Rear Gearbox Fluid - Small Drive Unit (Remove and Replace)

FRT No: 40300402

Special tools required for this procedure:

Part Number Description
1000991 Axle Extractor Tool
1082171-00-A S-hook
1052583-00-A Seal Puller
Note: Technicians may use this tool or equivalent.
1051509-00-A Output Seal Installation Tool

Drain

  1. Put the vehicle into "Tow" mode.
  2. Remove the LH rear wheel (refer to procedure).
  3. Release the bolts (x2) that secure the brake caliper to the knuckle (torque 120 Nm). Release the caliper and use the S-hook to support it.
    Caution: To avoid damage to the brake line, the brake caliper must be supported at all times.

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

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

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

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  7. Use the park brake caliper release tool to release the park brake calipers (refer to procedure).
  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. Remove the mid aero shield (refer to procedure).
  11. Prepare a drain pan to catch the gearbox fluid.
  12. On the LH side of the gearbox, release the drain plug. Allow the fluid to completely drain, then reinstall the drain plug (torque 28 Nm).

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    Caution: Do not attempt to fill the drive unit through the upper plug.

Fill

Caution: Do not attempt to fill the drive unit through the upper plug.
  1. Use the axle extractor tool to release the axle from the drive unit.
  2. Use the seal puller or an equivalent tool to remove the seal from the drive unit.

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  3. Slowly fill the gearbox through the axle opening.
    Caution: If the gearbox is filled too quickly, fluid will spill out onto the drive unit casing.
    Note: Use the fluid specified in General Information > Fluids and Capacities > Fluids .
    Note: Use the amount specified in General Information > Fluids and Capacities > Fluid Capacities .
    Caution: Use exactly the specified amount of transmission fluid. Do not fill to the top of the axle opening.

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  4. Inspect the axle seal for damage and replace if necessary. Use the seal installation tool to install the seal.

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  5. Reinstall the axle to the drive unit.
    Note: When installing the axle 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 drive unit 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.
  6. Reinstall the components that were removed for access.
  7. Perform a four wheel alignment check (refer to procedure) .