Contents: Removal ⇩ Installation ⇩
Removal
1. Raise and lower the vehicle onto stands.
2. Drain the transmission fluid. Refer to procedure: Draining Transmission Fluid from Differential and Filling Differential with Transmission Fluid (205-02 Rear Drive Axle/Differential, General Procedures).
3. Remove the rear differential. Refer to the procedure: Differential Case (205-02 Rear Drive Axle/Differential, Removal and Installation).
4. Remove the differential housing bolts.
5. Remove the differential housing.
6. Remove and discard the differential housing seal.
7. Remove the ring gear assembly.
8. Clamp the differential assembly in a suitable vice as shown.
9. Using a special tool, remove the pinion shaft seal.
CAUTION: Make sure that the pinion recess is not damaged when removing the seal.
10. Using special tools, remove the pinion shaft nut.
WARNING: Use of high torque.
CAUTION: Do not use air tools or heat to remove the nut (this may contaminate the front bearing). Failure to do so may result in damage to this component.
NOTE: The special tool must be turned clockwise to remove the pinion shaft nut.
11. Secure the differential housing in the special tool. Place the support bolt in the lowest position.
12. Using a suitable press, remove the differential pinion shaft.
CAUTION: Failure to use support plates to secure the fixture to the press may result in twisting or damage to the crankcase.
13. Remove and discard the pinion shaft soft lining.
14. Remove the rear bearing inner race.
15. Using special tools, remove the outer ring of the rear bearing of the drive pinion shaft.
16.
- Remove the differential from the support.
- Clean the pinion shaft thoroughly, paying particular attention to the threads.
- Using a suitable cleaning fluid, thoroughly clean the differential housings.
CAUTION: Working on the rear differential requires absolute cleanliness. Always cover all open openings with lint-free material to prevent entry of foreign material. Failure to do so may result in component damage.
Installation
1.
- Secure the differential housing in a special tool.
- Using a suitable press and special tool, install the outer race of the rear bearing of the pinion shaft.
CAUTION: Do not clean or lubricate the new pinion shaft rear bearing, it is supplied in a light grease. Failure to do so will result in the rear bearing having to be replaced before the differential is assembled.
2. Install a new pinion shaft gasket.
3.
- Install the pinion shaft into the differential housing.
- Lubricate the support bearing at the pinion gear with differential oil.
- Place the support bolt in its highest position.
4. Using a suitable press and special tool, install the inner race of the rear bearing of the pinion shaft.
CAUTION: Do not clean or lubricate the new pinion shaft rear bearing, it is supplied in a light grease. Failure to do so will result in the rear bearing having to be replaced before the differential is assembled.
5. Clamp the differential assembly in a suitable vice as shown. Remove the differential from the support.
6. Using the special tools, install the new pinion nut. Tighten to the specified torque 250 Nm (184 lbs/ft).
WARNING: Use of high torque.
The special tool should be turned counterclockwise to install the pinion shaft nut.
Do not use an air tool to install the nut. Failure to do so may result in damage to this component.
NOTE: The pinion shaft gasket begins to collapse at minimum torque 250 Nm (184 lbs/ft).
7.
- Using the special tool, check the torque required to rotate the pinion shaft. Recommended torque 1.1+/-0.2 Nm
- If the specified torque for rotating the pinion shaft is not achieved, use special tools to tighten the flange nut in one degree increments, checking the torque after each increment until the recommended torque is achieved 1.1+/-0.2 Nm
Make sure the specified shaft rotation torque is not exceeded. If excessive preload is applied to the joint, the pinion shaft must be removed and a new shim, pinion shaft rear bearing, pinion shaft rear bearing outer race and pinion nut must be installed.
To obtain a constant value, the special tool should be rotated at a speed of 60 rpm (1 revolution per second).
Before measuring the torque, the pinion shaft should be turned manually two full revolutions.
8. Using a suitable press, special tool and adapter, install the pinion bearing seal.
CAUTION: Do not lubricate the pinion oil seal.
9. Install the ring gear assembly.
10. Install the differential housing seal. Apply a small amount of clean differential oil to the new seal.
Make sure the mating surfaces are clean, failure to do so may result in damage to the differential.
Make sure that the new seal is not twisted during installation, failure to do so may result in damage to the differential.
11. Install the differential housing bolts. Tighten the 7 bolts to 110 mm 29 Nm.
12. Install the rear differential. Refer to procedure: Differential Case (205-02 Rear Drive Axle/Differential, Removal and Installation).
13. Fill the differential case 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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