY – Disassemble, step 10.

Figure 4B-131

3. Grip the differential case in a vice with soft

jaws.

4. Remove ring gear (1) attaching bolts (2).

NOTE: Ring gear attaching bolts (2) use a left

hand thread and are identified by an 'L' on the bolt

head.

5. Remove differential case from vice.

Figure 4B-132

6. Using a soft faced hammer (1), remove ring

gear (2) from differential case (3) by hitting

down on ring gear. Support ring gear during

this operation so that it does not strike bench

top as it comes free of case.

NOTE: Do not use a screwdriver to prise between

ring gear and case.

Figure 4B-133

7. Drive out differ ential pinion gear lon g shaft and

short shafts retaining pins (1) from differential

case, using a suitable size pin punch and

hammer.

Figure 4B-134

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

jaws. Usin g a brass drif t (1) and ham mer, dr ive

out pinion long shaft (2) from differential case.

Figure 4B-135

9. Remove differential case (3) from vice. Using a

brass drift (1) and hammer (2), separate two

differential case halves by driving against

thrust block.

NOTE: Do not use a screwdriver to prise the

differential case halves apart.

Figure 4B-136

10. Using a brass drift (1) and hammer, drive out

pinion gear short shafts (2) from differential

case.

Figure 4B-137

11. Lift out pinion gears (1), thrust washers and

thrust block (2) from differential case.

Remove differential side gears and thrust

washers from differential case halves.

NOTE 1: When removing the thrust block from

either th e 3.07:1 or 3.46: ra tio dif ferential, note that

the pinion shafts are angled at 96° and not 90° as

is usual.

NOTE 2: Keep the gears with their respective

thrust washers in pairs so they can be reinstalled in

their original position.

Figure 4B-138

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 diff erential cas e side bear ings have be en rem oved, chec k case j ournals f or dam age and th at bear ing sea ting

surfaces are free from dirt and burrs.

2. The ring gear spigot and mounting face should be clean and free from dirt and burrs.

3. The mating surfaces for differential case halves should be clean and free from burrs.

4. The thrust surfaces for differential side gears and pinions should be examined for excessive wear.

5. The differential side gear journal bores should be clean and free from scoring.

6. The case bores for differential pinion gear shafts should be checked for ovality.

Differential Side Gears and Pinion Ge ars

1. Examine all gear teeth for cracks and hard contact marks.

2. The differential side gear splines should be checked for excessive wear. Wear on splines can contribute to

excessive driveline backlash.

3. Check differential side gear journals and back faces for scoring.

4. Check fit of differential side gears in differential case cap and cover. Wear on side gear hubs or in the case

bores can cause a "clunking" noise 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 f ree 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. Inspec t gear teeth f or scoring or damage. Scor ing of gear t eeth is usu ally caused b y excessive s hock loadi ng,

use of inc orrect lubr icant or ins uffic ient "run in" befor e towing a heav y load. (Refer MY2003 VY Seri es 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 surface 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 by ‘A’. The pinion installation

marking figure is indicated by ‘B’.

7. On ring gear bolts, clean the serrations under

each bolt flange.

Figure 4B-139

Bearings

1. Bearing cups should have an even wear pattern and must be free from flaking or pitting. Ensure that seating

surfaces are clean and free from burrs or raised metal.

2. The bearing 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 for the pinion oil seal should be free from burrs.

4. Inspect rear cover face and bolt holes for damage.

5. Check rear cover seating surface for scoring or other damage.

Screw Adjusters and Inner Axle Shafts

1. Inspect inner axle shaft needle bear ings inside

screw adjusters for wear or damage.

2. If inner axle shaft needle bearings are to be

replaced, reinstall screw adjusters into

differential carrier and remove inner axle shaft

seals. Refer to Step 7 of FINAL DRIVE

ASSEMBLY – Disassemble.

Remove screw adjusters (2) from carrier and

position each onto a block of wood (3). Then,

using a 1.25 inch socket (1) and bar or a 73

mm diameter tube, press the bearing from

each of the screw adjusters (2).

3. Remove and discard O-rings from screw

adjusters.

4. Exam ine adjuster seal bore s for burr s, nicks or

other damage. Examine oil passages and

ensure they are free from obstructions and

loose part icles .

Adjuster thread and bearing bores should be

clean and free from burrs or other damage.

Figure 4B-140

5. To install new screw adjuster needle bearings,

place screw adjuster (2) over fixture, Tool No.

AU409 and press needle bearing (1) into

adjuster (2) using Tool No. AU411. Repeat

procedure for the remaining screw adjuster.

NOTE 1: Side bearing cups must be installed into

screw adjusters before installing needle bearings.

This is to ensure that needle bearings are located

correctly into screw adjuster bores.

NOTE 2: To install side bearing cups, refer to

step 1, Differential Case Side Bearing Pre-Load

Setting, in this Section.

Figure 4B-141

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 axle shafts to

ensure that they are not damaged and move

freely in grooves. Replace spring clips if

necessary, by expa nd ing ends of each c li p and

removing from inner axle shafts. Expand ends

of new cli ps suf fic iently to allo w ins tallat ion in to

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 differential gears, bearings, thrust

washers and d iffer ential pin ion gear shaf ts with

the recommended rear axle lubricant before

assembly.

2. Position differential side gears (1) with their

thrust washers (2) into differential case halves

(3).

Figure 4B-142

3. Using a soft faced hammer, reinstall pinion

gear short shafts (1) and long shaft (2) into

differential case, just enough to allow a pinion

gear thrust washer to sit on the end of each

shaft.

NOTE: Ensure that the retaining pin holes in the

differential case and pinion gear shafts are in

alignment and with the chamfered edge of the

holes in each shaft facing up.

Figure 4B-143

4. Install one of the pinion gear thrust washers

over inside end of one of the short shafts.

5. Position appropriate pinion gear (1) next to

thrust washer and tap in short shaft (2) until it

comes through centre of the gear (1).

6. Carr y out steps 4 and 5 for second pinion gear

short shaft.

Figure 4B-144

7. Reinstall thrust block (1) between two installed

pinion gears. Knock the two pinion gear short

shafts into position, ensuring that retaining pin

holes in the shafts line up with holes in

differential case.

Figure 4B-145

8. Install pinion gear thrust washer and gear to

long shaft (1). Tap long shaft (1) through gear

and thrust block.

Figure 4B-146

9. Reinstall remaining pinion gear and thrust

washer. Tap long shaft through pinion gear,

ensuring that thrust washer aligns with cross

shaft and the retaining pin hole in the shaft

aligns with hole in differential case.

Figure 4B-147

10. Install pinion gear long shaft and short shaft

retaining pins. Ensure that ends of retaining

pins (1) protrude 6 mm from differential case

cap to cover mating surface. This is necessary

to prov ide a posit ive locatio n for the d ifferential

case cover to case cap.

Figure 4B-148

11. Holding differential side gear (1) 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-149

12. Place ring gear (1) into position on differential

case cap (2) and install ring gear attaching

bolts.

NOTE 1: For ease of assembly, it may be

necessar y 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 (3) 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 diff erential case sp igot. Tighten a ll bolts to

the correct torque specification.

FINAL DRIVE RING GEAR

BOLT TORQUE SPECIFICATION 125 - 150 Nm

NOTE: Ring gear attaching bolts use a left hand

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

Figure 4B-150

14. If installin g n ew side b eari ngs (1), us e Tool N o.

E9277 to press on side bearings to differential

case journals.

NOTE: Check that both nearing assemblies are of

the same manufacture – Timken or Koyo.

Figure 4B-151

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

ma tching is m aintained a nd that t he pair of bear ing

assemblies are of the same manufacture – either

Timken or Koyo.

NOTE 2: The screw adjuster used on either the

3.07 or 3.46:1 ratio final drives is 1.9 mm deeper

than the one used for 3.08:1 ration unit. The

deeper screw adjuster can be identified by a

groove on the inner edge.

This depth change is necessary to accommodate

the greater s ide be arin g span us ed wit h the 3.0 7 or

3.46:1 ratio final drives assemblies.

2. Install new O-rings to screw adjusters and

apply a lubricant such as rubber grease to

each.

3. While s upportin g the dif fer ential c ase in carr ier,

fit screw adjusters to both sides of carrier.

Continue tightening adjusters until case

assem bl y is supported b y side bear ings .

Figure 4B-152

4. Rotate diff erential c ase se ver al tim es to ensure

that side bearings are correctly seated.

5. Wrap a piece of string around differential case

flange and check side bearing pre-load by

pulling on end of string with a spring balance

(1). Spring balance reading must be within

specification.

Tighten or loosen one of the screw adjusters

until the correct pre-load is obtained.

SIDE BEARING PRE LOAD SPECIFICATION

New Bearings

Timken Koyo

15 – 35 N 8 – 24 N

Used Bearings

Timken Koyo

8 – 18 N 5 – 13 N

Figure 4B-153

6. Using Tool No. 205-463 (or 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-154

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), dummy pinion spacer, Tool No. DT-47696 and dummy

arbour Tool No. AU408.

The gauge and arbour provide a nominal or 'zero' pinion

as a gauging reference.

NOTE 1: If a new gear set is to be installed, ensure that

the same matching number (‘A’) appears on both the

pinion and the ring gear, in either white or yellow marker.

NOTE 2: The pinion installation marking figure is

indicated by ‘B’, in either white or yellow marker.

NOTE 3: The final drive pinion fitted to the 3.07:1 and

3.46:1 ratio assemblies, has a different mounting

distance to the 3.08:1 pinion (102.50 mm and 94.49 mm

respectively). Also, as the 3.07:1 and 3.46:1 ratio, final

drive assemblies have a different rear pinion bearing,

gear set sizes, differential case assemblies and screw

adjusters, none of these parts are to be mixed.

Figure 4B-155

8. Inspect pinion bearing cups/cones for nicks and burrs.

Replace if damaged.

9. Lubricate pinion front and rear bearings with the

recommended differential carrier lubricant. Do not use

engine or other oils, as a misleading rotating torque can

be obtained.

NOTE: Ensure that both pinion bearings used on the dummy

pinion to determine the pinion positioning shim thickness, are

those that will be used on the final reassembly.

MY2003 VY Series Vehicles with the 3.08:1 Ratio Axle

Assembly:

10. Install the rear bearing onto dummy pinion, Tool No.

E9300A.

MY2003 VY Series Vehicles with the 3.07:1/3.46:1 Ratio

Axle Assembly:

11. Install the spacer, Tool No. DT-47696, to the dummy

pinion, supplied as part of E9300A, then install the rear

(inner) pinion bear ing onto the dummy pinion.

FINAL DRIVE AND DRIVE SHAFTS 4B - 65

12. Install dummy pinion and rear (inner) bearing into

carrier housing. Fit front (outer) bearing to dummy

pinion, then install the dummy pinion thrust collar and

nut.

13. Tighten nut on end of dummy pinion, using a

commercially available, dial type torque wrench (1),

until the specified rotational torque is obtained.

DUMM Y PINION ROT ATIONAL TORQUE SPECI FI CATION

New Bearings, No Pinion Oil Seal Installed

Timken Koyo

1. 4 – 2.0 Nm 1.5 – 1.9 Nm

Used Bearings, No Pinion Oil Seal Install ed

Timken Koyo

0. 7 – 1.2 Nm 0.7 – 1.2 Nm

14. Rotate dummy pinion back and forth during

tightening to ensure that bearings settle in their

cups.

NOTE 1: W hen the specified preload is reached, remove

the block from the rear of the dummy pinion (to allow

continuous rotation of the pinion during the preload

tightening process). Rotate the pinion approximately 50

turns in each direction, then re-check the bearing

preload, readjusting as required, to achieve the specified

figure.

NOTE 2: Pinion bearing pre-load is very important

because it retains pinion in its correct relationship to ring

gear.

NOTE 3: 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 responsible for scuffing of ring gear

and pinion teeth.

Figure 4B-156

NOTE 4: Bearings that have too much pre-load, may

become pitted or flaked and result in premature failure. It

is therefore essential to ensure that bearings are pre-

loaded to specified torque specification.

15. Position arbour Tool No. AU408 in carrier assembly

and install screw adjusters with side bearing cups.

Adjust screw adjusters to lightly clamp arbour, using

Tool No. 205-463 (or AU407).

NOTE: Ensure that arbour is free of burrs that may

damage bearing cups.

Figure 4B-157

16. Check clearance between arbour (Tool No. AU408)

and head of dummy pinion with a feeler gauge (1).

Record this dimension.

Figure 4B-158

17. On the end of the pinion, a drive pinion installation

marking figure (1) is applied with either a white or

yellow marker. A zero marking ('0') indicates that

shim size equal to the dimension measured in Step

16 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 16, refer to the following chart.

A negative marking, e.g. –3, means that a thickness

measurement equivalent to this numerical marking

must be added to the shim size measured in Step

16. Refer to the following chart for specific details.

PINION SHIM THICKNESS

MARKING

REQUIRED

–4 Add 0.10 mm to measurement of step 16.

–3 Add 0.075 mm to measurement of step 16.

–2 Add 0.050 mm to measurement of step 16.

–1 Add 0.025 mm to measurement of step 16.

0 Size as measured in step 16.

+1 Subtract 0.025 mm from measurement of step 16.

+2 Subtract 0.050 mm from measurement of step 16.

+3 Subtract 0.075 mm from measurement of step 16.

+4 Subtract 0.10 mm from measurement of step 16.

NOTE: Pinion positioning shims are serviced in

thicknesses of 0.2 – to 0.75 mm in 0.025 mm

increments. They are also dimensioned differently,

depending on the pinion bearing used.

Figure 4B-159

18. Remove dummy pinion and arbour from carrier assembly.

FINAL DRIVE AND DRIVE SHAFTS 4B - 67

Pinion Installation

1. Select pinion positioning shim stack as determined

in the Hypoid Pinion Positioning Shim Selection

procedure, in this Section.

2. Remove pinion rear (inner) bearing cup, using Tool

No. E9293, using adaptor Tool No. E9293-2.

NOTE: When removing the inner pinion bearing cup from

3.07 and 3.46 assemblies, the adaptor to be used with

E9293, is

DT-47695

Figure 4B-160

3. Install pinion positioning shim/s (1) into pinion rear

bearing cup bore (2).

Figure 4B-161

4. Reinstall pinion rear bearing cup using Tool No.

E9271. Ensure that cup is seated squarely in bore.

NOTE: When installing the inner pinion bearing cup to

3.07 and 3.46 assemblies, the adaptor to be used with

E9271, is 205-552-2 .

Figure 4B-162

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 pres s plates are p erfectly flat, fr ee of burrs

and foreign matter prior to installing the rear

bearing.

NOTE 2: Locate b eari ng in ner rac e s quare ly on the

pinion and press only on inner race surface.

NOTE 3: Only lubricate the bearing with the

recommended differential carrier lubricant.

Figure 4B-163

6. Place the pinion in the carrier.

7. Lubricate pinion front bearing with the

recommended differential carrier lubricant and

assem ble the coll apsible pinion bear ing spac er

and front bearing onto pinion, while supporting

pinion head.

8. Install pinion flange and the original pinion

flange retaining nut.

9. Install Tool No. KM620-1A and, using a

suitable l ength of pipe ( 1) to hold pi nion flange ,

tighten re taining n ut until p inion f ront bearing is

squarely engaged on the pinion shaft and not

cocked.

NOTE 1: If not previously done so, drill out holes

stamped ‘B’ on Tool No. KM620-1A to 12.5 mm.

NOTE 2: Use either the rear coupling to pinion

flange r eta in ing bo lts with a 25 m m spac er (e.g. f lat

washers) insta lled firs t or u se three b olts M 12 x 1.5

x 40, with the thread extending to within 12 mm of

the head.

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

of the installed tool for leverage, then remove

the pinion flange retaining nut, using a

comm erc ially ava ilabl e dee p soc ket and soc k et

bar (2).

Figure 4B-164

11. Install extractor, Tool No. KM628-A to the

pinion flange using the same three bolts used

to secure the flange holding tool, KM620-1A

(refer step 9).

NOTE: If not previo us l y done s o, dr i ll out t he f lan ge

holes on Tool No. KM628-A to 12.5 mm.

IMPORTANT: If using the original bolts, they must

have the 25 mm spacers fitted so the tool is

clam ped to the pinion f lang e. If this is not don e, the

screw thread on the extractor Tool No. KM628-A

will not be long enough to fully remove the pinion

flange.

12. While holding the extractor tool with a suitable

spanner, withdraw pinion flange by tightening

the forcing screw in the direction indicated.

Figure 4B-165

13. Lubricate pinion oil seal lips and the pinion oil

seal bore in the carrier hou sing with diffe rential

carrier lubricant.

14. Install oil seal into carrier bore using Tool No.

E9055 and a pl astic f aced hamm er (1) until the

seal fits flush to 0.25 mm below car rier ho usin g

surface.

Figure 4B-166

15. Reinstall pinion flange and fit a NEW retaining

nut. Hold pinion flange using Tool No. KM620-

1A and a suitable length of pipe (1). Gradually

tighten the retaining n ut while rota ting pinio n in

both directions to seat bearings.

16. Check bearing pre- load f requentl y by rem oving

flange hold ing tool (KM62 0-1A) and inst alling a

pulley and string to the pinion flange. Refer to

7. SPECIAL TOOLS at the end of this Section

for pulley details.

17. Using a spring scale, measure rotational

torque.

18. Continue to tighten the nut until specified

torque is achieved.

PINION ROTATIONAL TORQUE SPECIFICATION

New Bearings, With Pinion Oil Seal Installed

Timken Koyo

1. 4 – 2.4 Nm 1.5 – 2.1 Nm

Used Bearings, With Pinion Oil Seal Installed

Timken Koyo

0. 7 – 1.2 Nm 0.7 – 1.2 Nm

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 m m 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.

CAUTION: Should the retaining nut be over-

tightened and pre-load exceeded, it will be

necessar y to r emov e th e pi nio n f rom t he c arr ier

and install a new collapsible spacer. Under no

circumstances must the retaining nut be

backed off to decrease the pre-load reading.

Figure 4B-167

Differential Backlash Setting

1. Check threads of screw adjusters and ensure

that they are free of damage.

2. Holding differential case in carrier, with ring

gear in mesh with pinion, fit screw adjusters

and side bearing cup assemblies to both sides

of carrier. Using Tool No. 205-463 (or AU407),

continue tightening adjusters until case

assem bl y is supported b y side bear ings .

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-lo ad Set ti ng ’ in this Section.

Figure 4B-168

5. Mount a dial indicator on carrier and check

gear backlash between the ring gear and

pinion. Backlash 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 SPECIFICATION 0.10 - 0.18 mm at

the 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 the s ame amount, then t ig hte n bot h as

detailed in step 4.

7. With back lash corr ectly set, check gear c ontact

pattern as detailed in the following instructions.

Figure 4B-169

Ring Gear and Pinion Contact Patter n

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: W hen 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 th e t ooth i s c alle d t he 'H E EL' and th e small end the 'TOE', also t he top of the toot h whic h is abo ve

the pitch li ne is called the ' FACE' while the are a below the pitch line is called th e 'FLANK'. The clear ance between

the pinion and ring gear teeth is referred to as 'BACKLASH'.

Figure 4B-1 68 illus tr at es corr ect and incor rec t cont ac t 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 size of the

shim on the pinion side 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 much back lash. To correct, move 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 adj ustment, incr eas ing a nd d ec reas in g s him thick nes s b y 0.04 mm at a tim e. Chec k contact wit h gear

marking compound and continue adjustment until tooth contact appears as in 'A'. Backlash must remain within

specif ied limits .

To correct a pattern such as 'D', it will be necessar y to install a thicker pinion positioning shim as described unde r

HYPOID PINION PO SITIO NING SHIM SELECT ION in th is Sect ion. A 0.0 25 mm thick er shim is recomm ended as

a starting point. Continued changes may be necessary to obtain the correct setting. If the pattern shows a flank

contact 'E', it ind icates t hat the p in ion is in too f ar . T o c or rec t, repl ac e the pi ni on s him with a 0. 02 5 m m thinn e r s him

and recheck contact pattern.

In mak ing pinion pos itio n adj ustm ents, be sur e back lash is corre ct bef ore testing c ontact patt ern. Movi ng the pinion

'IN' reduces backlash and moving pinion 'OUT' increases backlash.

Figure 4B-170

Legend

1. Convex Side (Drive)

2. Concave Side (Coast)

3. Heel

4. Toe

A. Low Flank Contact – Decrease Pinion Shim Thickness

B. Heel Contact – Decrease Backlash

C. High Face Contact – Increase Pinion Shim Thickness

D. Toe Contact – Increase Backlash

E. Ideal Contact

Ideal Contact

Figure 4B-171

Legend

A. Drive Side

B. Coast Side 1. Face Width

2. Toe

3. Heel

Drive Side

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

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

There should be c learance of about 1 m m between the contact marking and the toe and along the top f ace angle

line.

Coast Side

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

Total length approximately 5/8th 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-172

Legend

A. Drive Side

B. Coast Side 1. Face Width

2. Toe

3. Heel

Drive Side

A central face contact marking, lengthwise in position, is shown in Figure 4B-172. 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 5/8th 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-172, is preferred for coast side contacts which tend to be toward the

heel.

A centra l profile m ar k ing pos itio n is ac c epta ble , pro vi di ng the pinion fac e ang le ed ge l ines d o not app ear lo w on th e

gear.

Acceptable Toe Contacts

Figure 4B-173

Legend

A. Drive Side

B. Coast Side 1. Face Width

2. Toe

3. Heel

Drive Side

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

A slightly low contact marking is shown in Figure 4B-173. 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-173. 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 DIFFERENTIAL

NOTE: The following fasteners MUST be replaced

when performing this operation:

n Final drive ring gear bolts.

n LSD case cap to cover attaching bolts.

The overha ul proc edures , r ing gear an d pini on positi onin g and t ooth m ark ings for the lim ited sl ip dif fer ential are the

same as for the standard type of rear axle assembly, except for the servicing of the internal components of the

limited slip differential assembly.

NOTE: The 3.07:1 and the 3.46:1 r atio diff erentials ha ve unique parts and are no t interchangea ble with the 3.08:1

ratio un it. The genera l overhaul pr ocedures ho wever, rem ain the same f or both types. T he unique c omponents f or

the 3.07:1 and the 3.46:1 ratio differentials are; differential case, differential pinions, side gears and thrust block.

DISASSEMBLE

1. Before disassembling differential case, inspect 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.

IMPORTANT: T he side bearings c an be manuf actured by either one of two m anufacturers; T imken or Ko yo. W hen

replac ing the diff erentia l sid e bear ings , the t wo bear ing s and cu ps m us t be of the sam e brand. The pi nion b ear ings

may be of a different manufacture but again, they must be a matched pair. The reason for matched pairs of

bearings is that a different preload specification is required for each brand.

2. If replacing side bearings, use Tool No.

E1673MT, adaptors E1673N15 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 Sect ion.

Figure 4B-174

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

4. Remove ring gear attaching bolts (1).

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-175

6. Using a soft faced hammer (2), remove ring

gear (1) from differential case (3) by hitting

down on ring gear. Support ring gear during

this operation so that it does not strike bench

top as it comes free of case.

NOTE: Do not use a screwdriver to prise

between ring gear and case.

7. Place differential case in a vice equipped with

soft jaws.

Figure 4B-176

8. Loosen and remove differential case cap to

cover attaching bolts (1) evenly. Lift off

differential case cover. If necessary, remove

clutch cup f rom cover (s ometimes the c one will

remain inside the cover).

Figure 4B-177

9. Remove clutch cone (1), shim (if fitted), side

gear (2) and thrust spring plate (3) from pinion

cross shaft.

NOTE: The 3.07:1 and the 3.46:1 ratio clutch

cones and s ide gears ar e an int egral un it and m ust

stay assembled to each other.

Figure 4B-178

NOTE: T o ensure that the c lutch cones ( 1) (are not

interchanged during reassembly, mark the cone

and corresponding side of the differential case (2)

with a felt tipped pen or similar. If shims are

present, t hey must als o be mark ed so that the y ca n

be reassembled into the correct case half.

Figure 4B-179

10. Remove three concentric differential pre-load

springs (1) from centre of pinion cross shaft.

Figure 4B-180

11. Lift pinion cross shaft (1), pinion gears and

thrust washers from case. Remove pinion

gears and thrust washers from cross shaft.

NOTE: Keep the pinion gears with their

respective thrust washers in sets so they can

be reinstalled in their original position.

12. Remove remaining thrust spring plate, side

gear, shim (if fitted) and clutch cone from

differential case cap.

Figure 4B-181

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 removed, check case journals for damage and that seating

surfaces are free from dirt and burrs.

2. The ring gear spigot and mounting face should be clean and free from dirt and burrs.

3. The mating surfaces for differential case halves should be clean and free from burrs.

4. The thrust surfaces for the 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 dam age on the clutch cone surface will requir e renewal of bot h clutch cones (3.08:1 ra tio only) or the

clutch cone/side gear assemblies (3.07:1 and the 3.46:1 ratio differentials) 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 Ge ars

1. Examine all gear teeth for cracks or hard contact marks.

2. The differential side gear splines should be checked for excessive wear. Wear on splines can contribute to

excessive driveline backlash.

3. The differential pinion bores and thrust surfaces should be smooth and free from scores. Inspect all thrust

washers for cracks, nicks or burrs. Wear of thrust washers or thrust surfaces on gears can contribute to

excessive driveline backlash.

4. Check that pinion gear cross shaft is not bent and that surfaces on which pinions run, are not scored or worn.

Ring Gear and Pinion

1. Inspect gear teeth for scoring or damage. Scoring of the gear teeth is usually caused by excessive shock

loading, use of the incorrect lubricant or insufficient "run in" before towing a heavy load. (Refer MY2003 VY

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 (A) appears on both the pinion and

ring gear.

T he ide ntific ation number ( B) on th e pin ion e nd

is used when setting the pinion depth, on

reassembly.

3. On ring gear bolts, clean serrations under bolt

flanges.

Figure 4B-182

Bearings

1. Bearing c u ps s hou ld ha ve an even wear pat tern a nd be f r ee f rom flak ing or pit t in g . Ens ure the s eat ing s ur f ac es

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

lubric ant bef ore ass embly.

2. With the 3.08:1 ratio unit, reinstall respective

clutch cones (2) and shims (3)(if fitted) into

differential case halves.

To check if shims are required:

a. Using a depth gauge (1), 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-183

3. Remove clutch cones and shims from

differential case halves.

NOTE: With the 3.07:1 and the 3.46:1 ratio

assemblies, shimming is not required, as the side

gear and cone are an integrated, single assembly.

4. Clamp the left hand inner axle shaft (1) in a

vice equ ipped with sof t jaws (2), af ter rem oving

the snap ring from the end of the shaft.

NOTE: The axle shaft (or inner axle shaft) is used

as a mounting tool with 3.08:1 ratio differentials, to

ensure correct side gear and clutch cone spline

alignment. Failure to follow this procedure will

prevent installation of the inner axle shafts at final

assembly.

Figure 4B-184

5. Place differential case cap (1) 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-185

7. For 3.08:1 ratio differentials (view ‘A’), 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 3.07:1 and the 3.46:1 ratio differentials

(view ‘B’), install the clutch cone/side gear

assembly (2) to the housing.

Figure 4B-186

8. Plac e a thr ust spring plate ( 1), stepped s ide up

on side gear (2).

9. Assemble the four pinions and thrust washers

onto pinion cross shaft.

10. Install pinions and cross shaft assembly to

case c ap, ensuring that pin ions mesh with si de

gear.

Figure 4B-187

11. Install three ne w co ncentr ic diff er ential pre- l oad

springs (1) into cen tre of the pinion cross shaft

(2).

NOTE: NEW pre-load springs (1) must always be

installed on reassembly, DO NOT RE-USE OLD

SPRINGS.

Figure 4B-188

12. Assemble second thrust spring plate (1),

stepped side down, onto pre-load springs.

Figure 4B-189

13. For 3.08:1 ratio differentials (view ‘A’), install

clutch cone (1), shim (if required) and side

gear (3) to case cover (2).

With 3.07:1 and the 3.46:1 ratio differentials

(view ‘B’), install the clutch cone/side gear

assembly (4) into the case cover (2).

Figure 4B-190

14. Install case cover onto case cap.

NOTE: Ensure that the cut out (1) on each side of

the case cover and cap align.

Figure 4B-191

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

attaching b olts i n opposite bolt hol es and f inger

tighten.

16. Install other inner axle shaft (1) through case

cover, rotating axle shaft to engage clutch cone

splines and then side gear splines. Leave axle

shaft in this position. Install remaining, NEW,

cap-to-cover attaching bolts and t ighten evenly

to the correct torque specification.

DIFFERENTIAL CASE CAP TO

TO COVER ATTACHING BOLT

TORQUE SPECIFICATION 35 – 45 Nm

17. With 3.08:1 ratio assemblies, 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 tim e mus t the side gears and clutc h

cones be rot ated until t he i nner axl e shaf ts are f ull y

installed. Failur e to obs er ve this c ondit ion wil l res ult

in side gear and clutch cone spline misalignment,

thus preventing inner axle shaft installation.

Figure 4B-192

Should splines become misaligned, loosen case

cap to c over b olts and rep e at s teps 4, 5, 15 and 1 6

of REASSEMBLE procedure.

18. Place ring gear (1) into position on differential

case cap (2) and install ring gear attaching

bolts.

NOTE 1: For ease of assembly, it may be

necessar y 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 (3) 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.

FINAL DRIVE RING GEAR

TORQUE SPECIFICATION 125 - 150 Nm

NOTE: Ring gear attaching bolts use a left hand

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

Figure 4B-193

20. If installin g n ew side b eari ngs (1), us e Tool N o.

E9277 to press on side bearings (1) to

differential case journals.

Figure 4B-194

21. Continue rear axle assembly, proceeding from

'Differential Case Side Bearing Pre-Load

Setting', 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 to inside edge of rear

cover and bolt holes and completely around

drain plug hole.

2. Install rear cover to differential carrier housing.

Fit screw adjuster lock plates to rear cover,

ensuring that lock plates fit over ribs or

between ribs on the screw adjusters.

If equipped with ABS, i nstall both sensor s, and

tighten rear c over attach ing bolts to the correc t

torque specification.

REAR COVER ATTACHING

TORQUE SPECIFICATION 23 - 31 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. If removed, reinstall a spring clip to the end of

each inner axle shaft (1), then reinstall, aligning

splines with clutch cones (if a 3.08:1 ratio unit

is equipped with an LSD) and side gears.

NOTE: To avoid premature seal failure, ensure

axle shaft splines or spring clip do not score or

damage the seal lips during installation.

5. Lig htly tap on end of each shaft flange (1) with

a soft faced hammer (2) to compress spring

clip on shaft into clutch cup and side gear

splines. Fully engage both shafts until clips

snap into side gear grooves.

IMPORTANT: With 3.08:1 ratio, LSD type

differential assemblies, ensure that both inner axle

shafts are instal led ful ly befor e rotating e ither s haft.

If rotation of one shaft occurs before both are fully

installed, misalignment of opposite side gear and

clutch cone will occur, thus preventing ass embly of

remaining shaft.

NOTE: For vehicles equipped with ABS, the inner

axle shafts are unique for this application.

Figure 4B-195

6. Reinstall differential carrier assembly. Refer to

3.2 FINAL DRIVE ASSEMBLY in this Section.

4. DIAGNOSIS

4.1 GENERAL INFORMATION

Very of ten, fin al dr ive as sem blies ar e consi dered as n ois y, when in re ality, th e no ise is em anating fr om s ome 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 diagn osis guide will assist in locating and definin g the different characteristics

of the components which could be responsible for a noise.

Road Test

Ensure th at the final dr ive ass embly lubric ant is cor rect and at the cor rect le vel. Drive at lo w speed unt il thor oughly

familiar with vehicle noises by which time the final drive assembly should have warmed up. Accelerate gradually

from the lowes t pr actica l sp eed in a d irect r atio gear (1:1) to 100 k m /h, noting any nois es and t he sp eeds at which

they occur. Release the accelerator and without using the brakes, allow the vehicle to lose speed. Next, allow the

vehicle t o coast to res t from 100 km /h with the trans mission in ne utral pos ition. An y noises comm on to earlier tes ts

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

T yr e noise can easily be mis taken for final drive asse mbly noise ev en though th e noisy t yres m ay be operating on

the front wheels. Tyre noise changes with different road conditions, but final drive assembly noise does not. Final

drive ass em bly noise us ual ly ceases when coas ting with the tra nsm iss ion in neutral at s peeds under 50 k m /h. T yre

noise continues, but with a lower tone as vehicle speed is reduced.

T yre noise nat urally shou ld be first elim inated; drivin g on a grass s urface is idea l to check against this condit ion. 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

W orn, brinelled, c hipp ed or incorrec tly adj usted fr ont whee l bear ings wi ll caus e a noise, ver y similar to t yre n oise. 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.

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 un der a consta nt throttle opening, but dis appears o n 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 s udden st art, either forward or reverse, m ay be caused by a loose p inion f lange. If lo ose, replac e nut or

flange as outli ned un der 2.9 PINION FLANGE in this Section.

This condition may also be caused by incorrect lubricant in an LSD Drain and refill with correct lubricant.

Techline

Engine And Other Contributing Factors

Noises whic h emanate fr o m the engin e, tra ns miss ion or muffler ar e oc cas io nal ly confus ed with final dri ve as sem bl y

noises.

To is olate t hese nois es, fir st car efull y not e the appr oxim ate veh icle s peed and c ondit ions wher e the supp ose d fina l

drive assembly noise is m ost 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 lubric ant le ve l or inc or rec t lubr ic ant us ed.

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 bearin gs .

5. Bruised or chipped teeth.

6. Excessive runout of pinion head or ring gear backlash.

7. Ring gear creep ing on d ifferentia l case r esulting f rom ring g ear bolts l oosening - n oise fr om this s ource usual ly

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

BEARING RELATED NOISE

Differential Pinion Gear Bearings

W orn, rough or lo ose beari ngs will tend to a ggravate and magnif y drive, float an d coast noise, and r esult in heav y,

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 ov er- run.

Drive Shaft Bearings

Drive s haf t bear ings t hat are roug h or p itt ed can be res pons ib le f or a gro wlin g no i s e which on first impres sion c oul d

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 Side Bearings

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

cannot be det ermined by the diagn osis procedure for drive shaft bearing noise), but will be in t he same frequenc y

as drive shaft bearings.

Common Causes of Bearing Related Noises

1. Low lubric ant le ve l or inc or rec t lubr ic ant us ed.

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

specif ied l ubric a nt a nd r e- e va luat e L SD o per at ion f or a m inimum of 20 k m . Chatte r will us ua lly disapp ear with in th is

time.

Should chatter still occur, remove carrier and overhaul LSD. Refer to 3.4 LIMITED SLIP DIFFERENTIAL in this

Section.

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

DESCRIPTION:

Pattern on races and rollers caused by fine abrasives.

CORRECTION:

Clean all parts and housings

Check seals and bearings, replacing if leaking, rough or noisy.

GALLING

DESCRIPTION:

Metal smears on roller ends due to overheating, lubricant failure or

overload.

CORRECTION:

Replace bearing, check seals and check for proper lubrication.

BENT CAGE

DESCRIPTION:

Cage damage due to improper handling or tool use.

CORRECTION:

Replace bearing.

ABRASIVE STEP WEAR

DESCRIPTION:

Pattern on bearing ends caused by fine abrasives.

CORRECTION:

Clean all parts and housing. Check seals and bearings, replacing if

leaking, rough or noisy.

ETCHING

DESCRIPTION:

Bearing surfaces appear grey or greyish-black in colour with related

etching away or material, usually at the roller spacing.

CORRECTION:

Replace bearings. Check seals and check for proper lubrication.

Figure 4B-196

Final Drive Bearing Diagnosis – Continued

BENT CAGE

DESCRIPTION:

Cage damage due to improper handling or use of tools.

CORRECTION:

Replace bearing.

INDENTATIONS

DESCRIPTION:

Surface depressions on race and rollers caused by hard particles of

foreign material.

CORRECTION:

Clean all parts and housing. Check seals and replace bearings if rough

and nois y.

CAGE WEAR

DESCRIPTION:

Wear around outside diameter of cage and roller pockets caused by

abrasive materials and inefficient lubrication.

CORRECTION:

Replace bearings. Check seals and check for proper lubrication.

MISALIGNMENT

DESCRIPTION:

Outer race misalignment due to foreign object.

CORRECTION:

Clean related parts and replace bearing. Make sure races are properly

seated.

CRACKED INNER RACE

DESCRIPTION:

Race cracked due to improper fit, cocking or poor bearing seats.

CORRECTION:

Replace bearings and correct bearing seats.

FATIGUE SPALLING

DESCRIPTION:

Flaking of surface metal resulting from fatigue.

CORRECTION:

Replace bearings and clean all related parts.

Figure 4B-197

Final Drive Bearing Diagnosis – Continued

BRINELLING

DESCRIPTION:

Surface indentations in raceway caused by rollers either under impact,

loading or vibration while the bearing is not rotating.

CORRECTION:

Replace bearing if rough or noisy.

FRETTAGE

DESCRIPTION:

Corrosion set up by relative movement of parts with no lubrication.

CORRECTION:

Replace bearing. Clean related parts. Check seals and check for proper

lubrication.

STAIN DISCOLOURATION

DESCRIPTION:

Discolouration can range from light brown to black, caused by incorrect

lubrication or moisture.

Re-use bearing if stains can be removed by light polishing or if no

evidence of overheating is observed.

CORRECTION:

Check seals and related parts for damage.

HEAT DISCOLOURA TION

DESCRIPTION:

Heat discolouration can range from faint yellow to dark blue, resulting

from overload or improper lubricant.

Excessive heat can cause softening of races or rollers.

To check for loss of temper on races or rollers, a simple file test may be

made. A file drawn over a tempered part will grab and cut metal,

whereas a file drawn over a hard part will glide readily with no metal

cutting action.

CORRECTION:

Replace bearings if overheating damage is indicated. Check seals and

other parts.

SMEARS

DESCRIPTION:

Smearing of metal due to slippage that can be caused by poor fits,

lubrication, overheating, overloads or handling damage.

CORRECTION:

Replace bearings. Clean related parts and check for proper fit and

lubrication.

Figure 4B-198

5. SPECIFICATIONS

GENERAL

Rear Axle Assembly

V6 Engine

(Except Manual Transmission Station Wagon)... SAA – 76 Series

GEN III V8/V6 Supercharged Engines (and

Manual Transmission Station Wagon)................ SAA – 80 Series

Axle Type ................................................................... Independent Housing

ST ANDARD AND L SD AXLES

Gear Type .................................................................. Hypoid

Gear Ratio (See I.D. tag attached to the carrier)

V6 Engine

(Except Manual Transmission Station Wagon)... 3.08:1

GEN III V8/V6 Supercharged Engines (and

Manual Transmission Station Wagon)................ 3.07:1

GEN III V8/V6 Utility and Manual Transmission... 3.46:1

No. of Teeth: .............................................................. 3.08:1 3.07:1 3.46:1

Ring Gear.............................................................. 37 43 45

Drive Pinion Gear.................................................. 12 14 13

LUBRICANT

Capacity..................................................................... 1.6 litres

Type ........................................................................... Refer Lubrication in this Section.

DIFFERENTIAL GEARS

Type ........................................................................... Straight Bevel

No. of Teeth: .............................................................. 3.08:1 3.07:1 3.46:1

Pinion Gears ......................................................... 10 10 10

Side Gears............................................................ 16 15 15

FINAL DRIVE PINION GEAR BEARINGS

Bearing Type.............................................................. Adjustable Tapered Roller

Bearing Adjustment.................................................... Collapsible Spacer

Bearing Pre- L oad:...................................................... Timk en Koyo

Dummy pinion - New bearings.............................. 1.4 – 2.0 1.5 – 1.9 Nm

Dummy pinion - Used bearings............................. 0.7 – 1.2 0.7 – 1.2 Nm

New with oil seal................................................... 1.4 – 2.4 1.5 – 2.1 Nm

New without oil seal.............................................. 1.4 – 2.0 1.5 – 1.9 Nm

Used with oil seal.................................................. 0.7 – 1.2 0.7 – 1.2 Nm

Used without oil seal............................................. 0.7 – 1.2 0.7 – 1.2 Nm

DIFFERENTIAL CARRIER SIDE BEARINGS

Type ........................................................................... Adjustable Tapered Roller

Adjustment ................................................................. Screw adjusters on each side of the carrier.

Bearing Pre-Load

(Refer to text for measurement conditions) .......... Timken Koyo

New Bearings........................................................ 15 – 35 N 8 – 24 N

Used Bearings ...................................................... 8 – 18 N 5 – 13 N

RUN-OUT SPECIFICA TIONS

Trunnion Assembly Hub............................................. 0.06 mm Total Indicated Run-out

Case Assembly (without ring gear attached)............. 0.05 mm (maximum)

Ring Gear Rear Face (assembled to case flange) .... 0.13 mm (maximum)

BACKLASH SPECIFICA TIONS

Ring Gear to Drive Pinion .......................................... 0.10 – 0.18 mm (at the tightest point)

LSD TORQUE CHECK

Torque Check Specification....................................... 45 Nm (minimum)

ABS SEN SO R

Air Gap (non-adjustable)............................................ 0.4 – 1.5 mm

SEALANTS

Drive Shaft Dust Caps/Shield........................................ RTV 732 Sealant, or commercial equivalent

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

As Required ............................................................... Loctite 242 or commercial equivalent, to

GM Specification 9985283.

LUBRICANTS

As Specified in Text ...................................................... Molybond HE50

As Specified in Text ...................................................... Commercially available Lithium Soap Based Grease.

6. TORQUE WRENCH SPECIFICATIONS

Brake caliper anchor plate to trailing arm bolts....................... 70 – 100

 Collar nut to trunnion assembly .............................................. 295 – 305

Crossmember front mounting bolt........................................... 125 Nm, plus 30° – 40°

turn angle

Crossmember front mounting brace to underbody bolts ........ 60 – 85

Drain plug................................................................................ 23 – 31

 Drive shaft constant velocity joint to trunnion flange/inner

axle shaft flange bolts............................................................. 50 Nm, plus 90°

turn angle

Filler plug................................................................................. 23 – 31

 Final drive assembly to crossmember attaching bolts............ 90 Nm, plus 30° – 45°

turn angle

 Final drive ring gear bolts........................................................ 125 – 150

Intermediate exhaust pipe to catalytic converter

attaching bolts – All engines.............................................. 40 – 50

 LSD case cap to cover attaching bolts ................................... 35 – 45

Rear cover attaching bolts...................................................... 23 – 31

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

Lower bolt s................ 85 – 90

....Rear mount to vehicle underbody attaching bolts................... 30 – 40 Nm, plus 55° – 65°

turn angle.

 Rear mount to differential carrier rear cover attaching bolts... 85 – 105

Road wheel attaching nut ....................................................... 100 – 125

z Shock absorber lower mounting bolt ...................................... 105 – 125

 New bolts/nuts and washers MUST be used on reassembly.

z Vehicle MUST be at curb weight before tightening to specifica tion

7. SPECIAL TOOLS

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

1150

PULLER

Used in conjunction with forcing

screw E6661S and adaptor AU412 to

remove side bearing cups from the

screw adjusters

Previously released.

Unique

205-463

SCREW ADJUSTER SOCKET

Used for checking and adjusting final

drive side bearings.

Previously released.

(Also released as AU407

Unique

205-551

ADAPTORS

Used to remove the pini on beari ng

cups, in conjunction with

Remover /Ins tal ler E92 93.

205-551-1 is required for 3.07:1 and

3.46:1 assemblies.

New release.

Unique

205-552

ADAPTORS

Used to install the pinion bearing

cups, in conjunction with

Remover /Ins tal ler E92 71.

205-552-2 is required for 3.07:1 and

3.46:1 assemblies.

New release.

Unique

7208 REAR AXLE REMOVAL ADAPTOR

Used with E6662B for LSD torque

check.

Previously released.

Unique

7374 SLIDE HAMMER & PLATE

Used to remove inner axle shafts

from the rear axle assembly.

Previously released.

Available

AU408

DUMMY ARBOU R

Used with dummy pinion from

E9300A.

Previously released.

Unique

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

AU409 PRESS FIXTURE

Used for installing needle bearings into

screw adjusters. Used with AU411.

Previously released.

Unique

AU410 SEAL INSTALLER

Used to install inner axle seals to screw

adjuster.

Previously released.

Unique

AU411 BEARING & CUP REMOVER

Used in conjunction with AU409.

Previously released.

Unique

AU412

ADAPTOR

Used with forcing screw E6661S and

puller 1150 to remove side bearing cups

from screw adjust ers.

Previously released.

Unique

AU416

TOR X BIT

Used to remove and reinstall upper rear

brake backing plate to trailing arm bolts

Previously released.

Unique

DT-47695

REAR PINION BEARING CUP

REMOVER

Used in conjunction with remover E9293

to remove the rear (inner) pinion bearing

cup on 3.07/3.46:1 assemblies.

New release

Unique

DT-47696

SPACER

Used in conjunction with the dummy

pinion from E9300A when checking pinion

depth on 3.07/3.46:1 assemblies

New release.

Unique

E1673A15 BASIC PULLER

Used with adaptors to remove bearings

from the final drive assembly.

Previously released.

Unique

E1673A15

ADAPTOR

Used with puller E1673MT and stepped

plug E1673B16 to remove the rear pinion

bearing on 3.08:1 assemblies.

Previously released.

Unique

E1673B16

STEPPED PLUG

Used with puller E1673MT and adaptor

E1673N15 to remove bearings from the

differenti al cas e.

Previously released.

Unique

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

E1673N15 ADAPTOR

Used with puller E16 73MT and

stepped plug E1673B16 to remove

the side bearings from the differential

case.

Previously released.

Unique

E1673S15 ADAPTOR

Used with puller E16 73MT to remove

the rear pinion bearing on 3.07:1 and

3.46:1 assemblies.

Previously released.

Unique

E3C10AER PINION REAR BEARING

REPLACER

Used to install the rear pinion bearing

during final drive overhaul.

Previously released.

Unique

E308

SEAL REMOVER

Used as a universal seal remover.

Also released as 56750.

Previously released.

Available

E6661S

FORCING SCREW

Used in conjunction with puller 1150

and adaptor AU41 2.

Previously released.

Unique

E6662B

TORQUE WRENCH ADAPTOR

Used in conjunction with 7208 to

check breakaway torque of LSD

differential.

Previously released.

Unique

E7115

ANGLE WRENCH

Used to tighten fas teners when an

angle torque is specified.

Also released as BT8653-A

Previously released.

Unique

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

E9055

PINION OIL SEAL INSTALLER

Used to install the pinion oil seal.

Also released as 17-010A.

Previously released.

Unique

E9271

PINION BEARING CUP INSTALLER

Previously released.

Unique

E9277 SIDE BEARING INSTALLER

Used to install bearings to the

differential case.

Previously released.

Unique

E9293 PINION BEARING CUP REMOVER

Previously released.

Unique

E9300A

PINION HEIGHT SETTING GAUGE

Previously released as E9300, this

set now has an additional spacer to

be used on the 3.07:1 and 3,46:1

ratio, final dr i ve ass emblies.

Previously released.

Unique

J3289-20

HOLDING FIXTURE BASE

Used with either KM480 or dealer

fabricated bracket to hold the final

drive assembly.

Previously released.

Unique

J22610 CLAMP PLI ER S

Used to crimp the drive shaft boot

clamps. Also released as E1896.

Previously released.

Available

J22912-01

PRESS PLATES

Used in a number of different

applicat ions in removing be ar ings and

other transmission components when

pressing operations are required.

Previously released.

Unique

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

J24292-C PRESS TOOL

Used to remove rear wheel studs

from the trunnion flange.

Previously released.

Unique

KM468 HOLDING BAR

Used to stop the rear trunnion from

rotating.

Previously released.

Available

KM480 HOLDING FIXTURE

Modify by drilling two 14 mm holes as

shown. Fixture originally released for

THM 125 automatic transaxle (’J’’

car).

Previously released.

Unique

KM620-B REMOVER/INSTALLER

Used for removing and installing

trunnion flange and rear wheel

bearing. KM 620-1 A is also us ed to

hold the pinion flange.

NOTE: Holes in KM620-1A, stamped

with a ‘B’ must be enlarged to 12.5

mm.

Previously released.

Unique

KM620-7AUS

SUPPORTS

The two revised length supports are

require d when us in g KM62 0- B for

service operations on the rear

trunnion and /or bear in g.

Previously released.

Unique

KM628-A EX TR A CTOR TO O L

Used to remove the final drive pinion

flange. Also used for several

disassembly operations on the V6

manual transmission. Each of the

three mounting holes must be

enlarged to 12.5 mm.

Previously released.

Unique

PINION FLANGE PULLEY

Dealer fabricated:

1. Made from a 13 mm thick piece of wood.

2. Drill a sm all hol e at 'A' and attach a o ne m etre len gth of

string at this point.

3. Drill two 10 mm holes as shown in the figure.

TOOL

NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

DIAL INDICAT O R PLATE

Dealer fabricated:

1. Fabricated from 6 mm Mild Steel Plate

2. If using the brake caliper bolts to fasten, then 17 mm

spacer swill need to be installed on each bolt, prior to

installing.

DIFFERENTIAL CARRIER HOLDING FIXTURE

If KM480 is not available, fabricate

a holding fixture as shown.