Differentials: Removal & Installation Jaguar XJR II

Removal & Installation

For removal and installation procedures, see REMOVAL & INSTALLATION in AXLE SHAFTS - REAR article.

Removal

1. Disconnect battery ground connection. Raise and support vehicle. Remove rear wheels.
2. Disconnect brake pad wear sensor multi-plug at right hub carrier and remove tie straps from wishbone. Release ABS speed sensors from both hub carriers and remove tie straps from wishbones.
3. Remove rear brake calipers, and wire aside at bump stop. Disconnect main hand brake cable at compensator, short cables at joining piece and remove compensator.
4. Mark drive shaft position and remove drive shaft from differential drive flange. CAUTION: Manufacturer recommends that, under no circumstances, the flexible coupling on drive shaft flange be loosened or removed.
5. Remove center bearing-to-crossmember bolts and push drive shaft rear section forward to disengage coupling from pinion spigot. NOTE: Ensure any shims between center bearing and crossmember are saved to be returned in the same order on reassembly.
6. Remove bolts securing exhaust overaxle pipe mountings to subframe. Support rear suspension with floor jack. Disconnect rear strut assembly from body. Remove shock absorber lower mounting bolts. Disconnect subframe mounting bolts from body. Ensure all wiring, hoses and other components necessary for differential subframe removal are either disconnected or removed.
7. Carefully lower differential subframe from vehicle. Remove subframe assembly from underneath vehicle. Separate axle shafts from differential output shafts. Note position of camber shims between axle shaft and differential output shaft.
8. Disconnect and remove lower wishbone and axle shaft as an assembly. Invert subframe assembly and separate differential assembly from subframe. Remove subframe. Remove speed sensor bracket (if necessary).

Installation

To install, reverse removal procedure. Renew all self locking nuts/bolts. Replace all safety wire and cotter pins. Tighten all nut/bolts to specification. See TORQUE SPECIFICATIONS. Inspect and top off oil level (if necessary). Check and adjust rear wheel camber setting as required.

1. Raise and support vehicle. Disconnect main hand brake cable at compensator.
2. Mark drive shaft position for installation reference. Remove drive shaft flange from pinion flange. Measure and record preload torque at flange nut. Mark nut, pinion shaft and drive flange for reassembly reference. Loosen flange retaining nut about 1/2 turn and retighten to match mark. NOTE: If force required does NOT exceed 100 ft. lbs. (135 N.m), manufacturer recommends replacement of final drive unit.
3. Remove pinion flange retaining nut and washer. Using a puller, remove pinion flange. Remove oil seal from case.

1. Lubricate and install NEW oil seal. Ensure seal is fully seated. Install pinion flange, washer and nut. Noting pinion flange nut-to-flange marks made in removal procedure, tighten flange nut until marks are aligned. Recheck preload torque.
2. Preload torque should exceed torque reading recorded in removal procedure by 5-10 INCH lbs. (.6-1.1 N.m). If turning torque exceeds 44 INCH lbs. (5 N.m), differential must be overhauled. To complete installation, reverse removal procedure. Tighten all nut/bolts to specification. See «TORQUE SPECIFICATIONS»(ref-125458-S30507711912001100500000) .

1. Disconnect battery ground. Raise and support vehicle. Place matching marks on axle and output shaft flange for reassembly reference. Remove nuts securing axle shaft to output shaft. Position hub assembly on a stand. Ensure brake hose is not stressed.
2. Remove shim from output shaft housing. Remove output shaft housing bolts. Remove output shaft assembly. Remove "O" ring from shaft. Remove shims from output shaft housing. DO NOT drill into output shaft, drill 3 holes in bearing retaining collar, using a 1/8" drill bit. (Scheme 1)
3. Using a chisel, cut into but not through bearing retainer collar. Using a press, remove output shaft from housing and collar. Discard collar. Remove seal from housing.

Scheme 1

1. Install NEW seal into housing. Ensure seal is seated properly. Position output shaft into housing. Place bearing onto shaft. Press output shaft and bearing into housing. Press bearing retainer collar onto shaft. Install housing and shims without "O" ring seal.
2. Ensure housing is fully seated in differential. DO NOT install output shaft housing bolts. Using a feeler gauge, measure clearance between output shaft housing and differential casing. Clearance should be .003-.005" (.08-.13 mm). If clearance is not within specification, remove shaft assembly and re-shim until correct clearance is obtained. NOTE: There should always be 3 shims behind output shaft bearing.
3. If clearance is within specification, remove shaft assembly. Install NEW "O" ring onto housing. Install output housing and shims. Install and tighten housing bolts to specification. See «TORQUE SPECIFICATIONS»(ref-125458-S33769643102001100500000) table. NOTE: Output shaft end play is preset in output shaft bearing.
4. Position dial indicator against output shaft flange and measure shaft end play. End play should be .001-.006" (.03-.15 mm). If end play is not within specification, replace output shaft bearing. To complete installation, reverse removal procedure.