Contents: Removal ⇩ Installation ⇩
NOTE: The removal procedure descriptions in this manual may contain installation steps.
Removal
1. Raise and support the vehicle
WARNING: Ensure that the vehicle is supported securely.
2. Remove the left rear wheel and tire assembly. Refer to procedure: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
3. Using assistance, remove the rear muffler. Refer to procedure: Exhaust System (309-00A Exhaust System - 3.2L NA - I6, Removal and Installation).
4. Discard the bolts.
WARNING: Do not use a pry bar to disconnect the driveshaft joints from the transfer case or rear differential flanges.
Mark the position of the elements to facilitate subsequent installation. Secure the cardan shaft with suitable clamps.
5.
6.
7. Remove the left rear halfshaft. Refer to the procedure: Rear Left Halfshaft (205-05 Rear Drive Axle Shafts, Removal and Installation).
8. Support the differential with a gearbox jack.
9. Discard the bolts.
CAUTION: Mark the positions of the components to facilitate subsequent installation.
10. Discard the bolts.
CAUTION: Mark the positions of the components to facilitate subsequent installation.
11. Carefully disconnect the inner joint of the right axle shaft from the differential, move it to the side and tie it up.
12.
13. Carefully lower and remove the differential case.
14.
NOTE: Do not perform further disassembly if the component is removed only for access.
15.
Installation
1. Install a new O-ring onto the active clutch.
CAUTION: Clean the area around the element and remove any foreign material.
2. Align the active clutch with the differential and tighten the bolts. Tightening torque: 24 Nm
Clean the area around the element and remove any foreign material. Use new bolts.
3. Install the rear differential support bracket. Tightening torque: 35 Nm
4. Using a transmission jack, carefully lift the unit.
5. Connect the differential ventilation lines.
6. Attach the right axle inner joint to the differential.
7. Screw in the rear differential front bushing mounting bolts. Tightening torque: 175 Nm
The timing marks must be aligned. Use new bolts.
8. Screw in the rear differential rear bushing mounting bolts. Tightening torque: 110 Nm
The timing marks must be aligned. Use new bolts.
9. Install the left halfshaft. Refer to the procedure: Rear Left Halfshaft (205-05 Rear Drive Axle Shafts, Removal and Installation).
10. Connect the electrical connector of the active clutch module.
11. Install the rear propeller shaft support bracket. Tightening torque: 35 Nm
12. Connect the propeller shaft to the rear flange. Tightening torque: 40 Nm
CAUTION: Use new bolts.
13. Install the rear muffler. Refer to procedure: Exhaust System (309-00A Exhaust System - 3.2L NA - I6, Removal and Installation).
14. Install the left rear wheel. Refer to the procedure: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
15. Check the active clutch fluid level and add fluid if necessary. Refer to procedure: Active Clutch Filler (205-02 Rear Drive Axle/Differential, General Procedures).
16. Fill the differential with transmission fluid. Refer to procedure: Draining Transmission Fluid from Differential and Filling Differential with Transmission Fluid (205-02 Rear Drive Axle/Differential, General Procedures).
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