Axle Assembly (RHD AWD)

Axle Assembly

Special Service Tools






Remover halfshaft inboard joint

205-735(LRT-54-026)





Installer halfshaft oil seal

308-626/1





Installer/Guide halfshaft oil seal

308-626/2





Impulse extractor

100-012(LRT-99-004)





Ball joint separator

205-754(LRT-54-027)

Removal

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
1 Disconnect the battery ground cable. For additional information, refer to Specifications
2
WARNING: Make sure to support the vehicle with axle 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 - 5.0L Service and Repair
6 Remove the RH air cleaner assembly. For additional information, refer to Air Cleaner Element Service and Repair
7 Remove the front driveshaft. For additional information, refer to Front Driveshaft - 5.0L Front Driveshaft




8
NOTE:
Use an additional wrench to prevent the ball joint rotating.
RH front: Disconnect the suspension height sensor link arm.
- Remove the nut.




9
CAUTION: Note the fitted position of the special washer.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
RH front: Disconnect the stabilizer bar link.
- Remove the nut.
- Remove the flat washer.





10
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
RH front: Disconnect the steering gear tie rod end ball joint.
- Use the special tool.
- Loosen the tie-rod end ball joint retaining nut.
- Discard the nut.





11
CAUTION: Support the lower arm.
RH front: Disconnect the lower arm.
- Remove the bolt and discard the nut.





12
CAUTION: Support the tie rod.
RH front: Disconnect the tie rod.
- Remove the bolt and discard the nut.





13
WARNING: Do not remove the nuts.
RH front: Release the air suspension spring.
- Loosen the 3 nuts.





14
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Disconnect the suspension height sensor link arm.
- Remove the nut.





15 LH front: Remove the suspension height sensor.
- Remove the clip.
- Disconnect the electrical connector.
- Remove the 2 bolts.





16
CAUTION: Note the fitted position of the special washer.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Disconnect the stabilizer bar link.
- Remove the nut.
- Remove the flat washer.





17
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
LH front: Disconnect the steering gear tie rod end ball joint.
- Use the special tool.
- Loosen the tie-rod end ball joint retaining nut.
- Discard the nut.





18
CAUTION: Support the lower arm.
LH front: Disconnect the lower arm.
- Remove the bolt and discard the nut.





19
CAUTION: Support the tie rod.
LH front: Disconnect the tie rod.
- Remove the bolt and discard the nut.





20
WARNING: Do not remove the nuts.
LH front: Release the air suspension spring.
- Loosen the 3 nuts.

21 Drain the differential fluid. For additional information, refer to Differential Draining and Filling Procedures

22
CAUTION: Support the halfshaft.
RH front: Using the special tool, release the halfshaft from the differential.





23
CAUTION: Support the halfshaft.
LH front: Using the special tool, disconnect the halfshaft from the differential.
- Remove and discard the retaining clip.





24 Remove the engine compartment LH heat shield.
- Remove the 2 nuts.
- Remove the 2 screws.





25 Remove the LH engine mount heat shield.
- Remove the 2 screws.





26 Release the LH engine mount.
- Remove the bolt.

27 Using a transmission jack, raise the engine clear of the engine mount.

28 LH front: Protect the power steering gear gaiter.

29
CAUTION: Always plug any open connections to prevent contamination.
Disconnect the differential case breather line.





30
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 and discard the 4 bolts.





31 Remove the front driveshaft joint shield.
- With assistance, position the front differential case rearward.
- Remove the 2 Torx screws.





32 LH front: Raise the stablizer bar.
- Secure the stabilizer bar in the raised position.





33
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.





34 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 Install a new clip to the LH halfshaft.
5
WARNING: Make sure to support the vehicle with axle stands.
CAUTION: Make sure that a new bolt is installed.
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.
6 Install the front driveshaft joint shield.
- Tighten the Torx screws to 3 Nm (2 lb.ft).
7
CAUTION: Make sure the O ring seal remains in its fitted position.
CAUTION: Make sure that new bolts are installed.
With assistance, align and secure the front differential case.
- Engage the front drive shaft joint shield with its securing stud.
- Tighten the front drive shaft joint shield nut to 10 Nm (7 lb.ft).
8 Tighten the 100 mm length bolts.
- Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).
- Stage 2: Tighten the bolts a further 90 degrees.
9 Tighten the 55 mm length bolts.
- Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).
- Stage 2: Tighten the bolts a further 60 degrees.

10 Remove the engine support.

11 Secure the engine to the LH engine mount.
- Tighten the bolt to 100 Nm (74 lb.ft).

12 Install the LH engine mount heat shield.
- Tighten the screws.

13 Connect the differential case breather line.





14
CAUTION: The seal protector must be left in place until the halfshaft has been installed.
LH front: Using the special tools, install a new halfshaft oil seal.
- Clean the component mating faces.





15
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.
NOTE:
Do not fully engage the halfshaft until the oil seal protector has been removed.
With assistance, secure the LH halfshaft.
- Open the halfshaft seal protector and install the halfshaft.
- Release the halfshaft seal protector from the halfshaft seal.
- Break the halfshaft seal protector in to two pieces and remove the halfshaft seal protector.
- Fully install the halfshaft.
- Clean the component mating faces.

16
NOTE:
Remove and discard the blanking caps.
Secure the RH inner halfshaft joint to the differential.

17 Release the stabilizer bar.

18
NOTE:
Do not fully tighten the locking nut at this stage.
LH front: Connect the tie rod.
- Install the bolt with a new nut.

19
NOTE:
Do not fully tighten the locking nut at this stage.
LH front: Connect the lower arm.
- Install the bolt with a new nut.

20
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
LH front: Connect the steering gear tie rod end ball joint.
- Clean the component mating faces.
- Tighten the new nut to 80 Nm (59 lb.ft).

21
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.
LH front: Connect the stabilizer bar link.
- Install the washer.
- Tighten the nut to 100 Nm (74 lb.ft).

22 LH front: Install the suspension height sensor.
- Tighten the bolts to 3.5 Nm (2.5 lb.ft).
- Connect the electrical connector.
- Install the clip.

23
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Connect the suspension height sensor link arm.
- Tighten the nut to 8 Nm (6 lb.ft).

24
NOTE:
Do not fully tighten the locking nut at this stage.
RH front: Connect the tie rod.
- Install the bolt with a new nut.

25
NOTE:
Do not fully tighten the locking nut at this stage.
RH front: Connect the lower arm.
- Install the bolt with a new nut.

26
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
RH front: Connect the steering gear tie rod end ball joint.
- Clean the component mating faces.
- Tighten the new nut to 80 Nm (59 lb.ft).

27
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).

28
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).

29 Install the engine compartment LH heat shield.
- Tighten the screws.
- Tighten the nuts.

30 Install the front driveshaft. For additional information, refer to Front Driveshaft - 5.0L Front Driveshaft

31 Fill the front differential case with the correct amount of fluid. For additional information, refer to Differential Draining and Filling Procedures

32 Install the front wheels and tires.
- Tighten the wheel nuts to 140 Nm (103 lb.ft).

33
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
Tighten the lower arm nuts and bolts to 165 Nm (122 lb.ft) plus a further 90 degrees.

34
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
Tighten the tie rod nuts and bolts to 165 Nm (122 lb.ft) plus a further 90 degrees.

35 Secure the front air springs.
- Tighten the nuts securing the air springs to 56 Nm (41 lb.ft).

36 Install the RH air cleaner assembly.

37 Install the engine cover. For additional information, refer to Engine Cover - 5.0L Service and Repair

38 Connect the hood support struts.

39 Connect the battery ground cable. For additional information, refer to Specifications

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