Install Front Differential

INSTALL FRONT DIFFERENTIAL

NOTE:
The bolt above the pinion must be located in the differential prior to installation.

1. With assistance, carefully install the differential to the engine sump.

2. Tighten the front differential securing bolts to 110 N m (81 lbf ft).

3. Connect the breather hose to the differential.





4. Remove the screw securing the left-hand stabilizer bar heatshield. (Figure 37)





5. Install the new front propeller shaft heatshield. (Figure 38)

6. Install and tighten the nuts and bolts securing the front propeller shaft heatshield to 15 N m (11 lbf ft).

7. Install and tighten the screw securing the front propeller shaft heatshield and the stabilizer bar heatshield.

8. Remove plastic cap from the new front propeller shaft.

9. Install new gasket to front propeller shaft.





10. Extend the front propeller shaft joint and fill with grease. (Figure 39)

11. Install the front propeller shaft.

12. Clean the coupling and flange mating faces.





13. Install the coupling and flange with arrows on coupling pointing towards securing bolts as illustrated. (Figure 40)

14. Install the bolts securing the coupling and tighten the new nuts to 110 N m (81 lbf ft).

CAUTION:
Ensure gasket is correctly located in propeller shaft joint.

15. Install three new washers and six new bolts securing the propeller shaft to the differential flange.





^ Tighten to 45 N m (33 lbf ft) then a further 90 degrees. (Figure 41)

16. Remove the wooden block and allow the stabilizer bar to return to the lowered position.

17. Remove the right-hand driveshaft support.

CAUTION:
Pull the driveshaft to ensure the clip is fully engaged and retains the shaft in the differential.

18. Install the right-hand driveshaft to the differential, ensuring the clip is fully engaged.

19. Remove the right-hand tie rod and lower arm support.

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

20. Position the right-hand lower suspension arm and align to the sub-frame; install a new bolt but do not tighten at this stage.

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

21. Position the right-hand tie rod and align to the sub-frame; install a new bolt but do not tighten at this stage.

CAUTION:
Use an open ended wrench on the flats provided to prevent the ball joint from rotating.

22. Connect the right-hand front height sensor link and tighten the nut to 8N m (6 lbf ft).

CAUTION:
Inspect PAS reservoir for presence of a 'Pentosin CHF202' label:

^ If label is present, indicating Technical Bulletin LTB00112 has been performed, use only Pentosin CHF202 PAS fluid (LRN003401).

^ If label is not present and Technical Bulletin LTB00112 has not been performed, use PAS Fluid - Texaco Cold Climate PSF 14315 (LRN2261).

NOTE:
It is not necessary to perform the front wheel alignment check.

23. Refer to Workshop Manual (GTR) section 57 - STEERING (57.10.01) to install the steering gear. It is not necessary to perform the front wheel alignment check.

24. Lower the vehicle.

25. Tighten the bolt securing the right-hand lower suspension arm to the sub-frame to 165 N m (121 lbf ft) plus a further 90-degrees.

26. Tighten the bolt securing the right-hand tie rod to the sub-frame to 165 N m (121 lbf ft), plus a further 90-degrees.

27. Fill the differential to the correct level with oil (LRN7591).