Final Drive, Replacing

Final drive, replacing






Removal

Preparations

Note! Check that the parking brake is not applied and that the gear selector is in position P or in gear.

Ignition off
Position the rear lifting arms so that they do not obstruct the front brackets securing the rear axle arms to the body.

Removing drive shafts
Remove the drive shafts on both sides according to: Drive shaft rear, replacing, TF-80SC AWD Drive Shaft Rear, Replacing.

Removing the spare wheel and rear section of the exhaust system




Remove the rear section of the exhaust system and the spare wheel.
Support the rear edge of the three-way catalytic converter (TWC) so as not to put strain on the exhaust manifold.
Remove the propeller shaft from the final drive and the member for the center bearing. See Propeller Shaft, B6324S5, TF-80SC AWD Propeller Shaft.

Removing the screws for the center bearing member and propeller shaft
Tie up the shaft.
Use the rear cross member as support.
Remove one screw and slacken off the other. Turn out the member.

Removing the cable harness




Remove the connector from the Differential Electronic Module (DEM).
Detach the cable harness from the final drive housing and the mounting in the rear axle member.
Fold the cable harness to one side to prevent damage when removing the final drive.

Removing the final drive





Remove:
- the cover for the rear axle member
- the screw for the front mounting for the final drive housing.
Slacken off the 2 rear screws for the rear axle member/final drive housing. Leave the screws in place by a few threads.

Removing the rear axle member




Bring 998 5972 JACK 998 5972 JACK into light contact with the front section of the rear axle member.
Remove the screws from the front mounting in the body for the rear axle member, on both sides.
Carefully lower the frame. Remove the jack.

Removing the final drive housing




Support the final drive housing. Remove the two loose screws.
Lift out the final drive housing from the rear axle member. Position the final drive housing on a workbench.

Installation

Note! For tightening torques, see: Tightening torque Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Removal and Replacement.

Installing the rear axle member




Install the final drive housing in the rear axle member. Loosely secure the final drive housing to the rear bushings in the frame using screws.
Bring 998 5972 JACK 998 5972 JACK into light contact with the front section of the rear axle member.

Install:
- the screws for the front mounting in the body for the rear axle member, on both sides.
- the 2 x M12 screws for the bracket/body. Tighten.
- the M14 screw for the bracket, the rear axle frame and body. Tighten. See: Tightening torque, B6324S5 Tightening Torque.
Remove 998 5972 JACK 998 5972 JACK.

Installing the final drive housing





Install:
- 1 M12 front screw for the final drive housing. Tighten
- the cover for the rear axle member using 4 M12 screws. Tighten
- the 2 x rear M12 screws for the subframe/final drive housing. Tighten.

Installing the cable harness




Connect the connector for the differential electronic module (DEM). Install the cable harness in the mounting in the rear axle member.
Install the propeller shaft on the final drive. Install the member for the center bearing. See: Propeller Shaft, B6324S5, TF-80SC AWD Propeller Shaft.

Installing drive shafts
Install the drive shafts on both sides according to: Drive shaft rear, replacing, TF-80SC AWD Drive Shaft Rear, Replacing.

Installing the spare wheel and rear section of the exhaust system




Check that the gasket for the flanged joint between the front and rear exhaust pipe is not damaged. Replace if necessary.
Install the rear cross member. Use 2 x M8 screws. Tighten.

Filling and checking the oil level




Top up and check the oil level in the active on demand coupling (AOC).
Use oils, see: Lubricant transmission Capacity Specifications
Tighten both the level plugs. See: Tightening torque Tightening Torque.
Top up and check the oil level in the rear axle gear.
Use oils, see: Lubricant transmission Capacity Specifications
Tighten both the level plugs. See: Tightening torque Tightening Torque.