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Differentials: Removal & Installation Land Rover Freelander I рестайлинг

Differentials & Drive Axles 46 illustrations ~4205 words

Removal & Installation

  1. Raise and support front of vehicle. DO NOT work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Remove 2 screws securing bumper valance to underbelly panel brackets.
  2. Remove 4 screws securing wheel arch liners to bumper valance, if equipped. Remove 2 bolts securing rear of underbelly panel. Remove 6 bolts securing underbelly panel frame. Remove underbelly panel.
  3. To install, position underbelly panel. Install bolts securing underbelly panel frame and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) . Install bolts securing rear of underbelly panel and tighten to specification.
  4. Install and tighten screws securing wheel arch liners to bumper valance, if equipped. Install and tighten screws securing bumper valance to brackets. Remove stands and lower vehicle.

Removal

  1. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS. Raise and support front of vehicle. Remove road wheel. Remove underbelly panel. See «UNDERBELLY PANEL»(ref-165921-S18267577202004090800000) under REMOVAL & INSTALLATION. Remove 3 bolts securing right splash shield to body and remove shield.
  2. Release stake from drive shaft nut. With an assistant depressing brake pedal, remove and discard drive shaft nut. Remove clip securing brake hose and release hose from damper bracket.
  3. Release ABS sensor harness and brake hose from damper. Release ABS sensor from hub. Remove 2 bolts securing brake caliper to hub. Release caliper from hub and tie aside.
  4. Remove 2 bolts securing damper to hub. Release hub from damper. (Scheme 1) Release axle shaft from hub. Position container to catch oil spillage.
  5. Secure LRT-54-026 to axle shaft inboard joint. (Scheme 2) Using a lever, release drive shaft from transmission. Remove drive shaft. Remove and discard circlip from drive shaft.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Installation

  1. Inspect transmission seal for signs of wear or damage. Wipe axle shaft ends, transmission oil seal and hub. Lubricate oil seal running surfaces. Install NEW circlip to axle shaft. Install drive shaft ensuring circlip is fully engaged.
  2. Position axle shaft in hub. Install NEW hub nut but do not tighten at this stage. Install hub to damper, install nuts and bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) .
  3. Position caliper to brake disc, install bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) . Clean ABS sensor and mating face. Lubricate ABS sensor with anti-seize grease. Install ABS sensor.
  4. Position ABS harness and brake hose in bracket and secure with clip. Install splash shield and secure with bolts. With an assistant depressing brake pedal, tighten front hub nut to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) . Stake front hub nut.
  5. Install road wheel and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) . Check transmission oil level and top up oil level as required. See «OIL DRAIN & REFILL PROCEDURE»(ref-165921-S31012641032004090800000) under LUBRICATION.
  6. Install underbelly panel. See «UNDERBELLY PANEL»(ref-165921-S18267577202004090800000) under REMOVAL & INSTALLATION. Remove supports and lower vehicle. Connect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS.

Removal (Left Side)

Remove left side axle shaft. See INTERMEDIATE REDUCTION DRIVE AXLE SHAFTS . Carefully remove and discard oil seal, take care not to damage oil seal recess.

Installation (Left Side)

CAUTIONOil seal is waxed on outer diameter and MUST NOT be lubricated before fitting.

Clean oil seal recess. Using Seal Installer LRT-44-027, install NEW oil seal. (Scheme 3) Install left axle shaft. See INTERMEDIATE REDUCTION DRIVE AXLE SHAFTS. Check and top off transmission fluid. See DRAIN & REFILL PROCEDURE under LUBRICATION.

Scheme 3

Scheme 3
Scheme 3

Removal (Right Side)

Remove right axle shaft. See INTERMEDIATE REDUCTION DRIVE AXLE SHAFTS . Carefully remove and discard oil seal, take care not to damage oil seal recess.

Installation (Right Side)

Clean oil seal recess. Locate seal on Drift LRT-37-031 and Seal Replacer LRT-37-027 with sealing lip facing towards housing. (Scheme 4) Carefully drift oil seal into housing until fully seated in recess. Install right axle shaft. See INTERMEDIATE REDUCTION DRIVE AXLE SHAFTS.

Scheme 4

Scheme 4: Installation (Right Side)
Scheme 4: Installation (Right Side)
  1. Raise and support vehicle on 4-post ramp. Drain fluid from IRD. See «INTERMEDIATE REDUCTION DRIVE (IRD)»(ref-165921-S04183210712004090800000) under OIL DRAIN & REFILL PROCEDURE.
  2. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS. Remove engine acoustic cover.
  3. Release pre-catalytic converter H02S harness from clips. (Scheme 5) Release and disconnect HO2S connector. Loosen tail pipe clamp nut. Release 2 rubber mountings from tail pipe and remove tail pipe and silencer. Remove 3 bolts and remove left heat shield. (Scheme 6)
  4. Remove 2 nuts securing intermediate pipe to front pipe. Loosen nut securing intermediate pipe clamp to catalytic converter. Release intermediate pipe from mounting. Release and remove intermediate pipe. Remove and discard gasket.
  5. Remove 2 bolts and remove right heat shield. (Scheme 7) Release post catalytic converter HO2S harness from clips. (Scheme 8) Release and disconnect post catalytic converter HO2S connector.
  6. Remove 2 bolts securing pipe clamp and remove clamp. (Scheme 9) Remove 2 nuts securing catalytic converter, remove catalytic converter and discard gasket. (Scheme 10)
  7. Remove right front axle shaft. See «INTERMEDIATE REDUCTION DRIVE AXLE SHAFTS»(ref-165921-S10750092542004091500000). Remove right axle shaft seal. Remove engine lower steady. (Scheme 11)
  8. Remove 3 bolts securing IRD support bracket to sump. (Scheme 12) Remove 2 bolts securing IRD support bracket to engine front mounting plate. (Scheme 13)
  9. Remove 5 bolts securing support bracket to IRD. (Scheme 14) Remove support bracket. Remove 8 bolts securing end cover to IRD main housing. (Scheme 15) Remove end cover.

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Clean remains of old sealant from mating faces of end cover and IRD main case. Apply a narrow bead of sealant, Part No. STC 4600 to mating face of end cover. (Scheme 16)
  2. Install end cover to IRD and tighten bolts progressively to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Install IRD support bracket and tighten bolts sufficiently only to pull mating faces together.
  3. Final tighten IRD support bracket bolts to specification in the following sequence: Bolts (5) securing support bracket-to-IRD. (Scheme 14) Bolts (2) securing support bracket-to-engine front mounting bracket. (Scheme 13) Bolts (3) securing support bracket-to-sump. (Scheme 12) See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  4. Position lower engine steady, TOP mark facing upward. Install one bolt but DO NOT tighten at this stage.
  5. Install manifold heat shield and install nut securing heat shield to pinion housing finger tight. Install bolts securing manifold heat shield to IRD support bracket and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  6. Install remaining engine lower steady bolt and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Install heat shield.
  7. Install axle shaft right seal and axle shaft. See «INTERMEDIATE REDUCTION DRIVE AXLE SHAFTS»(ref-165921-S10750092542004091500000). Fill IRD to correct level with fluid. See «INTERMEDIATE REDUCTION DRIVE (IRD)»(ref-165921-S04183210712004090800000) under OIL DRAIN & REFILL PROCEDURE.
  8. Clean right catalyst converter and mating face. Using a NEW gasket, install catalyst. Install nuts but do not tighten at this stage. (Scheme 10)
  9. Install pipe clamp, install bolts, but do not tighten at this stage. (Scheme 9) Connect post catalyst converter H02S connector and install to bracket. Install harness into clips.
  10. Install heat shields and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Install intermediate pipe and silencer. Tighten nuts securing catalyst to manifold to specification.
  11. Tighten bolts securing pipe clamp to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Connect precatalyst converter H02S connector and install to bracket. Install harness into clips. Install acoustic cover. Connect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS.

Scheme 16

Scheme 16
Scheme 16
  1. Raise and support front of vehicle. Remove underbelly panel. See «UNDERBELLY PANEL»(ref-165921-S18267577202004090800000) under REMOVAL & INSTALLATION.
  2. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS. Remove intermediate pipe and silencer.
  3. Remove 3 bolts securing heat shield and remove heat shield from front pipe. Remove 2 bolts securing pipe clamp and remove lower half of clamp. Remove 2 nuts securing front pipe to manifold. Remove bolt securing front pipe to bracket and remove front pipe. Discard gasket.
  4. Drain fluid from IRD. See «INTERMEDIATE REDUCTION DRIVE (IRD)»(ref-165921-S04183210712004090800000) under OIL DRAIN & REFILL PROCEDURE. Raise one rear wheel for rotation of drive shaft to access bolts. Reference mark front drive shaft for reassembly. (Scheme 17)
  5. Remove 6 nuts and bolts securing drive shaft to IRD drive flange. Release drive shaft from IRD drive flange and tie shaft aside.
  6. Remove 2 nuts from pinion housing securing front exhaust pipe bracket, remove bracket. Remove nut securing heat shield to IRD unit and remove shield. (Scheme 18)
  7. Remove 2 remaining nuts securing pinion housing. Remove pinion housing. Remove and discard "O" ring. Remove and retain spacing washer. (Scheme 19)
  8. Attach pinion housing to suitable mounting plate and secure mounting plate in vice. Check pinion bearings torque-to-turn figure. Reference mark pinion flange and pinion shaft for assembly purposes.
  9. Restrain pinion flange using Spanner Wrench LRT-51-003. (Scheme 20) Remove and discard nut. Position pinion housing onto press.
  10. Install suitable adaptor on end of pinion shaft and press pinion shaft from drive flange and housing. (Scheme 21) Remove and discard collapsible spacer. Using a suitable lever, remove pinion oil seal. Remove pinion bearing inner race.

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Clean pinion shaft, axle flange and housing. Clean oil seal recess. Lubricate and install bearing to pinion housing. Lubricate NEW seal. Using a suitable adapter, press seal into housing.
  2. Assemble pinion to housing using NEW collapsible spacer. (Scheme 21) Lightly lubricate drive flange splines with Molybdenum Disulfide grease. Align pinion to drive flange reference marks and press flange onto pinion shaft until a 0.079" (2.0 mm) clearance exists in bearings.
  3. Install pinion assembly to mounting plate and secure in vice. Install NEW pinion nut, hold pinion drive flange using LRT-51-003 and tighten pinion nut to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  4. Check pinion bearings torque-to-turn. If turning torque is too low, carefully tighten nut and recheck reading. If turning torque is too high, pinion assembly will have to be dismantled and a NEW collapsible spacer installed. Reassemble using NEW nut and recheck torque-to-turn.
  5. Check drive flange run-out using a Dial Test Indicator (DTI). Remove pinion housing from vice and mounting plate. Install pinion housing.
  6. Clean pinion housing and mating face on IRD casing. Clean spacing washer. (Scheme 19) Install spacing washer to IRD. Lubricate NEW "O" ring with IRD fluid and install to groove in pinion housing.
  7. Install pinion housing to IRD casing. Install exhaust bracket and heat shield, secure with nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Install nut securing heat shield to IRD and tighten to specification.
  8. Install remaining nuts securing pinion housing and tighten all nuts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Ensure mating face of drive shaft and IRD drive flange are clean.
  9. Install drive shaft to IRD flange and align reference marks. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Install front exhaust pipe. Lower axle and remove support.
  10. Fill IRD to correct level with fluid. See «INTERMEDIATE REDUCTION DRIVE (IRD)»(ref-165921-S04183210712004090800000) under OIL DRAIN & REFILL PROCEDURE. Install underbelly panel. See «UNDERBELLY PANEL»(ref-165921-S18267577202004090800000) under REMOVAL & INSTALLATION.
  11. Remove stands and lower vehicle. Connect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS.
  1. Remove Intermediate Reduction Drive (IRD) unit. See «INTERMEDIATE REDUCTION DRIVE UNIT»(ref-165921-S22897292772004090800000).
  2. Remove 8 bolts securing end cover to main case of IRD. (Scheme 15) Remove end cover.
  3. Remove intermediate shaft and differential from primary shaft. (Scheme 22)
  4. Remove primary shaft from main case. (Scheme 23) Remove 2 seals from primary shaft. Remove 2 primary shaft inner oil seals from main case. (Scheme 24)

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Clean primary gear shaft and intermediate shaft and differential. Clean seal locations. Install seal to each end of primary gear shaft with seal lips facing outwards.
  2. Install primary gear shaft to main case. Install suitable protection over splines on intermediate shaft. Carefully install intermediate shaft to primary shaft.
  3. Clean remains of old sealant from mating faces of end cover and IRD main case. Apply a narrow bead of sealant, Part No. STC 4600 to mating face of end cover. (Scheme 16)
  4. Install end cover to IRD and tighten bolts progressively to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  5. Install seal protector, part of LRT-41-015 to IRD splines. (Scheme 25) Using plain end of LRT-41-015, install inner seal into main case until it contacts shoulder.
  6. Using flanged end of LRT-41-015 install outer seal to depth dictated by tool flange. Remove oil seal protector. Install IRD unit. See «INTERMEDIATE REDUCTION DRIVE UNIT»(ref-165921-S22897292772004090800000).

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26
  1. Raise and support vehicle. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS. Remove underbelly panel. See «UNDERBELLY PANEL»(ref-165921-S18267577202004090800000) under REMOVAL & INSTALLATION.
  2. Remove bolt securing engine lower steady to beam. (Scheme 11) Remove 4 bolts securing anti-roll bar saddle clamps to beam. (Scheme 27) Support anti-roll bar.
  3. Loosen nuts securing lower arm rear mountings. (Scheme 28) Remove 2 bolts securing each lower arm rear bushing housing. (Scheme 29)
  4. Remove lower arm pivot bushing bolts. (Scheme 29) Release lower arms from beam. Support beam and remove 2 remaining bolts securing beam. (Scheme 30) Lower and remove beam.
  5. Loosen clip and disconnect fresh air intake hose from acoustic cover. Loosen clip and disconnect air intake hose from Air Flow Meter also known as Mass Air Flow (MAF) sensor. Release 2 turnbuckles securing acoustic cover to left camshaft cover. Release retaining strap and remove acoustic cover.
  6. Release pre-catalytic converter H02S harness from clips. (Scheme 5) Release and disconnect HO2S connector. Loosen tail pipe clamp nut. Release 2 rubber mountings from tail pipe and remove tail pipe and silencer. Remove 3 bolts and remove left heat shield. (Scheme 6)
  7. Remove 2 nuts securing intermediate pipe to front pipe. Loosen nut securing intermediate pipe clamp to catalytic converter. Release intermediate pipe from mounting. Release and remove intermediate pipe. Remove and discard gasket.
  8. Remove 2 bolts and remove right heat shield. (Scheme 7) Release post catalytic converter HO2S harness from clips. (Scheme 8) Release and disconnect post catalytic converter HO2S connector.
  9. Remove 2 bolts securing pipe clamp and remove clamp. (Scheme 9) Remove 2 nuts securing catalytic converter, remove catalytic converter and discard gasket. (Scheme 10)
  10. Using a 3/8" drive breaker bar, raise ancillary drive belt tensioner and release drive belt from alternator and PAS pump pulleys. Remove 3 bolts securing A/C compressor to mounting brackets and position compressor aside. Remove compressor heat shield.
  11. Release and disconnect HO2S connector. Release HO2S harness from clip. Release and disconnect post catalytic converter HO2S connector. (Scheme 31)
  12. Release HO2S harness from clips. Remove 2 nuts securing exhaust front pipe to exhaust manifold. (Scheme 32) Remove 4 nuts securing manifold and remove exhaust manifold. (Scheme 33) Remove and discard manifold and down pipe gaskets.
  13. Drain fluid from Intermediate Reduction Drive (IRD). Drain JATCO A/T. See appropriate procedure under «OIL DRAIN & REFILL PROCEDURE»(ref-165921-S31012641032004090800000) under LUBRICATION.
  14. Remove 3 bolts securing right splash shield to body and remove shield. (Scheme 34) Secure LRT-54-026 to drive shaft inboard joint. (Scheme 1) Using a suitable lever, release drive shaft from IRD.
  15. With assistance, pull hub outwards and release axle shaft from IRD. Remove and discard drive shaft circlip. Reference mark front drive shaft to drive flange for reassembly. (Scheme 17)
  16. Raise one rear wheel for rotation of drive shaft to access bolts. Remove 6 nuts and bolts securing drive shaft to IRD drive flange. Release drive shaft from IRD drive flange and tie shaft aside.
  17. Remove nut securing manifold heat shield to IRD unit. (Scheme 18) Remove nut securing heat shield to IRD pinion housing. Remove 2 bolts securing heat shield and remove heat shield.
  18. Disconnect breather hose from IRD housing. (Scheme 35) Position container to collect coolant spillage. Release clips and disconnect coolant hoses from IRD. (Scheme 36)
  19. Remove bolt securing engine lower steady to IRD support bracket. (Scheme 11) Remove lower engine steady noting that TOP mark on engine steady faces upward.
  20. Remove 3 bolts securing IRD support bracket to sump. (Scheme 12) Remove 2 bolts securing IRD support bracket to engine front mounting plate. (Scheme 13)
  21. Remove 5 bolts securing support bracket to IRD. (Scheme 14) Remove support bracket. Remove 4 bolts securing IRD. (Scheme 37)
  22. With assistance, release IRD from transmission and remove. Remove and discard "O" ring from IRD. see scheme 2

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
  1. Clean mating faces of IRD and transmission. Lubricate and fit NEW "O" ring. With assistance, install IRD. Install bolts securing IRD to transmission and tighten sufficiently only to pull mating faces of IRD and transmission together at this stage.
  2. Install IRD support bracket and tighten bolts sufficiently only to pull mating faces together. Final tighten bolts securing IRD to transmission to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  3. Final tighten IRD support bracket bolts to specification in the following sequence: Bolts (5) securing support bracket-to-IRD. (Scheme 14) Bolts (2) securing support bracket-to-engine front mounting bracket. (Scheme 13) Bolts (3) securing support bracket-to-sump. (Scheme 12) See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  4. Position lower engine steady, TOP mark facing upward. Install bolt but DO NOT tighten at this stage. Connect coolant hoses and secure with clips. Connect breather hose to IRD housing.
  5. Install manifold heat shield and install nut securing heat shield to pinion housing finger tight. Install bolts securing manifold heat shield to IRD support bracket and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  6. Install nut securing heat shield to IRD and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Final tighten nut securing manifold heat shield to IRD pinion housing to specification.
  7. Clean drive shaft flange and mating face. Install drive shaft to IRD flange, align marks and tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Inspect axle shaft oil seal, renew if worn or damaged.
  8. Clean axle shaft and flange splines. Install NEW circlip to axle shaft. With assistance, pull hub outwards, align axle shaft and install to IRD taking care not to damage oil seal. Install splash shield and secure with bolts.
  9. Position and align rear beam. Install NEW bolts securing rear beam to body, but do not fully tighten at this stage. Locate lower arm bushings, install but do not fully tighten bolts.
  10. Clean bushing housing and mating faces on rear beam. Align bushing housings ensuring roll pin is correctly located. Install bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  11. Tighten rear beam-to-body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Install anti-roll bar saddle clamp bolts and tighten to specification. Align engine lower steady, install bolt and tighten to specification.
  12. Lower vehicle. Tighten lower arm front bushing bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Tighten lower arm rear bushing nuts to specification.
  13. Final tighten bolt securing lower engine steady-to-IRD support bracket to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Fill IRD to correct level with fluid. See «INTERMEDIATE REDUCTION DRIVE (IRD)»(ref-165921-S04183210712004090800000) under OIL DRAIN & REFILL PROCEDURE.
  14. Clean right catalytic converter and mating face. Using a NEW gasket, install catalytic converter and nuts, but do not tighten at this stage. Install exhaust pipe clamp and bolts, but do not tighten at this stage. Connect post catalytic converter H02S connector and install to bracket. Install HO2S harness into clips.
  15. Install heat shields and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  16. Clean intermediate pipe and mating faces. Install NEW gasket to front pipe flange. Install intermediate pipe and connect mounting. Tighten intermediate pipe flange nuts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  17. Install tail pipe and silencer. Clean mating faces of tail pipe and intermediate pipe. Install tail pipe and connect rubber mountings. Tighten tail pipe clamp nut to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  18. Tighten catalytic converter-to-manifold nuts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Tighten bolts securing clamp to specification. Connect pre-catalytic converter H02S connector and install to bracket. Install harness into clips. Install acoustic cover.
  19. Clean left exhaust manifold and mating faces. Using NEW gaskets, install exhaust manifold and tighten nuts to cylinder head to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Connect H02S connectors, secure connectors to brackets and harness to clips.
  20. Clean A/C compressor and mounting bracket mating faces. Install compressor heat shield. Position compressor to mounting and align heat shield. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  21. Using a 3/8" drive breaker bar, raise ancillary drive belt tensioner and install drive belt to pulleys. Install underbelly panel. See «UNDERBELLY PANEL»(ref-165921-S18267577202004090800000) under REMOVAL & INSTALLATION.
  22. Install engine acoustic cover. Connect air intake and air bypass hoses, secure clip. Connect fresh air intake hose to acoustic cover and tighten clip screw.
  23. Fill JATCO A/T with fluid. See «JATCO A/T - DRAIN & REFILL»(ref-165921-S04695266992004091300000) under DRAIN & REFILL PROCEDURE.
  24. Connect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(ref-165921-S35898369032004090800000) under SERVICE PRECAUTIONS. Refill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167278-S18627052362004101200000) in ENGINE COOLING article.
  1. Remove both rear axle shafts. See «AXLE SHAFTS - REAR»(ref-165949-S32238732062004101200000) in AXLE & DRIVE SHAFTS article. Reference mark rear drive shaft and pinion flanges to aid reassembly. (Scheme 38) Position container to catch oil spillage.
  2. Remove 4 nuts and bolts securing drive shaft to differential. (Scheme 38) Release drive shaft and tie aside.
  3. Support weight of differential assembly on a jack. Remove 2 bolts securing differential to front mounting. (Scheme 39) Depress Red locking collar and disconnect breather pipe from differential casing. (Scheme 40)
  4. Remove 4 bolts securing differential assembly to rear mountings. (Scheme 41) With assistance, rotate differential assembly through 90 degrees and remove from subframe.

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41
  1. With assistance position differential assembly to subframe and locate in mountings. Install bolts, but DO NOT tighten at this stage. Position Centralizing Jig LRT-51-013 to align differential assembly. (Scheme 42)
  2. Tighten forward bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Tighten rearward bolts to specification and remove LRT-51-013. Connect breather pipe.
  3. Position rear drive shaft to rear differential and align reference marks. Install and tighten nuts and bolt securing drive shaft to rear axle to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  4. Install axle shafts. Check differential oil level. See «OIL DRAIN & REFILL PROCEDURE»(ref-165921-S31012641032004090800000) under LUBRICATION.

Scheme 42

Scheme 42
Scheme 42

Removal & Installation (Front Mounting)

  1. Remove rear differential rear mounts. See «REMOVAL & INSTALLATION (REAR MOUNTINGS)»(ref-165921-S00476146422004091000000).
  2. Remove 2 bolts securing right mounting to differential. Remove 2 bolts securing front mounting to differential. Remove bolt securing front mounting subframe. (Scheme 43) Ease differential away from front mounting and remove front mounting.
  3. To install, ease differential away from front mounting and install front mounting. Ensure differential is correctly located in Centralizing Jig LRT-51-013. (Scheme 42)
  4. Install bolt securing mounting bushing to subframe and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  5. Install bolts securing front mounting to differential and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Tighten right mounting bolts to specification. Install left mounting bolts and tighten to specification.

Scheme 43

Scheme 43
Scheme 43

Removal & Installation (Rear Mountings)

  1. Raise and support rear of vehicle. Position Centralizing Jig LRT-51-013 to align differential assembly. (Scheme 42) Remove bolt securing differential mounting to subframe.
  2. Remove 2 bolts securing left mounting to differential. (Scheme 41) Remove left mounting.
  3. Remove bolt securing differential mounting to subframe. Remove 2 bolts securing mounting to differential. Remove mounting.
  4. To install, position differential mounting. Install bolts securing mounting to differential and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  5. Install bolt securing mounting to subframe and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000). Remove Centralizing Jig LRT-51-013. (Scheme 42) Remove supports and lower vehicle.
  1. Raise and support rear of vehicle. Position container to catch oil spillage.
  2. Remove oil level plug. Remove 10 bolts securing rear cover to differential casing. Remove rear cover. (Scheme 44)

Scheme 44

Scheme 44
Scheme 44
  1. Clean rear cover, mating face on differential and sealant from bolts and bolt threads. Apply sealant, Part No. STC 3811 to casing and install rear cover.
  2. Apply sealant, Part No. STC 50552 to threads of rear cover bolts. Install rear cover bolts and tighten in a crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) .
  3. Fill differential with oil. See «REAR DIFFERENTIAL»(ref-165921-S31156943972004090800000) under DRAIN & REFILL PROCEDURE. Install filler/level plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000) . Remove support and lower vehicle.
  1. Remove both axle shafts. See «AXLE SHAFTS - REAR»(ref-165949-S32238732062004101200000) in AXLE & DRIVE SHAFTS article. Reference mark rear drive shaft and pinion flanges to aid reassembly. (Scheme 38)
  2. Remove 4 nuts and bolts securing drive shaft to differential. (Scheme 38) Release drive shaft and tie aside.
  3. Check and record pinion preload torque-to-turn required to rotate pinion and differential. Using Spanner Wrench LRT-51-003 to restrain differential flange, remove nut and washer securing pinion flange. (Scheme 20) Discard nut.
  4. Remove pinion flange. Carefully remove and discard oil seal, take care not to damage oil seal recess. (Scheme 45) Remove oil slinger. Remove pinion bearing inner race. Remove and discard collapsible spacer.

Scheme 45

Scheme 45
Scheme 45
  1. Install NEW collapsible spacer. Install pinion bearing inner race and oil slinger. (Scheme 45) Clean pinion flange and oil seal recess.
  2. Install NEW oil seal using Seal Installer LRT-51-010. (Scheme 46) Install pinion flange and washer.
  3. Restrain pinion flange using Spanner Wrench LRT-51-003. (Scheme 20) Install NEW pinion nut and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  4. Check for pinion end float. If end float exists continue to tighten pinion nut until end float is removed. Continue to tighten pinion nut until pinion preload torque-to-turn is 15.0-24.8 INCH lbs. (1.7-2.8 N.m), if pinion preload is higher, replace collapsible spacer.
  5. Clean drive shaft flange and mating face. Position drive shaft to differential flange and align reference marks. Tighten drive shaft nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165921-S04959808072004090800000).
  6. Install axle shafts. See «AXLE SHAFTS - REAR»(ref-165949-S32238732062004101200000) in AXLE & DRIVE SHAFTS article. Check differential oil level. See «OIL DRAIN & REFILL PROCEDURE»(ref-165921-S31012641032004090800000) under LUBRICATION.

Scheme 46

Scheme 46
Scheme 46

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