Rear Halfshaft Assembly - Large Drive Unit - LH (Remove and Replace)

FRT No: 40302602

Special tool(s) required for this procedure:

Part Number Description
1000991 Axle Extractor Tool

Remove

  1. Remove the LH rear wheel arch liner (refer to procedure).
  2. Remove and discard the axle nut (torque 245 Nm). The axle nut must be replaced during reinstallation.

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  3. Remove the wedge-lock washer.
  4. Put the vehicle into "Tow" mode.
  5. Loosen the bolts (x2) that secure the brake caliper to the knuckle (torque 120 Nm). Remove and support the calipers.
    Caution: To avoid damage to the brake line, the brake caliper must be supported at all times.

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  6. Release the bolt that secures the upper link to the knuckle (torque 140 Nm).

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  7. Disconnect the harness from the electric park brake (EPB) caliper.

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  8. Release the bolt that secures the toe link to the knuckle (torque 130 Nm).

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  9. Release the nut and bolt that secure the damper to the knuckle (torque 140 Nm).

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  10. Release the ABS harness from the bracket on the knuckle.

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  11. Remove the mid aero shield (refer to procedure).
  12. Release the ABS harness from the bracket on the subframe.

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  13. Tap the exposed end of the halfshaft with a nylon mallet to release it.
  14. Swing the brake rotor and knuckle assembly outward and release the outer halfshaft spline from the rear hub, using a driver to disengage the axle from the hub splines.
  15. Use the axle extractor tool to release the halfshaft from the transmission.
    Caution: Ensure that the axle extractor tool does not contact any of the differential retaining studs.
    Note: If the halfshaft is difficult to release, rotate the halfshaft slightly, then try releasing the halfshaft again.

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  16. Carefully withdraw the halfshaft assembly from the vehicle.
    Caution: To avoid damage to the halfshaft boots and oil seals, exercise caution when removing and installing halfshafts.
    Caution: Plug the transmission opening to prevent ingress of dirt or moisture.

Installation

Installation procedure is the reverse of removal, except for the following:
Caution: Ensure that the new halfshaft has a snap-ring already installed. If it does not, then install a different halfshaft that has a snap-ring already installed. Return any halfshafts without a snap-ring using the MRB process. Do not remove or reuse snap-rings.
  • Apply approximately 1 gram of Molykote M-77 Lubricant Paste to the outboard side of the halfshaft to the hub mating face.
  • When installing the halfshaft into the drive unit:
    • Ensure that the opening of the snap ring is facing towards the bottom of the drive unit.
    • Do not damage or displace the oil seal.
    • Verify that the halfshaft is fully seated by carefully pushing it into the drive unit until there is an audible "click" from the snap ring.
  • Pump the brake pedal at least 5 times to seat the pads against the brake rotors.
    Warning: Always check that the brake pads are seated correctly before driving the vehicle.
Caution: Only fully tighten suspension nuts and bolts when the vehicle is on a 4-post lift and the suspension is in the ride height position.
Caution: Ensure that the bolt that secures the spring assembly to the knuckle is inserted towards the rear of the vehicle; the head of the bolt faces the front of the vehicle and the nut is tightened at the rear.