NRRWM 21/11/01 11:21 am Page 1

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Workshop Manual (2006MY)

Service Procedures: SECTION 2 - Chassis
PART 205: DRIVELINE
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WSM-6107 Range Rover L322 2006MY
Table of Contents
SECTION 2: Chassis
205: Driveline
205-01: Driveshaft
205-01-01: General Specification
205-01-02: Description and Operation
205-01-03: Universal Joints
205-01-04: Front Driveshaft – V8 4.4L Petrol/V8 S/C 4.2L Petrol
205-01-05: Rear Driveshaft – V8 4.4L Petrol/V8 S/C 4.2L Petrol
205-02: Rear Drive Axle/Differential
205-02-01: General Specification
205-02-02: Description and Operation
205-02-03: Differential Draining and Filling
205-02-04: Drive Pinion Seal
205-02-05: Axle Assembly
205-03: Front Drive Axle/Differential
205-03-01: General Specification
205-03-02: Description and Operation

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205-03-03: Differential Draining and Filling
205-03-04: Axle Assembly V8 4.4L Petrol, LHD AWD
205-04: Front Drive Halfshafts
205-04-01: Description and Operation
205-04-02: Halfshaft Joint
205-04-03: Halfshaft Seal LH
205-05: Rear Drive Halfshafts
205-05-01: General Specification
205-05-02: Description and Operation
205-05-03: Rear Halfshaft
205-05-04: Outer Constant Velocity (CV) Joint Boot
205-05-05: Inner Constant Velocity (CV) Joint Boot
Published: 11-May-2011
Driveshaft -
Front Drive (Propeller) Shaft
Item Specification
Type One piece, variable length steel tube.
Constant velocity joints Plunging type, installed at front and rear.

Rear Drive (Propeller) Shaft

Item Specification
Two piece, variable length steel tube with isolated centre bearing and swaged front section to provide
Type
controlled collapse of the shaft during a crash.
Constant Plunging constant velocity joints are positioned at the front and rear of the shaft with a, fixed Hookes type
velocity joints universal joint at the centre.

Torque Specifications
Description Nm lb-ft
* Front driveshaft to front axle drive flange Torx bolts:
Stage 1 45 33
Stage 2 Further 90° Further 90°
* Front driveshaft to transfer case drive flange Torx bolts:
Stage 1 45 33
Stage 2 Further 90° Further 90°
* Rear driveshaft to rear axle drive flange Torx bolts
Stage 1 42 31
Stage 2 Further 45° Further 45°

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* Rear driveshaft to transfer case drive flange Torx bolts
Stage 1 42 31
Stage 2 Further 45° Further 45°
Rear driveshaft center bearing bolts 21 15
Fuel tank heat shield bolts 5 4
Fuel tank heat shield nuts 3 2
* New 'Patched' Torx bolts must be installed
Published: 11-May-2011
Driveshaft - Driveshaft
Description and Operation

Driveshaft - Component Location

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Item Description
1 Front driveshaft
2 Rear driveshaft assembly

GENERAL

Drive shafts are used to transmit drive from the transfer box to the front and rear differentials.

The front drive shaft is a 1-piece unit, connected to the transfer box and front differential unit via Constant Velocity (CV)
joints.

The rear drive shaft is a 2-piece unit, supported on a central bearing due to its increased length. The rear drive shaft is
connected to the transfer box and the rear differential via CV joints. These joints allow for angular deviations of the drive shaft
due to acceleration and braking.
The front and rear drive shafts are not serviceable items and a failure will require the replacement of the complete drive shaft
assembly.

FRONT DRIVESHAFT

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Item Description
1 CV joint
2 Front drive shaft
The front drive shaft is constructed from 1.7 mm wall tubular steel. A CV joint is attached to each end of the drive shaft (see
'Halfshaft Joint' section for more information on CV joints). The shaft has an overall nominal length of 681 mm.

Each CV joint has 6 holes, which allow for attachment to the input flange of the front differential and the front output flange of
the transfer box. The CV joints are secured to the front differential and transfer box with 6 Torx head adhesive retained bolts.

Three compression link washers are fitted under each pair of bolts. The washers are required to prevent compression of the
CV joints attachment flange.

A shroud is pressed over the CV joint. The shroud seals to the joint body using an internal gasket and to the front output
flange of the transfer box using an end cap and internal gasket. This prevents the ingress of dirt and moisture. The CV joints
allow for movement of the drive shaft caused by small movements in the transmission and transfer box mountings.

REAR DRIVESHAFT ASSEMBLY

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Item Description
1 Washer
2 Bolt
3 Driveshaft - Front
4 Bolt M12 (6 off)
5 Shim (3 off)
6 Nut (2 off)
7 Shaft bearing assembly
8 Driveshaft - Rear
9 Bolt M12 (6 off)
10 Shim (3 off)
The rear driveshaft comprises front and rear shaft assemblies and a centrally mounted shaft bearing. The rear driveshaft has
an overall length of 1282 mm.

Front Shaft Assembly

The front shaft assembly incorporates a crash feature within the tube, which controls the collapse of the drive shaft during a
crash.
The front shaft assembly comprises a CV joint at the front and a splined shaft at the rear. The front shaft comprises a tube
with welded, splined shafts at each end.

The forward splined shaft accepts the CV joint, which is secured with a circlip. The CV joint is packed with grease and sealed
on both sides with metal shrouds to prevent the ingress of dirt and moisture. The CV joint (transfer box end) has 6 radial
holes, which provide for the attachment to the transfer box rear output flange. The joint is secured to the output flange with 6
bolts, which screw into threaded holes in the flange. Three compression link washers are fitted under each pair of bolts. The
CV joint is not a serviceable component and a failure would require replacement of the rear driveshaft assembly. The rear
splined shaft mates with splines in the rear shaft universal joint and is pressed in and fixed with Locktite. A threaded hole is
provided in the splined shaft to secure the front and rear driveshaft sections together. A machined surface on the shaft
accepts the shaft bearing, which is a press fit.

Shaft Bearing Assembly

The shaft bearing assembly comprises a pressed steel housing, a rubber bush and a ball bearing. The rubber bush is bonded
into the housing. An internal metal ring, bonded to the bush, allows for the bearing to be press fitted into it. The rubber bush
allows for small deviations in alignment and also absorbs vibrational forces. The shaft bearing assembly is located on studs,
which are integral with the body, and secured with flanged nuts.

Rear Shaft Assembly

The rear shaft assembly comprises a universal joint at the front and a CV joint at the rear. The rear shaft comprises a tube
with the welded universal joint at one end and a welded splined shaft at the opposite end.

The opposite end of the universal joint has a splined bore, which mates with the splined shaft on the rear of the front shaft
assembly. A bolt and washer is fitted through the splined bore and screws into the splined shaft on the front shaft assembly,
securing the front and rear shaft assemblies together.

The rear CV joint (final drive end) has 6 radial holes, which provide for the attachment to the rear differential input flange.

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The joint is secured to the input flange with 6 torx bolts, which screw into threaded holes in the flange. Three compression
link washers are fitted under each pair of bolts. The rear splined shaft mates with splines in the rear shaft CV joint hub and is
pressed in and fixed with Locktite.
Published: 11-May-2011
Driveshaft - Universal Joints
Description and Operation

Item Description
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1 Universal joint
2 Rear shaft assembly
3 Front shaft assembly
The rear driveshaft is a 2-piece unit with a universal joint connecting the rear shaft assembly to the front shaft assembly. This
configuration allows for angular deviations of the driveshaft due to acceleration and braking.

The rear shaft assembly comprises a tube with the welded universal joint at the front and a Constant Velocity (CV) joint at the
rear. The front shaft assembly comprises a tube with a CV joint at the front and a welded splined shaft at the rear.

The front splined shaft mates with splines in the rear shaft universal joint. A threaded hole is provided in the splined shaft to
secure the front and rear shaft assemblies together.
Published: 11-May-2011
Driveshaft - Front Driveshaft V8 4.4L Petrol/V8 S/C 4.2L Petrol
Removal and Installation

Removal

CAUTION: It is possible to fit the driveshaft incorrectly. Note the orientation before removal.

NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect the
operation or durabilty of the joint.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

2.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

3. Remove the transmission support crossmember.

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For additional information, refer to: Transmission Support
Crossmember - V8 4.4L Petrol/V8 S/C 4.2L Petrol (502-02 Full Frame
and Body Mounting, Removal and Installation).

4. CAUTIONS:

Mark the position of the driveshaft flange in

relation to the drive pinion flange.

To avoid damage to the joint or gaiter, do not

allow the driveshaft to hang.

Release the driveshaft from the transfer case drive

flange.
Remove the 6 Torx bolts and washers, discard the
bolts.

5. CAUTIONS:

Mark the position of the driveshaft flange in

relation to the drive pinion flange.

To avoid damage to the joint or gaiter, do not

allow the driveshaft to hang.

Release the driveshaft from the front axle drive flange.

Remove the 6 Torx bolts and washers, discard the
bolts.

6. Remove the front driveshaft.

Compress the joints to disengage the drive flanges.
Installation

1.
NOTE: A small amount of oil may weep from the driveshaft
joints during storage. The loss of this oil will not affect the operation
or durabilty of the joint.

Install the driveshaft.

Clean the components.
Compress the joints to engage the drive flanges.

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2. Attach the driveshaft to the front axle drive flange.
Tighten the new Torx bolts to 45 Nm (33 lb.ft), then a further
90 degrees.

3. Attach the driveshaft to the transfer case drive flange.

Tighten the new Torx bolts to 45 Nm (33 lb.ft), then a further
90 degrees.

4. Install the transmission support crossmember.

For additional information, refer to: Transmission Support
Crossmember - V8 4.4L Petrol/V8 S/C 4.2L Petrol (502-02 Full Frame
and Body Mounting, Removal and Installation).

5. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).
Published: 11-May-2011
Driveshaft - Rear Driveshaft V8 4.4L Petrol/V8 S/C 4.2L Petrol
Removal and Installation

Removal

NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect the
operation or durability of the joint.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Charging
System - General Information, Specifications).

2.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

3. Remove the exhaust system.

For additional information, refer to: Exhaust System (309-00A Exhaust
System - V8 S/C 4.2L Petrol, Removal and Installation).

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4. Remove the center heat shield.
Remove the 8 nuts.

5. Remove the fuel tank heat shield.

Remove the 8 screws.

6. CAUTIONS:

Mark the position of the driveshaft flange in

relation to the drive pinion flange.

To avoid damage to the joint or gaiter, do not

allow the driveshaft to hang.
 Release the driveshaft from the transfer case drive
flange.
Remove the 6 Torx bolts and washers.

7. CAUTIONS:

Mark the position of the driveshaft flange in

relation to the drive pinion flange.

To avoid damage to the joint or gaiter, do not

allow the driveshaft to hang.

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Release the driveshaft from the rear axle drive flange.
Remove the 6 Torx bolts and washers.

8. With assistance, remove the driveshaft.

Remove the 2 driveshaft center bearing mount
nuts.

Installation

1.
CAUTION: It is possible to fit the driveshaft incorrectly. The
universal joint must be rearward of the center bearing when installed
in the vehicle.

NOTE: A small amount of oil may weep from the driveshaft

joints during storage. The loss of this oil will not affect the operation
or durability of the joint.

Attach the driveshaft to the rear axle drive flange.

Clean the component mating faces.
Tighten the Torx bolts to 44 Nm (32 lb.ft), then a further 45
degrees.

2.
 NOTE: A small amount of oil may weep from the driveshaft
joints during storage. The loss of this oil will not affect the operation
or durability of the joint.

Attach the driveshaft to the transfer case drive flange.

Clean the component mating faces.
Tighten the Torx bolts to 44 Nm (32 lb.ft), then a further 45
degrees.

3.
CAUTION: Make sure the center bearing mount is not under
tension and central within the slots.

Attach the driveshaft center bearing mount.

Align the center bearing mount.
Tighten the nuts to 21 Nm (15 lb.ft).

4. Install the fuel tank heat shield.

Tighten the screws.

5. Install the center heat shield.

Tighten the nuts.

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6. Install the exhaust system.
For additional information, refer to: Exhaust System (309-00A Exhaust
System - V8 S/C 4.2L Petrol, Removal and Installation).

7. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00 Charging
System - General Information, Specifications).
Published: 11-May-2011
Rear Drive Axle/Differential -
Lubricants
Item Specification
* Recommended lubricant Castrol SAF-XO - 75W/90
Capacity 1.1 liters (2.3 US pints)
* Do not use any lubricant other than that specified

General Specifications
Item Specification
Reduction ratio:
V8 Petrol engine - Automatic transmission 3.73:1

Torque Specifications
Description Nm lb-ft
Oil drain plug 54 40
Oil filler plug 34 25
Differential front mounting bolts 100 74
* Differential rear mounting nut/bolt:
Stage 1 120 88
Stage 2 Further 180° Further 180°
** Driveshaft to rear axle drive flange Torx bolts:
Stage 1 44 32
Stage 2 Further 45° Further 45°

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** Driveshaft to transfer case output flange Torx bolts:
Stage 1 44 32
Stage 2 Further 45° Further 45°
Driveshaft centre bearing bolts 19 14
Road wheel nuts 140 103
* New nut must be installed

** New 'Patchlok' Torx bolts must be installed

Published: 11-May-2011
Rear Drive Axle/Differential - Rear Drive Axle and Differential
Description and Operation

REAR DIFFERENTIAL - Td6

Component Location -Td6

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Item Description
1 RH rear drive halfshaft
2 Rear differential
3 LH rear drive halfshaft
4 Rear driveshaft assembly
The rear differential converts the "angle of drive" through 90° and distributes drive, via the rear drive halfshafts, to the rear
wheels.

The rear differential is located centrally in the rear subframe. The front of the differential is attached to the subframe via
rubber bushes and bolts. The rear of the differential is mounted to the subframe via a single, offset rubber bush and a bolt.

The casing comprises two parts. The pinion housing is made from cast iron and provides locations for all the internal
components. The pinion housing is sealed at the rear by an aluminium casting which is secured to the pinion housing with
eight bolts and spring washers. A gasket between the two casings seals the unit. The rear cover has cast fins which assist
heat dissipation. A breather tube is fitted to the rear cover. This allows a plastic tube to be fitted and routed to a high point
under the vehicle body, preventing the ingress of water when the vehicle is wading.

The rear cover contains an oil level plug which allows for oil filling and level checking, with the differential installed in the
vehicle. The level plug allows the unit to be filled with oil until it leaks from the filler hole, ensuring the correct quantity of oil
is added. The differential unit contains approximately 1.2 litres of oil from a dry fill. If oil is being replaced, a smaller quantity
of oil will be required due to residual oil retained in the pinion housing.

The differential is a conventional design using a hypoid gear layout, similar to the front differential. The rear differential is
available in two ratios. V8 engine vehicles use a differential with a final drive ratio of 3.73:1 and Td6 engine vehicles use a
final drive ratio of 4.10:1. The ratio is changed by changing the amount of teeth between the crown wheel drive gear and
pinion gear. Therefore for a ratio of 4.10:1, the crown wheel drive gear will have 4.10 times more teeth than the pinion gear.
This equates to the crown wheel drive gear having 41 teeth and the pinion gear having 10 teeth.

Rear Differential Sectional View - Td6

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Item Description
1 Input flange
2 Bush mounting holes
3 Taper roller bearing
4 Collapsable spacer
5 Taper roller bearing
6 Snap ring
7 Oil seal
8 RH output flange
9 Taper roller bearing
10 Gasket
11 Sun wheel (RH drive shaft output)
12 Snap ring
13 Planet gear (2 off)
14 Shaft
15 Snap ring
16 Rear cover
 17 Crown wheel gear bolt (10 off)
18 Rear cover bolt (8 off)
19 Sun wheel (LH drive shaft output)
20 Carrier
21 LH output flange
22 Oil seal
23 Taper roller bearing
24 Crown wheel drive gear
25 Pinion gear
26 Pinion housing
27 Pinion shaft
28 Oil seal
29 Nut retainer
30 Flanged nut.
The differential comprises a pinion shaft and spiral bevel pinion gear and a crown wheel drive gear with an integral cage which
houses two planet gears. Two sun wheels are also located in the cage and pass the rotational drive to the drive shafts.

The pinion shaft is mounted on two opposed taper roller bearings, with a collapsable spacer located between them. The spacer
is used to hold the bearings in alignment and also collapses under the pressure applied to the pinion flanged nut. This allows
the flanged nut to be tightened by measuring the torque-to-turn, which collapses the spacer, setting the correct bearing
preload.

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The pinion shaft has an externally splined outer end which accepts and locates the input flange, which is retained by the
pinion nut. The output flange has six threaded holes and mates with the rear propeller shaft. Six bolts secure the rear
propeller shaft to the input flange. An oil seal is pressed into the pinion housing and seals the input flange to the pinion
housing. The pinion shaft has a spiral bevel gear at its inner end which mates with the crown wheel drive gear.

The crown wheel drive gear is located on the carrier and secured with ten screws. The carrier is mounted on taper roller
bearings located in machined bores on each side of the pinion housing. The bearings are retained in the casing by a circlip,
the thickness of which is selected to apply the correct bearing preload.

The carrier has a through hole which provides location for the shaft. The shaft provides the mounting for the planet gears in
the carrier cage. The shaft is fitted with a snap ring at one end which locates in a machined groove in the carrier, locking the
shaft in position.

The sun wheels are located in pockets in the carrier cage and mesh with the planet gears. Spacers are fitted between the sun
wheels and the carrier and set the correct mesh contact between the planet gears and the sun wheels. Each sun wheel has a
machined bore with internal splines and machined groove near the splined end. The groove provides positive location for a
snap ring fitted to the end of each output flange.

Each output flange has a splined shaft which located in each sun wheel. A snap ring fitted to the splined shaft locates in the
groove the sun wheel bore and positively located the output flange. Oil seals are pressed into each side of the pinion housing
and seal the output flange to the housing. Each output flange has six threaded holes which provide for the attachment of the
rear drive shafts.

The rear cover is located on the rear of the pinion housing and is sealed to the housing with a gasket and secured with eight
bolts.

Rear Differential Operation - Td6

The operating principles of the front and rear differentials are the same. Rotational input from the propeller shaft is passed via
the input flange to the pinion shaft and pinion gear. The angles of the pinion gear to the crown wheel drive gear moves the
rotational direction through 90°.

The transferred rotational motion is now passed to the crown wheel drive gear, which in turn rotates the carrier. The shaft,
which is secured to the carrier also rotates at the same speed as the carrier. The planet gears, which are mounted on the
shaft, also rotate with the carrier. In turn, the planet gears transfer their rotational motion to the left and right hand sun
wheels, rotating the drive shafts.

When the vehicle is moving in a forward direction, the torque applied through the differential to each sun wheel is equal. In
this condition both drive shafts rotate at the same speed. The planet gears do not rotate and effectively lock the sun wheels to
the carrier.

If the vehicle is turning, the outer wheel will be forced to rotate faster than the inner wheel by having a greater distance to
travel. The differential senses the torque difference between the sun wheels. The planet gears rotate on their axes to allow
the outer wheel to rotate faster than the inner one.

REAR DIFFERENTIAL - 4.2L AND 4.4L

Component Location - 4.2L and 4.4L

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Item Description
1 RH rear drive halfshaft
2 Rear differential
3 LH rear drive halfshaft
4 Rear driveshaft assembly
The rear differential converts the "angle of drive" through 90° and distributes drive, via the rear drive halfshafts, to the rear
wheels.

The rear differential for the 4.2L and 4.4L V8 petrol variants utilise the same output ratio and is located centrally in the rear of
the chassis.

The unit is mounted to the chassis via rubber bushes and bolts; two mounting points at the rear of the unit and one at the
front.

Rear Differential Exploded View - 4.2L and 4.4L

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Item Description
1 Cap
2 Seal
3 Bearing assembly, without race
4 Bearing pre-load spacer
5 Bearing
6 Roller bearing cup
7 Cover
 8 Seal
9 Differential carrier
10 Gear and pinion assembly
11 Bearing
12 Roller bearing cup
13 Shim
14 Collapsible spacer
15 Pinion nut
16 Retainer
17 Flange
18 Outer deflector
19 Inner deflector
20 Oil seal
21 Bearing
22 Roller bearing cup
23 Roll pin
24 Breather cap
25 Breather
26 Case

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27 Data location
28 Mounting bush
29 Bearing
30 Bearing pre-load spacer
31 Roller bearing cup
32 Plug
33 Drain plug
34 Thrust washer
35 Planet gears
36 Crosspin shaft
37 Sunwheel
38 Thrust washer
39 Bolt, 10 of
40 Bolt, 12 of
The cast iron casing comprises two parts; a cover and a carrier. The carrier provides locations for all the internal components.
The carrier is sealed to the cover via an O-ring seal and secured with twelve bolts. The cover and carrier have cast fins, which
assist mobility. A breather tube is fitted to the top of the carrier. This allows a plastic tube to be fitted and routed to a high
point under the vehicle body, preventing the ingress of water when the vehicle is wading.

The carrier contains an oil drain plug. The differential unit contains approximately 1.16 litres of oil from a dry fill. If oil is being
replaced, a smaller quantity of oil will be required due to residual oil retained in the pinion housing.

The differential is a conventional design using a hypoid gear layout, similar to the front differential and has a final drive ratio
of 3.73:1.

The differential comprises a pinion shaft and hypoid pinion gear and a crown wheel drive gear with an integral cage, which
houses two planet gears. Two sun wheels are also located in the cage and pass the rotational drive to the drive shafts.

The pinion shaft is mounted on two opposed taper roller bearings, with a collapsible spacer located between them. The spacer
is used to hold the bearings in alignment and also collapses under the pressure applied to the pinion-flanged nut. This allows
the flanged nut to be tightened by measuring the torque-to-turn, which collapses the spacer, setting the correct bearing
preload.

The pinion shaft has an externally splined outer end, which accepts and locates the input flange, which is retained by the
pinion nut and retainer. The input flange has four threaded holes and mates with the rear drive shaft. Four bolts secure the
rear drive shaft to the input flange. An oil seal is pressed into the pinion housing and seals the input flange to the pinion
housing. The pinion shaft has a hypoid gear at its inner end, which mates with the crown wheel drive gear.

The crown wheel drive gear is located on the differential case and secured with ten bolts. The differential case is mounted on
taper roller bearings located in machined bores on each side of the pinion housing. Shims are retained in the casing behind
the bearing cups, the shim thickness is selected to apply the correct bearing preload and hypoid backlash.
The differential carrier has a through hole, which provides location for the shaft. The shaft is supported by a sun gear and a
needle roller bearing. The shaft is fitted with a snap ring at one end, which locates in a machined groove in the sun gear,
locking the shaft in position.

The sun gears are located in pockets in the carrier cage and mesh with the planet gears. Spacers are fitted between the sun
wheels and the carrier and set the correct mesh contact between the planet gears and the sun wheels. Each sun wheel has a
machined bore with internal splines and machined groove near the splined end. The groove provides positive location for a
snap ring fitted to the end of each output flange.

Each output shaft has a spline, which locates in each sun wheel. A snap ring fitted to the splined shaft locates in the groove of
the sun wheel bore and positively locates the output shaft. Oil seals are pressed into each side of the pinion housing and seals
the output shaft.

Rear Differential Operation - 4.2L and 4.4L

The operating principles of the front and rear differentials are the same. Rotational input from the drive shaft is passed via the
input flange to the pinion shaft and pinion gear. The angles of the pinion gear to the crown wheel drive gear moves the
rotational direction through 90°.

The transferred rotational motion is now passed to the crown wheel drive gear, which in turn rotates the differential casing.
The shaft, which is secured to the casing, also rotates at the same speed as the casing. The planet gears, which are mounted
on the shaft, also rotate with the casing. In turn, the planet gears transfer their rotational motion to the left and right hand
sun wheels, rotating the drive halfshafts.

When the vehicle is moving in a forward direction, the torque applied through the differential to each sun wheel is equal. In
this condition both drive halfshafts rotate at the same speed. The planet gears do not rotate and effectively lock the sun
wheels to the differential casing.

If the vehicle is turning, the outer wheel will be forced to rotate faster than the inner wheel by having a greater distance to

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travel. The differential senses the torque difference between the sun wheels. The planet gears rotate on their axes to allow
the outer wheel to rotate faster than the inner one.
Published: 11-May-2011
Rear Drive Axle/Differential - Differential Draining and Filling
General Procedures

CAUTION: Do not fill the differential with lubricant up to the filler plug. The filler plug is only used to fill the differential
with lubricant, and not to act as a level indicator.

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Remove the differential case fluid filler plug.

Clean the area around the fluid filler plug.
Position a container to collect spillage.

3. Drain the differential fluid.

Clean the area around the fluid drain plug.
Remove the fluid drain plug.

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4.
CAUTION: There have been 2 different types of fixings used
for the drain plug. Note the type and differential serial number, and
make sure the correct torque is applied, see below.

Install the lubricant drain plug.

Clean the drain plug.
Up to differential serial number 263445: Tighten the hexagonal
drive drain plug to 54 Nm (40 lb.ft).
From differential serial number 263446: Tighten the 3/8'' square
drive drain plug to 28 Nm (21 lb.ft).

5.
CAUTION: Do not fill the differential case with fluid up to the
filler plug hole. The filler plug is only used to fill the differential case
with fluid, and not to act a level indicator.

Fill the differential with the correct amount of fluid.

For additional information, refer to: Specifications (205-02 Rear Drive
Axle/Differential, Specifications).

6. Install the differential case fluid filler plug.

Clean the filler plug.
Tighten the filler plug to 34 Nm (25 lb.ft).
Published: 11-May-2011
Rear Drive Axle/Differential - Drive Pinion Seal
In-vehicle Repair

Removal

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Remove the exhaust system.

For additional information, refer to: Exhaust System (309-00A Exhaust
System - V8 S/C 4.2L Petrol, Removal and Installation).

3. Remove the center heat shield.

Remove the 8 nuts.

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4. Remove the fuel tank heat shield.
Remove the 8 screws.

5. CAUTIONS:

Mark the position of the driveshaft flange in

relation to the drive pinion flange.

To avoid damage to the joint or gaiter, do not

allow the driveshaft to hang.

Release the driveshaft from the rear axle drive flange.

Remove the 6 Torx bolts and washers.
Discard the bolts.

6. Remove the 2 driveshaft center bearing mount nuts.

 With assistance, release the driveshaft and tie
aside.

7. Measure the depth of the pinion nut on the pinion

shaft.
Note measurement for installation.

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8.
CAUTION: This step must be carried out to
make sure that the drive pinion nut is correctly tightend
on assembly.

Accurately scribe a line to mark the drive pinion shaft to

the drive pinion nut and pinion flange.

9. Remove the drive pinion flange retaining nut.

Using the special tool, counter hold the drive pinion
flange.
Note number of turns for installation.
 10. Using a two legged puller remove the pinion flange.
Check flange seal journal for any damage.
Carefully remove and discard the oil seal.

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Installation

1. Clean the drive pinion flange.

2. Clean the drive pinion seal mating faces.

3. Using the special tool, install the new drive pinion

seal.

4. Remove the special tool.

Install special tool 205-821-01 to the seal face.
 5.
CAUTION: Make sure adaptor is removed or
damage to the vehicle may occur.

Using the special tool, install the new drive pinion seal.
Remove the special tools.

6.
CAUTION: Make sure the drive pinion flange scribed marks
are aligned.

Install the drive pinion flange.

7. CAUTIONS:

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Make sure the mark on the drive pinion nut is never
tightened short of the scribed mark on the drive pinion
shaft.

Make sure the drive pinion flange has no end float and
is free to rotate.

Make sure the scribed mark on the drive pinion nut is

no more than a maximum of 5 degrees past the scribed
mark on the drive pinion shaft.

Install the drive pinion flange retaining nut.

Using the special tool, counter hold the drive pinion
flange.
Install nut to previously noted number of turns.
Measure the depth of the pinion nut on the pinion
shaft.

8.
CAUTION: It is possible to fit the driveshaft incorrectly. The
universal joint must be rearward of the center bearing when installed
in the vehicle.

NOTE: A small amount of oil may weep from the driveshaft

joints during storage. The loss of this oil will not affect the operation
or durability of the joint.

Attach the driveshaft to the rear axle drive flange.

Remove the cable tie.
Clean the component mating faces.
Align the driveshaft to the previously noted position.
Tighten the Torx bolts to 44 Nm (32 lb.ft), then a further 45
degrees.
Remove the cable tie.

9.
CAUTION: Make sure the center bearing mount is not under
tension and central within the slots.

Attach the driveshaft center bearing mount.

Align the center bearing mount.
 Tighten the nuts to 21 Nm (15 lb.ft).

10. Install the fuel tank heat shield.

Tighten the screws.

11. Install the center heat shield.

Tighten the nuts.

12. Install the exhaust system.

For additional information, refer to: Exhaust System (309-00A Exhaust
System - V8 S/C 4.2L Petrol, Removal and Installation).

13.
CAUTION: Make sure the correct specification and quanity
of oil is used.

Check the differential oil level and top up if necessary

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Published: 11-May-2011
Rear Drive Axle/Differential - Axle Assembly
Removal and Installation

Removal

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00,
Specifications).

2.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

3. Remove both rear road wheels and tires.

4. Remove the exhaust system.

For additional information, refer to: Exhaust System (309-00,
Removal and Installation).

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5. Remove the fuel tank heat shield.
Remove the 8 screws.

6. CAUTIONS:

Mark the position of the driveshaft flange in relation to the drive

pinion flange.

To avoid damage to the joint or gaiter, do not allow the

driveshaft to hang.

Release the driveshaft from the rear axle drive flange.

Remove the 6 Torx bolts and washers.

7.
CAUTION: Before disconnecting or removing the
components, ensure the area around the joint faces and
connections are clean and dry. Plug open connections to
prevent contamination.

Disconnect the axle case breather line.

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8. Remove the RH rear halfshaft.

9.
NOTE: The RH halfshaft is similar to the LH halfshaft.

Remove the LH rear halfshaft.

For additional information, refer to: Halfshaft (205-05, Removal and
Installation).

10.
WARNING: Secure the component to the
transmission jack.

Remove the axle assembly.

Using a transmission jack, support the axle.
Remove and discard the nut and bolt.
Remove the 2 bolts.
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11. With assistance, remove the axle from the transmission jack.

Installation

1. With assistance, secure the axle to the transmission jack.

2. Install the axle assembly.

Clean the component mating faces.
Tighten the bolts to 100 Nm ( 74 lb.ft).
Tighten the new nut and bolt to 120 Nm (89 lb.ft), then a
further 180 degrees.

3. Connect the axle case breather line.

4. Install the RH rear halfshaft.

5.
NOTE: The RH halfshaft is similar to the LH halfshaft.

Install the LH rear halfshaft

For additional information, refer to: Halfshaft (205-05, Removal and
Installation).

6. Attach the driveshaft to the rear axle drive flange.

Clean the component mating faces.
Install the washers.
Tighten the Torx bolts to 44 Nm (32 lb.ft), then a further 45
degrees.

7. Install the fuel tank heat shield.

Tighten the screws.
8. Install the exhaust system.
For additional information, refer to: Exhaust System (309-00,
Removal and Installation).

9. Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

10. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00,
Specifications).

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Published: 11-May-2011
Front Drive Axle/Differential -
Lubricants
Item Specification
* Recommended lubricant Castrol SAF-XO - 75W/90
Capacity - refill Refill: 0.75 litres (1.6 US pints)
Capacity - fill from new Fill from new: 0.80 litres (1.7 US pints)
* Do not use any lubricant other than that specified

Reduction Ratio
Model Specification
TD6 Diesel engine - Automatic transmission 4.10:1
V8 Petrol engine - Automatic transmission 3.73:1

Torque Specifications
Description Nm lb-ft
Oil drain plug 54 40
Oil filler plug 34 25
Front drive axle/differential to engine sump bolts 110 81
* Driveshaft to front axle drive flange Torx bolts:
Stage 1 45 33
Stage 2 Further 90° Further 90°
Front driveshaft CV joint heat shield Torx screws 3 2
Front driveshaft CV joint heatshield nut 10 7

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Left-hand engine mount to engine mount bracket bolt 100 74
Steering gear tie rod end ball joint nut 80 59
Stabilizer bar link to front shock absorber and air spring assembly 100 74
Suspension height sensor bolt 3.5 2.5
Suspension height sensor link arm nut 8 6
Front suspension lower arm to front subframe nut/bolt:
Stage 1 165 122
Stage 2 Further 90° Further 90°
Front suspension lower tie rod to front subframe nut/bolt:
Stage 1 165 122
Stage 2 Further 90° Further 90°
Front shock absorber and air spring assembly top mount nuts 56 41
* New 'Patchlok' Torx bolts must be installed
Published: 11-May-2011
Front Drive Axle/Differential - Front Drive Axle and Differential
Description and Operation

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Item Description
A Td6 version
B 4.2L/4.4L version
1 Front RH drive halfshaft
2 CV joint
 3 Engine sump
4 Front drive shaft
5 Front LH drive halfshaft
6 Front differential

GENERAL

The front differential converts the "angle of drive" through 90° and distributes drive, via the drive halfshafts, to the front
wheels.

The front differential is mounted on the LH side of the vehicle sump. The sump has a cast tube through it, which allows for the
fitment of the RH drive halfshaft and separates the engine oil from the differential oil. The differential unit is secured to the
engine sump with 4 bolts. The bolts pass through lugs in the differential casing and are secured into threaded holes in the
sump. An O-ring seal is fitted to the casing and locates in the sump to provide a seal between the casing and the sump.

The casing comprises two halves with machined mating faces. When assembled, the iron casing halves are sealed with a thin
film of Loctite 574 sealant and secured together with twelve bolts. The LH casing is the carrier for all the rotating parts and
the RH casing is a cover to close the unit and a support for the RH carrier bearing. A breather tube is fitted to the casings.
This allows a plastic tube to be fitted and routed to a high point in the engine compartment, preventing the ingress of water
when the vehicle is wading.

The LH casing is fitted with a drain plug and a filler plug. The filler plug allows the unit to be filled with oil. The differential unit
contains approximately 0.8 liter of oil for a dry fill and requires approximately 0.75 liter if oil is changed due to residual oil
retained in the casings.

CAUTION: If a thread of fluid runs/drips from the filler plug after refilling, the differential has been overfilled. Drain the

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fluid and refill with the correct amount.
For additional information, refer to: Differential Draining and Filling (205-03 Front Drive Axle/Differential, General
Procedures).

The differential is a conventional design using a hypoid gear layout. This employs a hypoid bevel pinion gear and crown wheel,
with the pinion offset above the center line of the crown wheel. This design allows for a larger pinion gear to be used, which
has the advantages of increased gear strength and reduced operating noise.

The front differential is available in two ratios. V8 engine vehicles use a differential with a final drive ratio of 3.73:1 and Td6
engine vehicles use a final drive ratio of 4.10:1. The ratio is changed by changing the amount of teeth between the crown
wheel drive gear and pinion gear. Therefore for a ratio of 4.10:1, the crown wheel drive gear will have 4.10 times more teeth
than the pinion gear. This equates to the crown wheel drive gear having 41 teeth and the pinion gear having 10 teeth.

Front Differential - Exploded View

NOTE: Td6 version shown

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Item Description
1 O-ring seal
2 Bearing pre-load spacer
3 Bearing cup
4 Taper roller bearing
5 Casing screws (12 off)
6 Dowel (2 off)
 7 RH Casing
8 Gasket
9 Crown wheel gear screws (10 off)
10 Carrier
11 Pinion gear and shaft assembly
12 Oil slinger
13 Taper roller bearing
14 Bearing cup
15 Oil baffle
16 Collapsible spacer
17 Bearing cup
18 Roller bearing
19 Oil seal
20 Deflector
21 Seal deflector
22 Input flange
23 O-ring seal
24 Pinion nut
25 Oil seal

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26 Cap
27 Vent
28 LH Casing
29 Information label
30 Filler/Level plug
31 Drain plug
32 Crown wheel drive gear
33 Roll pin
34 Thrust washer
35 Dished plate
36 Sunwheel
37 Shaft
38 Planet gear
39 Thrust washer.
Front Differential - Sectional View

NOTE: Td6 version shown

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Item Description
1 Crown wheel gear screw (10 off)
2 Planet gear
3 Taper roller bearing
4 Sun wheel (RH drive shaft output)
5 O-ring seal
6 Roll pin
7 RH casing
8 Input flange
9 Pinion nut
10 Oil seal
11 Taper roller bearing
12 Collapsible spacer
13 Taper roller bearing
14 Pinion gear
15 Planet gear
16 Oil seal
17 Taper roller bearing
18 Sun wheel (LH drive shaft output)
19 Shaft
20 Crown wheel drive gear
21 LH casing
22 Carrier.
The differential comprises a pinion shaft and hypoid bevel gear, a crown wheel drive gear with an integral cage, which houses
two planet gears. Two sun wheels are also located in the cage and pass the rotational drive to the drive halfshaft shafts.

The pinion shaft is mounted on two opposed taper roller bearings with a Collapsible spacer located between them. The spacer
is used to hold the bearings in alignment and collapses at a predetermined rate due the torque applied to the pinion nut. The
remaining load is carried as preload in the bearings and is set with the pinion nut to give the desired assembly torque-to-turn.
This can only be performed during first assembly when new bearings are coated with friction modifier.
The pinion shaft of the Td6 derivative has an externally splined outer end, which accepts and locates the input flange and is
retained by the pinion nut. The opposite end of the output flange has an internal spline, which provides positive location for
the front driveshaft. The flange has an external O-ring seal, which seals against the front driveshaft shroud preventing the
ingress of dirt and moisture into the splines. An oil seal is pressed into the LH casing and seals the input flange to the
differential unit. The pinion shaft has a hypoid bevel gear at its inner end, which mates with the crown wheel drive gear.

The crown wheel drive gear is located on the carrier and secured with ten screws. The carrier is mounted on taper roller
bearings located in each casing half. The bearings are press fitted into the casing and a spacer is located on the outside face
to apply preload to the bearing.

The carrier is fitted with a shaft onto which the two planet gears are mounted. The shaft is secured in the carrier with a roll
pin. The sun wheels are located in pockets within the carrier and mesh with the planet gears. Curved plates are located
between the carrier and the sun wheels and hold the sun wheels in mesh with the planet gears. Each sun wheel has a
machined, splined, bore to accept the drive halfshaft. A groove is machined in the bore to locate the snap ring fitted to the
drive halfshaft, providing positive drive halfshaft location.

The operating principles of the front and rear differential are the same.
For additional information, refer to: Rear Drive Axle and Differential (205-02 Rear Drive Axle/Differential, Description and
Operation).

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Published: 11-May-2011
Front Drive Axle/Differential - Differential Draining and Filling
General Procedures

CAUTION: The fluid filler plug is not a fluid level plug.

1. Raise and support the vehicle.

2. Remove the engine undershield.

For additional information, refer to: Engine Undershield (501-02 Front
End Body Panels, Removal and Installation).

3. Clean the area around the differential case, fluid drain and filler
plugs.

4.
WARNING: Observe due care when draining, as
the fluid can be very hot.

NOTE: Rotate the wheels and tires to drain excess

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oil collected in the differential casing.

Drain the differential fluid.

Position a container to collect the fluid.
Remove the differential case fluid drain plug.
Allow the fluid to drain.

5. Install the differential case fluid drain plug.

Clean the drain plug.
Apply sealant to the thread.
Tighten the drain plug to 54 Nm (40 lb.ft).

6. Remove the differential case fluid filler plug.

7. CAUTIONS:

The fluid filler plug is not a fluid level plug.

If a thread of fluid runs/drips from the filler plug hole after

refilling, the differential has been overfilled. Drain the fluid and refill
with the correct amount.

Fill the front differential case with the correct amount of fluid.
 If the differential has been replaced, fill with 800 ml (1.7 US
pints) of fluid.
If the differential has been drained but not replaced, add 750 ml
(1.6 US pints) of fluid.

8. Install the differential case fluid filler plug.

Clean the filler plug.
Apply sealant to the thread.
Tighten the plug to 35 Nm (26 lb.ft).

9. Install the engine undershield.

For additional information, refer to: Engine Undershield (501-02 Front
End Body Panels, Removal and Installation).

cardiagn.com
Published: 11-May-2011
Front Drive Axle/Differential - Axle Assembly V8 4.4L Petrol, LHD AWD
Removal and Installation

Special Tool(s)
Remover halfshaft inboard joint (LRT-54-026)

205-735

Installer halfshaft oil seal

308-626/1

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Installer/Guide halfshaft oil seal

308-626/2

Impulse extractor (LRT-99-004)

100-012

Ball joint separator (LRT-54-027)

205-754

Removal

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

2.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

3. Remove the front wheels and tires.

4. Secure the hood in the service position.

Release the support struts.

5. Remove the engine cover.

For additional information, refer to: Engine Cover - V8 4.4L Petrol
(501-05 Interior Trim and Ornamentation, Removal and Installation).

6. Remove the air cleaner assembly.

For additional information, refer to: Air Cleaner (303-12B Intake Air
Distribution and Filtering - V8 4.4L Petrol, Removal and Installation).

7. Remove the steering gear.

For additional information, refer to: Steering Gear - V8 4.4L Petrol,
LHD AWD (211-02 Power Steering, Removal and Installation).

8. Remove the front driveshaft.

For additional information, refer to: Front Driveshaft - V8 4.4L
Petrol/V8 S/C 4.2L Petrol (205-01 Driveshaft, Removal and
Installation).

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9.
NOTE: Use an additional wrench to prevent the
ball joint rotating.

RH front: Disconnect the suspension height sensor link

arm.
Remove the nut.

10.
CAUTION: Support the lower arm.

RH front: Disconnect the lower arm.

Remove the bolt and discard the nut.

11.
CAUTION: Support the tie rod.

RH front: Disconnect the tie rod.

Remove the bolt and discard the nut.
12.
WARNING: Do not remove the nuts.

RH front: Release the air suspension spring.

Loosen the 3 nuts.

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13.
CAUTION: Support the halfshaft.

RH front: Using the special tool, release the halfshaft

from the differential.

14. Remove the engine compartment LH heat shield.

Remove the 2 nuts.
Remove the 2 screws.
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15. Using a transmission jack, raise the engine clear of the engine
mount.

16.
CAUTION: Always plug any open connections to prevent
contamination.

Disconnect the differential case breather line.

17.
WARNING: Fluid loss is unavoidable, use
absorbent cloth or a container to collect the fluid.

NOTE: The upper rear bolt will remain in the

differential case.

Release the differential case.

Remove the nut securing the front driveshaft, joint
shield.
Remove the 4 bolts.
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18. Remove the front driveshaft joint shield.
With assistance, position the front differential case
rearward.
Remove the 2 Torx screws.

19. LH front: Raise the stablizer bar.

Secure the stabilizer bar in the raised position.

20.
CAUTION: Make sure component mating faces
are not damaged during removal.
 NOTE: The differential case is rotated by 90
degrees, and removed through the sub-frame with the
halfshaft oil seal uppermost.

With assistance, carefully remove the front differential

case.
Remove the bolt.
Remove and discard the O-ring seal.
Remove and discard the halfshaft oil seal.

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21. Remove the retaining clip from the RH halfshaft.

Installation

1. Clean the component mating faces.

2. Install a new O-ring seal to the differential case.

Lubricate the O-ring seal with petroleum jelly.

3. Install a new clip to the RH halfshaft.

4.
NOTE: Install the upper rear bolt to its location in the
differential case.

With assistance, carefully install the front differential case.

Position the differential rearward of its location.

5. Install the front driveshaft joint shield.

 Tighten the Torx screws to 3 Nm (2 lb.ft).

6.
CAUTION: Make sure the O ring seal remains in its fitted
position.

With assistance, align and secure the front differential case.

Engage the front drive shaft joint shield with its securing stud.
Align the dowel and tighten the bolts to 115 Nm (85 lb.ft).
Tighten the front drive shaft joint shield nut to 10 Nm (7 lb.ft).

7. Connect the differential case breather line.

8. Install the steering gear.

For additional information, refer to: Steering Gear - V8 4.4L Petrol,
LHD AWD (211-02 Power Steering, Removal and Installation).

9. Remove the engine support.

10. Release the stabilizer bar.

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11. CAUTIONS:

Keep the halfshaft horizontal to avoid damaging the oil seal.

Pull on the halfshaft to make sure the clip has fully engaged and
retains the halfshaft inboard joint within the differential case.

RH front: Fully install the halfshaft.

Remove the support.
Clean the component mating faces.
Lubricate the seal with clean differential fluid.

12.
NOTE: Do not tighten the locking nut at this stage.

RH front: Connect the tie rod.

Install the bolt with a new nut.

13.
NOTE: Do not tighten the locking nut at this stage.

RH front: Connect the lower arm.

Install the bolt with a new nut.

14.
CAUTION: Make sure the hardened steel washer is fitted
against the stabalizer bar link.

NOTE: Use an additional wrench to prevent the ball joint

rotating.

RH front: Connect the stabilizer bar link.

Install the washer.
Tighten the nut to 100 Nm (74 lb.ft).

15.
NOTE: Use an additional wrench to prevent the ball joint
rotating.

RH front: Connect the suspension height sensor link arm.

 Tighten the nut to 8 Nm (6 lb.ft).

16. Install the engine compartment LH heat shield.

Tighten the screws.
Tighten the nuts.

17. Install the front driveshaft.

For additional information, refer to: Front Driveshaft - V8 4.4L
Petrol/V8 S/C 4.2L Petrol (205-01 Driveshaft, Removal and
Installation).

18. Install the front wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

19.
CAUTION: Nuts and bolts must be tightened with the weight
of the vehicle on the suspension.

Tighten the front lower arm nuts and bolts to 165 Nm (122 lb.ft), then
tighten a further 90 degrees.

20.

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CAUTION: Nuts and bolts must be tightened with the weight
of the vehicle on the suspension.

Tighten the rear lower arm nuts and bolts to 165 Nm (122 lb.ft), then
tighten a further 90 degrees.

21. RH front: Secure the air spring.

Tighten the nuts securing the air springs to 56 Nm (41 lb.ft).

22. Install the air cleaner assembly.

For additional information, refer to: Air Cleaner (303-12B Intake Air
Distribution and Filtering - V8 4.4L Petrol, Removal and Installation).

23. Install the engine cover.

For additional information, refer to: Engine Cover - V8 4.4L Petrol
(501-05 Interior Trim and Ornamentation, Removal and Installation).

24. Connect the hood support struts.

25. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

26. Check, and if necessary, adjust the wheel alignment.

Published: 11-May-2011
Front Drive Halfshafts - Front Drive Halfshafts
Description and Operation

Front Drive Halfshaft Components

NOTE: 4.2/4.4L version shown

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Item Description
1 Front RH drive halfshaft
2 Engine sump
3 Front driveshaft
4 Front LH drive halfshaft
5 Front differential

GENERAL

The front drive halfshafts are handed components with the RH drive halfshaft being longer than the LH drive halfshaft. Both
shafts are of similar construction with constant velocity (CV) joints at each end to allow for steering and suspension
movement.

The front drive halfshafts are similar in their construction. The only difference is the lengths of each shaft. The LH drive
halfshaft has a total length of 677 mm. The RH drive halfshaft is a longer shaft, which passes through a housing and the
engine sump to the differential and has a total length of 1024 mm.
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Item Description
1 Snap ring (3 off)
2 Drive shaft
3 Outer CV joint
4 Stake nut
5 Inner CV joint.
The outer CV joint has a target on the outer diameter. This is used by the ABS wheel speed sensor for vehicle and wheel
speed calculations.For additional information, refer to: (206-09 Anti-Lock Control - Traction Control)

Anti-Lock Control - Traction Control - 3.0L - Td6 (Description and Operation),

Anti-Lock Control - Traction Control - V8 S/C 4.2L Petrol (Description and Operation),
Anti-Lock Control - Traction Control - V8 4.4L Petrol (Description and Operation).
Each drive halfshaft comprises two CV joints and gaiters, an outer tube, a solid shaft and a ball cage assembly.
Published: 11-May-2011
Front Drive Halfshafts - Halfshaft Joint
Description and Operation

Front Drive Halfshaft - Sectional View

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Item Description
1 Outer CV joint
2 Clamp
3 Outer tube
4 Sealing plug
5 Ball cage
6 Shaft
7 Inner CV joint
8 Snap ring - differential
9 Snap ring
10 Gaiter
11 ABS sensor target ring.

GENERAL

The CV joints are of the Birfield design. This design uses longitudinal, elliptical grooves which retain six steel balls. The balls
are further retained by a cage. The constant velocity is achieved by the position of the steel balls. If a centre line is drawn
through the balls and the driven hub or differential shaft, the two centre lines always bisect each other at the angle of drive.
This condition allows the rotational speed of the driven shaft to be passed to the driven hub or differential shaft with no loss of
rotational speed regardless of the shaft angle. The CV joints are packed with grease which is retained in the joint by a
synthetic rubber gaiter. The gaiter is retained at each end by a metal clamp which provides a water tight seal to prevent the
ingress of dirt and moisture. The CV joints are retained on their respective shaft or tube by an internal snap ring. The snap
rings are located in a groove on each shaft or tube end and locate in a mating groove in the CV joint. The CV joints can be
removed by a sharp tap with a soft mallet on the CV joint housing, which releases the snap ring from the groove.

The shaft is a sliding fit inside the outer tube, which allows for the small length changes which occur with articulation of the
suspension. The shaft is located in a ball cage, which is retained inside the outer tube. The ball cage ensures that the shaft is
held rigidly in the outer tube whilst allowing it to freely move in and out of the tube as necessary. A sealing plug is pressed
into the outer tube and retains grease around the balls in the cage.

The inner CV joint shaft is splined and mates with splines in the front differential. A snap ring is located around the inner shaft
and, when fitted in the differential, locates in a mating groove in the differential splined bore. The CV joint shaft is removed
from the differential in a similar manner as removing a CV joint.
Published: 17-Feb-2012
Front Drive Halfshafts - Halfshaft Seal LH
Removal and Installation

Special Tool(s)
Ball joint separator

211-314(LRT-57-036)

Ball joint separator

205-754(LRT-54-027)

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Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Halfshaft remover/replacer

204-506/2(LRT-60-030/2)

Retainers - halfshaft remover/replacer

204-506/5(LRT-60-030/5)

Remover halfshaft inboard joint

205-735(LRT-54-026)
Axle oil seal remover

308-005(LRT-37-004/2)

Installer halfshaft oil seal

308-626/1

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Installer/Guide halfshaft oil seal

308-626/2

Removal

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise the front of the vehicle.

2. Remove the LH front wheel and tire.

3.
CAUTION: Do not attempt to release the wheel hub
by hitting it with a hammer directly, loosen the wheel hub
retaining bolts partially before applying an even amount of
force to the head of each bolts to release the wheel hub
from the wheel knuckle. Failure to follow this instruction
may cause damage to the component.

With assistance, remove and discard the halfshaft nut.

4.
Remove the LH front brake disc.
For additional information, refer to: Brake Disc - Vehicles With: High
Performance Brakes (206-03 Front Disc Brake, Removal and
Installation).

5. Release the LH front anti-lock brake system (ABS) sensor

and wiring harness.
Release the clip.
Remove the bolt.

6. Loosen the LH tie rod end locking nut.

7.
CAUTION: Make sure the ball joint seal is not

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damaged. A damaged seal will lead to the premature
failure of the joint.

Using the special tool release the LH tie rod end.

Remove and discard the nut.

8. LH side front: Release the suspension height sensor.

9. Using the special tool release the LH front lower arm.

Remove the nut.
Loosen the nut and bolt.
 10. Using the special tool release the LH rear lower arm.
Loosen the nut and bolt.
Remove the nut.

11. Position a container to collect the fluid spillage.

12. Install the special tool, to the inner halfshaft joint.

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13.
CAUTION: Keep the halfshaft horizontal to avoid damaging
the seal.

LH front: Release the halfshaft from the differential housing.

Reposition the halfshaft.

14. Remove and discard the clip from the LH halfshaft.

15. Using the special tools, remove and discard the

halfshaft seal.
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Installation

1.
CAUTION: The halfshaft seal protector must be
left in place until the halfshaft has been installed.

Using the special tools, install a new halfshaft seal.

Clean the component mating faces.

2. CAUTIONS:

Pull on the halfshaft inboard joint to make sure the clip has fully
engaged and retains the halfshaft inboard joint within the differential
case.

Install the halfshaft nut finger tight.

Secure the halfshaft.

Install a new circlip.
Lubricate the seal.
Remove the halfshaft seal protector.

3. Remove the special tool.

4.
 CAUTION: Only tighten the nuts and bolts when the
suspension is in the normal drive position.

Secure the LH rear lower arm.

Tighten the nut to 80 Nm (59 lb.ft).
Tighten the rear lower arm nut and bolt to 165 Nm (122 lb.ft)
plus a further 90 degrees.

5.
CAUTION: Only tighten the nuts and bolts when the
suspension is in the normal drive position.

Secure the LH front lower arm.

Tighten the nut to 80 Nm (59 lb.ft).
Tighten the lower arm nut and bolt to 165 Nm (122 lb.ft) plus a
further 90 degrees.

6. LH side front: Secure the suspension height sensor.

7. Secure the LH tie rod end.

Install new nut and tighten to 80 Nm (59 lb.ft).

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8. Secure the LH front ABS sensor and wiring harness.
Apply anti-seize compound to the ABS sensor.
Tighten the bolt to 8 Nm (6 lb.ft)
Secure in the clip.

9. Install the LH front brake disc.

For additional information, refer to: Brake Disc - Vehicles With: High
Performance Brakes (206-03 Front Disc Brake, Removal and
Installation).

10.
CAUTION: Do not use air tools to install the nut. Failure to
follow this instruction may result in damage to the component.

With assistance tighten the wheel hub nut to 420 Nm (311 lb.ft).
Use a new nut.
Stake the nut to the halfshaft.

11. Install the LH front wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

12. Check and top-up the differential case.

13. Check, and if necessary, adjust the wheel alignment.

Published: 11-May-2011
Rear Drive Halfshafts -
Recommended Lubricant
Item Specification
Outboard joint Use grease supplied with replacement boot kit (Optimol MS139G)
Inboard joint Use grease supplied with replacement boot kit (Thermax MS141G )

General Specification
Item Specification
Fully floating, solid shafts incorporating plunging constant velocity joint at inboard end and fixed constant velocity joint
Type
at outboard end of shaft

Torque Specifications
Description Nm lb-ft
* Lower arm to wheel knuckle nut 275 203
Toe link bolt 175 129
*+ Halfshaft nut 350 258
Road wheel nuts 140 103
* New nut must be fitted

+ Stake nut on completion

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Published: 11-May-2011
Rear Drive Halfshafts - Rear Drive Halfshafts
Description and Operation

Rear Drive Halfshaft Components

NOTE: Td6 version shown

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Item Description
1 RH rear drive halfshaft
2 Rear differential
3 LH rear drive halfshaft
4 Rear driveshaft assembly

GENERAL

The rear drive halfshafts are identical in their construction with the LH shaft being slightly longer than the RH shaft. Each shaft
has a constant velocity (CV) joint at each end to allow for suspension movement.

Rear Drive Halfshaft Assembly

NOTE: 4.2/4.4L version shown

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Item Description
1 RH outer CV joint
2 RH rear drive halfshaft
3 RH inner CV joint
4 LH inner CV joint
5 LH rear drive halfshaft
6 LH outer CV joint
Each outer CV joint has a target wheel on the outer diameter. This target is used by the ABS wheel speed sensor for vehicle
and wheel speed calculations.For additional information, refer to: (206-09 Anti-Lock Control - Traction Control)

Anti-Lock Control - Traction Control - 3.0L - Td6 (Description and Operation),

Anti-Lock Control - Traction Control - V8 S/C 4.2L Petrol (Description and Operation),
Anti-Lock Control - Traction Control - V8 4.4L Petrol (Description and Operation).
Each rear drive halfshaft comprises two CV joints (inner and outer), boots and a solid barshaft, which is retained in the rear
differential by a circlip.

The CV joints used on the rear drive halfshafts share the same design and operating principles as the front drive halfshafts CV
joints (see 'Halfshaft Joint' section for more information on CV joints). The rear drive halfshaft inner joint hubs are retained by
peening over the lip of the joint body.
Published: 11-May-2011
Rear Drive Halfshafts - Rear Halfshaft
Removal and Installation

Special Tool(s)
Halfshaft remover/replacer (LRT-

60-030/1)

Retainers - halfshaft remover/replacer (LRT-

60-030/5)

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Halfshaft remover/replacer (LRT-

60-030/3)

Halfshaft installer adapter (LRT-

60-030/4)

Axle oil seal remover (LRT-

37-004/2)

Impulse extractor (LRT-

99-004)

Installer halfshaft oil seal

308-626/1
 Installer/Guide halfshaft oil seal

308-626/2

Removal
CAUTIONS:

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Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Do not store or install halfshafts with joints at maximum articulation or damage may occur to the joint

Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining
mechanism and can separate.

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Drain the differential lubricant.

3. Remove the wheel and tire.

4. Remove the wheel knuckle.

For additional information, refer to: Wheel Knuckle (204-02, Removal
and Installation).

5. Release the halfshaft from the differential housing.

Position a container to collect the oil spillage.

6. With assistance, remove the halfshaft.

Remove and discard the snap ring.
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7. Using the special tools, remove and discard the
halfshaft oil seal.

Installation

1.
CAUTION: The seal protector must be left in
place until the halfshaft has been installed.
 Using the special tools, install a new halfshaft oil seal.
Clean the component mating faces.

2.
CAUTION: Pull on the halfshaft inboard joint to make sure
the clip has fully engaged and retains the halfshaft inboard joint within
the differential case.

With assistance, install the halfshaft.

Clean the component mating faces.
Install the snap ring.
Open the halfshaft oil seal protector.

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3.
NOTE: The oil seal protector is designed to
break into two pieces.

Remove and discard the halfshaft oil seal protector.

4. Install the wheel knuckle.

For additional information, refer to: Wheel Knuckle (204-02, Removal
and Installation).

5. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

6.
CAUTION: Do not fill the differential with lubricant up to the
filler plug. The filler plug is only used to fill the differentail with
lubricant, and not to act as a level indicator.

Fill the differential with the correct amount of lubricant.

Published: 11-May-2011
Rear Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal and Installation

Removal

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Remove the wheel and tire.

3. Remove the halfshaft.

For additional information, refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).

4. Clamp the halfshaft in a vise.

5. Remove and discard the CV joint boot retaining

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clamps.

6. Slide the CV joint boot along the halfshaft to gain access to the
joint.

7. Using a drift against the inner part of the CV joint,

remove the CV joint from the halfshaft.
Remove and discard the snap ring.

8. Remove the outer CV joint boot.

Installation

1. Clean the components.

2. Install the CV joint boot.

3. Install the outer CV joint.

Install the snap ring.
Position the CV joint on the halfshaft, press the snap ring into
it's groove and push the CV joint fully on to the halfshaft.
Pull on the CV joint to ensure the snap ring has fully engaged.

4. Pack the CV joint with the grease supplied.

5. Install the CV joint boot to the CV joint.

Secure with the new clamps.

6. Install the halfshaft.

For additional information, refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).

7. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Published: 11-May-2011
Rear Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal and Installation

Removal

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Remove the wheel and tire.

3. Remove the halfshaft.

For additional information, refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).

4. Clamp the halfshaft in a vise.

5. Remove and discard the CV joint boot retaining

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clamps.

6. Slide the CV joint boot along the halfshaft to gain access to the
joint.

7. Using a drift against the inner part of the CV joint,

remove the CV joint from the halfshaft.
Remove and discard the snap ring.

8. Remove the inner CV joint boot.

Installation

1. Clean the components.

2. Install the inner CV joint boot.

3. Install the inner joint.

Install a new snap ring.
Position the CV joint on the halfshaft, press the snap ring into
it's groove and push the CV joint fully on to the halfshaft.
Pull on the CV joint to ensure the snap ring has fully engaged.

4. Pack the joint with the grease supplied.

5. Install the boot to the joint.

Secure with the new clamps.

6. Install the halfshaft.

For additional information, refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).

7. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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