Differential Output Shaft Bearing: Service and Repair

Removal





1. Disconnect the battery ground lead.
2. Raise the vehicle for access.

3. NOTE: In the wheel-free condition, the axle is in tension & the flanges will separate as the nuts are withdrawn.





Release the axle shaft.
Match mark the output & axle shaft flanges (if the output shaft is to be re-used).
Remove & discard the (4) nuts axle shaft to differential output shaft.
Remove & keep safe the camber shim.
4. Thoroughly clean the area around the output shaft housing & differential case.





5. Release the circlip & withdraw the output shaft assembly.
6. Prepare the retaining collar for removal.
Mark the bearing retaining collar axially.

CAUTION: Do not drill into the output shaft, it is not necessary to break the inside diameter of the collar.





Drill 3 off holes 4.0 mm in diameter equally spaced, to a MAXIMUM depth of 5.0 mm





7. Remove the retaining collar.

CAUTION: There is no need to split the collar when chiseling.

With a suitable chisel strike the collar across the three drilled holes (along the axis of the output shaft) to relieve tension within the steel.

CAUTION: The original bearing must NOT be reused.

Using a suitable press remove & discard the bearing, collar & circlip.

Installation
1. Inspect the output shaft for damage & corrosion, replace as necessary.





2. Identify the circlip cross section.
This circlip is correct.
This circlip MUST be discarded & the correct one used.





3. Fit the bearing using special tool 204 - 083.
Position a new circlip.
Locate the bearing.
Locate the collar.

NOTE: It is strongly recommended that a press equipped with a pressure gauge is used, the assembly load MUST exceed 20 Kn.

Press the assembly.





4. Fit the output shaft assembly to the final drive.
Lubricate the 'O' ring & seat the shaft assembly.
Secure the assembly with the circlip.
5. Ensure the correct circlip location.





Using a prybar, or similar, expand the circlip into its undercut by applying outward radial pressure. Start diametrically opposite to the circlip open ends & lever against the drive flange.
6. Verify the circlip location.





The gap MUST be greater than 10.0 mm

CAUTION: If the gap CANNOT be achieved, contact Jaguar Service.

A gap smaller than specified will indicate an improperly fitted circlip. This may be rectified by refitting or by the application of radial pressure around the inner circumference of the circlip.
7. Verify that the output shaft end-float is within specification.





8. Refer to the illustration.
If appropriate realign the previously made match marks.
9. Check the final drive oil level & adjust as required.
10. Check & adjust rear wheel camber setting.