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MODEL SELECTION INDEX
MY 2003 VY Series Regular Cab - Service Information
Section 4B Rear Axle
1 General Information
1.1 Cone Type Limited Slip Differential – M78 Series
1.2 Multi-Disc Type Limited Slip Differential – M86 series
1.3 Rear Axle Assembly Identification
1.4 Rear Axle Assembly Maintenance
Rear Axle Shaft and Bearings
Rear Axle Assembly
Rear Axle Assembly Breather
Limited Slip Differential Precautions
Lubrication
2 Minor Service Operations
2.1 Service Cautions and Notes
Road Wheel Replacement Caution
2.2 Checking Rear Axle Lubricant Level
2.3 Changing/Flushing Rear Axle Lubricant
2.4 Rear Axle Shaft Check For Run-Out and End Float
If Run-out and End Float is Within Specification
If the Run-out and End Float Check, Exceeds Specification
2.5 Rear Axle Shaft Wheel Studs
Replace
2.6 Combined Rear Axle Backlash Check
2.7 Limited Slip Differential Torque Check
2.8 Rear Axle Shaft Assembly
Remove
Reinstall
2.9 Rear Axle Shaft, ABS Pulse Ring, Oil Seal, Bearing and Retainer Collar
Disassemble
Inspect
Axle Shaft, Bearing and Cone
Reassemble
2.10 Pinion Oil Seal
Remove
Inspect
Reassemble
2.11 Pinion Flange
Replace (Using Old Oil Seal)
Replace (Using New Oil Seal)
Theoretical Example
3. Major Service Operations
3.1 Rear Axle Assembly
Preliminary Check
Remove
Reinstall
3.2 Rear Axle and Differential Housing Assembly
Preliminary Check
Disassemble
Inspect
Reassemble
3.3 Differential Assembly – M78 Series (Standard Non LSD)
Disassemble
Inspect
Differential Case
Differential Side and Pinion Gears
Ring Gear and Pinion Gear
Bearings
Reassemble
3.4 Differential Assembly – M78 Series (Cone Type Limited Slip)
Disassemble
Inspect
Differential Case
Differential Side Gears and Pinion Gears
Ring Gear and Pinion
Bearings
Reassemble
3.5 Differential Assembly – M86 Series (Multi-Disc Type Limited Slip)
Disassemble
Inspect
Differential Case
Differential Side Gears and Pinion Gears
Differential Concentric Grooved Disc’s, Clutch Plates, Retainers and Dished Spacers
Ring Gear and Pinion
Bearings
Reassemble
3.6 Differential Assembly Adjustment and Installation Procedures – All Models
Differential Side Bearing Preload And Shim Selection
Side Bearing Preload Shim Selection Chart
Hypoid Pinion Bearing Preload Shim Selection
Hypoid Pinion Shim Selection Table
Hypoid Pinion Bearing Preload Shim Selection Chart
Pinion Installation
Differential Backlash Setting
Ring Gear and Pinion Contact Pattern
Tooth Marking Terminology
Ideal Contact
Drive Side
Coast Side
Acceptable Heel Contacts
Drive Side
Coast Side
Acceptable Toe Contacts
Drive Side
Coast Side
4. Diagnosis
4.1 General Information
Road Test
Tyre Noise
Front Wheel Bearings
Transmission Rear Bearing (Manual Transmission)
Backlash Clunk
Drive-Line Snap
Engine and Other Contributing Factors
Vehicles with Manual Transmission
4.2 Final Drive Assembly Noise
Gear Related Noise
Ring Gear and Pinion Noise
Differential Side Gear and Pinion Noise
Common Causes of Gear Related Noises
Bearing Related Noise
Differential Pinion Gear Bearings
Axle Shaft Bearings
Differential Side Bearings
Common Causes of Bearing Related Noises
4.3 LSD Noise
4.4 Differential and Rear Axle Bearing Diagnosis
Factors When Diagnosing Bearing Condition
Bearing Condition Identification
Abrasive Roller Wear
Galling
Bent Cage
Abrasive Step Wear
Etching
Bent Cage
Indentations
Cage Wear
Misalignment
Cracked Inner Race
Fatigue Spalling
Brinelling
Frettage
Stain Discolouration
Heat Discolouration
Smears
5. Specifications
6. Torque Wrench Specifications
7. Special Tools