Published: 11-May-2012

Rear Drive Axle/Differential -

Lubrication
Description Lubricant Capacity (liters/pints/US quarts)
Haldex controlled coupling Statoil SL01-301 0.65/1.1/0.69
Rear drive axle/differential Castrol Axle EPX 80W-90 0.7/1.2/0.74
General Specification
Item Specification
Differential type Low offset hypoid spiral bevel design
Ratio 2.58:1
Electronic torque managed (ETM) range Up to 1500 Nm (1106 lbf.ft)
Torque Specifications
Description Nm lb-ft
Active on-demand coupling module 6 4
Active on-demand coupling to differential 24 18
Active on-demand oil pump 6 4
Driveshaft to the rear flange* 40 30
Rear differential front bush retaining bolts 175 129
Rear differential rear bush retaining bolts 110 81
Rear differential casing bolts 29 21
Rear drive axle/differential pinion flange nut* 130 96
Rear drive axle/differential fluid drain plug 35 26
Rear drive axle/differential fluid filler plug 35 26
* New nuts/bolts must be installed

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Differential Draining and Filling
General Procedures

1. WARNING: Make sure to support the vehicle with axle stands.

CAUTION: Make sure the vehicle is on a flat level surface.

Raise and support the vehicle.

2. No provision is made to fully drain the rear differential.

During repair procedures, fluid will be lost. A container
should be positioned to collect any spillage.

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3. Make sure the vehicle is level. Remove the rear differential filler plug
and discard the sealing washer.

4. Fill the rear differential, until a thin thread of fluid runs from the
filler hole.

Refer to: Specifications (205-02 Rear Drive Axle/Differential,

Specifications).

5. Using a new washer, install the drain plug.

Torque: 35 Nm

6. Lower the vehicle.

 Published: 09-Jun-2011
Rear Drive Axle/Differential - Active On-Demand Coupling Filling
General Procedures

NOTE: If installing a new active on-demand coupling, fill with 650 ml of fluid. It is not possible to completely drain
the active on-demand coupling fluid during service. The procedure below MUST be followed for both filling and topping up.

1. CAUTION: Make sure the vehicle is on a flat level surface.

Raise and support the vehicle.

2. No provision is made to fully drain the active on-demand coupling.

During repair procedures, fluid will be lost. A container should be
positioned to collect any spillage.

3. CAUTION: This is a filler plug only and must not

be used as a fluid level indicator.

Make sure the vehicle is level. Remove the filler plug

and discard the sealing washer.

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4. Fill the active on-demand coupling, until a thin thread of fluid runs
from the filler hole.

Refer to: Specifications (205-02 Rear Drive Axle/Differential,

Specifications).

5. Install the active on-demand fluid filler plug.

6. Turn the ignition on for 5 minutes.

7. Turn the ignition off and remove the remote handset.

8. Fill the active on-demand coupling, until a thin thread of fluid runs
from the filler hole.

9. CAUTION: This is a filler plug only and must not be used as a

fluid level indicator.

Using a syringe, remove exactly 70 ml of fluid.

10. CAUTION: Replace the washer.

Install and tighten the filler plug.

Torque: 35 Nm
 Published: 09-Jun-2011
Rear Drive Axle/Differential - Active On-Demand Coupling Vehicles With:
AWF21 6-Speed Automatic Transmission
Removal and Installation

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

3. CAUTION: Make sure that the driveshaft is

supported with suitable retaining straps.

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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.
5. NOTE: Use penetrating oil - spray through the
driveshaft bolt holes as shown.

6. NOTE: Driveshaft joint shown removed for clarity.

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7. NOTES:

Two washers must be installed to the assist in the

removal of the driveshaft.

Alternate tighten the bolts until the movement of

the driveshaft joint is detected.
 8. CAUTION: Make sure that the driveshaft is
supported with suitable retaining straps.

Remove the bolts, turn the propshaft and repeat

the above step at the other unthreaded hole.
Repeat above steps until the driveshaft joint is
fully released.

9.

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10. CAUTION: Be prepared to collect escaping oil.

NOTE: Remove and discard the O-ring seal.

Installation
1. CAUTIONS:

Make sure that the area around the component is

clean and free of foreign material.

Lubricate the O-ring seals.

Only use the specified material to lubricate the

seals.

Torque: 24 Nm

2.

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3. CAUTION: The component must be aligned with
the installation markings.

Torque: 40 Nm
 4. Torque: 25 Nm

5. Check and top-up the active on-demand coupling fluid level.

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Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive
Axle/Differential, General Procedures).

6. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).
 Published: 09-Jun-2011
Rear Drive Axle/Differential - Active On-Demand Coupling Module
Removal and Installation

Removal

NOTE: If a new Active on-demand coupling module is installed, the throttle valve must also be installed.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2.

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3. CAUTIONS:

Make sure that the area around the component is

clean and free of foreign material.

Be prepared to collect escaping fluids.

 4.

Installation

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1.
2. CAUTION: The throttle valve must be installed to
the active on-demand coupling module before the
assembly is installed to the active on-demand coupling.
Failure to follow this instruction may result in damage
to the vehicle.

3. NOTE: Lubricate the O-ring seal.

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Torque: 6 Nm

4.
cardiagn.com
 Published: 09-Jun-2011
Rear Drive Axle/Differential - Active On-Demand Coupling Oil Pump
Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise the vehicle on the lift.

2. Refer to: Drive Pinion Flange - Vehicles With: M66 6-Speed Manual
Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).

3.

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4. CAUTIONS:

Be prepared to collect escaping oil.

Make sure that the area around the component is

clean and free of foreign material.

Lubricate the O-ring seals.

Only use the specified material to lubricate the

seals.

NOTES:

Remove and discard the O-ring seals.

Install new O-ring seals.

Torque: 6 Nm

Installation

1. To install, reverse the removal procedure.

2. Check and top-up the active on-demand coupling fluid level.

Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Active On-Demand Coupling Drive Pinion
Seal
Removal and Installation

Special Tool(s)
100-012
Slide Hammer

205-862-1
Installer, Active On-demand Pinion Seal

308-529

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Remover, Seals

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise the vehicle on the lift.

2. Remove the differential drive flange.

Refer to: Drive Pinion Flange - Vehicles With: AW F21 6-Speed

Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).
Refer to: Drive Pinion Flange - Vehicles With: M66 6-Speed Manual
Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).

3. Carefully remove and discard the pinion oil seal.

Special Tool(s): 308-529, 100-012

Installation
1. CAUTION: Only use the specified material to lubricate the
seals.

Lubricate the oil seal.

Refer to: Specifications (205-02 Rear Drive Axle/Differential,

Specifications).

2.
Using the special tool, install a new oil seal.

Special Tool(s): 205-862-1

Tap in the seal until the head of the drift is
against the active on-demand coupling housing.

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3. Install the differential drive flange.

Refer to: Drive Pinion Flange - Vehicles With: AW F21 6-Speed

Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).
Refer to: Drive Pinion Flange - Vehicles With: M66 6-Speed Manual
Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).
 Published: 11-May-2012
Rear Drive Axle/Differential - Differential Case Vehicles With: AWF21
6-Speed Automatic Transmission
Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Remove the LH rear wheel and tire.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal

and Installation).

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Vehicles with petrol engine

4. Refer to: Exhaust System (309-00A Exhaust System - GTDi 2.0L

Petrol, Removal and Installation).

Vehicles with diesel engine

5. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

All vehicles

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.
7. NOTE: Use penetrating oil - spray through the
driveshaft bolt holes as shown.

8. NOTE: Driveshaft joint shown removed for clarity.

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9. NOTES:

Two washers must be installed to the assist in the

removal of the driveshaft.

Alternate tighten the bolts until the movement of

the driveshaft joint is detected.
10. CAUTION: Make sure that the driveshaft is
supported with suitable retaining straps.

Remove the bolts, turn the driveshaft and repeat

the above step at the other unthreaded hole.
Repeat above steps until the driveshaft joint is
fully released.

11.

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12.
13. Using a transmission jack, support the differential case.

14.

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15.
16.
Carefully release the RH inboard halfshaft joint
from the differential and tie aside.
Carefully lower and remove the differential case.

17. NOTE: Do not disassemble further if the

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component is removed for access only.
 18. NOTE: Remove and discard the O-ring seal.

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Installation

1. CAUTIONS:

Make sure that the area around the component is

clean and free of foreign material.

A new O-ring seal is to be installed.

Make sure that new bolts are installed.

Torque: 24 Nm
2. Torque: 35 Nm

3. Using a transmission jack, carefully raise the assembly.

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4. Torque: 110 Nm
5. Torque: 175 Nm

6.

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7.
 8. CAUTION: The component must be aligned with
the installation markings.

Torque: 40 Nm

9. Torque: 25 Nm

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Vehicles with diesel engine

10. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L
Diesel, Removal and Installation).

Vehicles with petrol engine

11. Refer to: Exhaust System (309-00A Exhaust System - GTDi 2.0L
Petrol, Removal and Installation).

All vehicles

12. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal
and Installation).

13. Install the LH rear wheel and tire.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

14. Check and top-up the active on-demand coupling fluid level.
 Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive
Axle/Differential, General Procedures).

15. Fill the differential case with fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Differential Support Insulator
Removal and Installation

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Support the rear differential using a transmission jack.

3. CAUTION: Mark the components to aid

installation.

Discard the bolts.

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4.

Installation

1. Torque: 35 Nm
2. CAUTIONS:

Make sure that new bolts are installed.

Make sure that the installation marks are aligned.

Torque: 175 Nm

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Differential Front Bushing
Removal and Installation

Special Tool(s)
205-860-01
Remover, Differential Bushing

205-860-02
Remover, Differential Bushing

205-860-03
Installer, Differential Bushing

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205-860-04
Installer, Differential Bushing

205-860-09
Installer, Differential Bushing

205-860-10
Spacer, Differential Bushing

LR-121
Hydraulic Cylinder 10t
Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Remove both rear wheels and tires.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. Remove the rear differential.

Refer to: Differential Case - Vehicles W ith: M66 6-Speed Manual

Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).
Refer to: Differential Case - Vehicles W ith: AWF21 6-Speed
Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).

4. CAUTIONS:

Mark the components to aid installation.

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Note the fitted position of the component prior to
removal.

Using the special tools, remove the bushing.

Special Tool(s): 205-860-01, 205-860-02, 205-860-10,

LR-121

Installation
 1. Using the special tool, compress the bushing.

Special Tool(s): 205-860-09, 205-860-04, LR-121

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2. CAUTION: Make sure the correct special tool is
used to install the bushings to the correct depth.

NOTE: Make sure that these components are

installed to the noted removal position.

Using the special tool, install the bushing.

Special Tool(s): 205-860-10, 205-860-01, 205-860-04,

205-860-03, LR-121

3. Install the rear differential.

Refer to: Differential Case - Vehicles W ith: M66 6-Speed Manual

Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).
Refer to: Differential Case - Vehicles W ith: AWF21 6-Speed
Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).

4. Install the rear wheels and tires.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).
 Published: 09-Jun-2011
Rear Drive Axle/Differential - Differential Rear Bushing
Removal and Installation

Special Tool(s)
205-860-09
Installer, Differential Bushing

205-861-01
Remover, Differential Bushing

205-861-02
Remover/Installer, Differential Bushing

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205-861-03
Installer, Differential Bushing

205-861-04
Installer, Differential Bushing

205-861-05
Installer, Differential Bushing

LR-121
Hydraulic Cylinder 10t
Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Remove both rear wheels and tires.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. Remove the rear differential.

Refer to: Differential Case - Vehicles W ith: M66 6-Speed Manual

Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).
Refer to: Differential Case - Vehicles W ith: AWF21 6-Speed
Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).

4. Take note of the fitted position of the rear bushings.

The RH bushing slot is positioned vertically and the LH
bushing slot is positioned horizontally.

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5. CAUTION: Note the fitted position of the
component prior to removal.

Using the special tool, remove the bushing.

Special Tool(s): 205-861-01, 205-861-02, LR-121

Installation
 1. CAUTION: Only use the specified special tool.

Using the special tool, compress the bushing.

Special Tool(s): 205-860-09, 205-861-05, LR-121

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2. CAUTION: Make sure the correct special tool is
used to install the bushings to the correct depth.

NOTE: Make sure that these components are

installed to the noted removal position.

Using the special tool, install the bushing, making sure

the slot on the RH bushing is positioned vertically and
the slot on the LH bushing is positioned horizontally.

Special Tool(s): LR-121, 205-861-04, 205-861-03,

205-861-05

3. Install the rear differential.

Refer to: Differential Case - Vehicles W ith: M66 6-Speed Manual

Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).
Refer to: Differential Case - Vehicles W ith: AWF21 6-Speed
Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).

4. Install the rear wheels and tires.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).
 Published: 29-Aug-2013
Rear Drive Axle/Differential - Drive Pinion Flange Vehicles With: AWF21
6-Speed Automatic Transmission
Removal and Installation

Special Tool(s)
205-053
Retainer, Drive Flange

Removal

All vehicles

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

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Vehicles with diesel engine

2. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

Vehicles with petrol engine

3. Refer to: Exhaust System (309-00A Exhaust System - GTDi 2.0L

Petrol, Removal and Installation).

All vehicles

4. CAUTION: Make sure that the driveshaft is

supported with suitable retaining straps.
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.

6. NOTE: Use penetrating oil - spray through the

driveshaft bolt holes as shown.

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7. CAUTION: Use a suitable bolt with a square cross
section end to avoid damaging the driveshaft joint.

NOTE: Driveshaft joint is removed for clarity.

 8. Disconnect the electrical connector for access to the
rear of the flange.

9. NOTES:

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Two washers must be installed to the assist in the
removal of the driveshaft.

Alternate tighten the bolts until the movement of

the driveshaft joint is detected.

10. CAUTION: Make sure that the driveshaft is

supported with suitable retaining straps.

Remove the bolts, turn the driveshaft and repeat

the above step at the other unthreaded hole.
Repeat above steps until the driveshaft joint is
fully released.
 11. CAUTIONS:

Discard the nut.

Be prepared to collect escaping oil.

Special Tool(s): 205-053

Installation

All vehicles

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1. WARNING: Make sure that a new nut is installed.

Special Tool(s): 205-053

Torque: 150 Nm
 2. Connect the electrical connector.

3. CAUTION: The component must be aligned with

the installation markings.

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Torque: 40 Nm

4. Torque: 25 Nm

5. Check and top-up the active on-demand coupling fluid level.

 Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive
Axle/Differential, General Procedures).

Vehicles with petrol engine

6. Refer to: Exhaust System (309-00A Exhaust System - GTDi 2.0L

Petrol, Removal and Installation).

Vehicles with diesel engine

7. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Drive Pinion Front Bearing
Removal and Installation

Special Tool(s)
100-012
Slide Hammer

205-067
Preload Gauge

308-615
Remover, Seals

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JLR-205-972
Mounting Bracket, Rear Axle

JLR-205-984
Remover/Installer, Drive Pinion Nut

JLR-205-985
Remover, Drive Pinion Bearing

JLR-205-986
Installer, Drive Pinion Bearing

Removal
1. Raise and support the vehicle.

2. Drain the differential fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

3. Remove the rear differential.

Refer to: Differential Case - Vehicles W ith: AWF21 6-Speed

Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).
Refer to: Differential Case - Vehicles W ith: M66 6-Speed Manual
Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).

4. Remove the differential casing bolts.

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5. Remove the differential case.

6. Remove and discard the differential case seal.

7. Remove the crown wheel assembly.

8. Position the differential assembly in a suitable vice as

shown.

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9. CAUTION: Make sure the pinion seal recess is not
damaged as the seal is removed.

Using the special tool remove the pinion shaft

oil seal.
Special Tool(s): 308-615, 100-012
10. WARNING: High torque application.

CAUTION: Do not use air tools or heat to remove

the nut (as this could contaminate the head bearing).
Failure to follow this instruction may result in damage
to the component.

NOTE: The special tool should be turned clockwise

to remove the pinion shaft nut.

Using the special tools remove the pinion shaft

nut.
Special Tool(s): JLR-205-984

11.
Secure the differential casing to the special tool.
Position the support bolt to its lowest setting.

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Special Tool(s): JLR-205-972

12. CAUTION: Twisting or damage to the casing may

occur if the base plates to support the jig on the press
are not used.

Using a suitable press remove the differential pinion

shaft.
13. Remove and discard the pinion shaft collapsible spacer.

14. Remove the tail bearing inner race.

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15.
Using the special tools remove the pinion shaft
tail bearing outer race.
Special Tool(s): 100-012
Special Tool(s): JLR-205-985
 16. CAUTION: It is essential that absolute cleanliness is observed
when working on the rear differential. Always cover any open orifices
using lint free non-flocking material to prevent the ingress of foreign
matter. Failure to follow this instruction may result damage to the
components.

Remove the differential from the supporting tool.

Thoroughly clean the pinion shaft paying particular attention
to the thread.
Using a suitable cleaning fluid thoroughly clean the
differential casings.

Installation

1. CAUTION: Do not clean or lubricate the new

pinion shaft tail bearing, as it is supplied coated with a
low friction oil. Failure to follow this instruction will
require the pinion shaft tail bearing to be replaced
before the differential can be successfully assembled.

Secure the differential casing to the special tool.

Using a suitable press and the special tool
install the pinion shaft tail bearing outer race.
Special Tool(s): JLR-205-986

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2. Install the new pinion shaft spacer.
3.
Install the pinion shaft to the differential case.
Lubricate the pinion head bearing with
differential oil.
Position the support bolt to its highest setting.
Special Tool(s): JLR-205-986

4. CAUTION: Do not clean or lubricate the new

pinion shaft tail bearing, as it is supplied coated with a

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low friction oil. Failure to follow this instruction will
require the pinion shaft tail bearing to be replaced
before the differential can be successfully assembled.

Using a suitable press and the special tool install the

pinion shaft tail bearing inner race.

Special Tool(s): JLR-205-986

5.
Position the differential assembly in a suitable
vice as shown.
Remove the differential from the supporting
tool.
6. WARNING: High torque application.

CAUTIONS:

The special tool should be turned counter

clockwise to install the pinion shaft nut.

Do not use air tools to install the nut. Failure to

follow this instruction may result in damage to the
component.

Using the special tools install the new pinion

nut.
Tighten to 250 Nm (184 ib. ft).
Special Tool(s): JLR-205-984

7. CAUTIONS:

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Make sure the specified torque to rotate the
pinion shaft is not exceeded. If excess preload is
applied to the joint the pinion shaft should be removed
and a new collapsible spacer, pinion shaft tail bearing,
pinion shaft tail bearing cup and pinion nut must be
installed.

The special tool should be rotated at 60 rpm (1x

revolution per second) to produce a consistent reading.

The pinion shaft should be rotated through two

full revolutions by hand before the torque measurement
is performed.

Using the special tool, check the torque required

to rotate the pinion shaft. The specified torque
is 1.1 Nm +/- 0.2 Nm
If the specified torque to rotate the pinion shaft
is not reached, using the special tools, tighten
the pinion flange nut in one degree increments
and check the rotational torque after each until
the specified torque of 1.1 Nm +/-0.2 Nm is
achieved.
Special Tool(s): 205-067
 8. CAUTION: Do not lubricate the pinion oil seal.

Using a suitable press, the special tool and adapter

install the pinion bearing oil seal.

Special Tool(s): JLR-205-986

9. Install the crown wheel assembly.

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10. CAUTIONS:

Make sure the mating faces are clean, failure to

follow this instruction may result in damage to the
differential.

Make sure the new seal is not twisted when

fitting, failure to follow this instruction may result in
damage to the differential.

Install the differential case seal.

Apply a thin amount of clean differential oil to
the new differential casing seal.
 11.
Install the differential casing bolts.
Torque: 29 Nm

12. Install the rear differential.

Refer to: Differential Case - Vehicles W ith: AWF21 6-Speed

Automatic Transmission (205-02 Rear Drive Axle/Differential,
Removal and Installation).
Refer to: Differential Case - Vehicles W ith: M66 6-Speed Manual
Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and
Installation).

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13. Fill the differential case with fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).
 Published: 09-Jun-2011
Rear Drive Axle/Differential - Drive Pinion Seal
Removal and Installation

Special Tool(s)
100-012
Slide Hammer

205-865
Installer, Differential Pinion Seal

303-538
Remover/Installer, Crankshaft Oil Seal

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308-615
Remover, Seals

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Remove the active on-demand coupling.

Refer to: Active On-Demand Coupling - Vehicles With: AW F21

6-Speed Automatic Transmission (205-02 Rear Drive
Axle/Differential, Removal and Installation).
Refer to: Active On-Demand Coupling - Vehicles With: M66 6-Speed
Manual Transmission AW D (205-02 Rear Drive Axle/Differential,
Removal and Installation).
 3. CAUTIONS:

Take extra care not to damage the edges of the

component.

Take extra care not to damage the mating faces.

Using the special tool, punch a hole in the oil seals

outer edge.

Special Tool(s): 303-538

4. CAUTIONS:

Take extra care not to damage the mating faces.

Be prepared to collect escaping oil.

Using the special tools and a self tapping screw,

remove the oil seal.

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Special Tool(s): 308-615, 100-012

Installation

1. CAUTIONS:

Take extra care not to damage the seal.

Make sure that the area around the component is

clean and free of foreign material.

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

Special Tool(s): 205-865

2. Install the active on-demand coupling.

 Refer to: Active On-Demand Coupling - Vehicles With: AW F21
6-Speed Automatic Transmission (205-02 Rear Drive
Axle/Differential, Removal and Installation).
Refer to: Active On-Demand Coupling - Vehicles With: M66 6-Speed
Manual Transmission AW D (205-02 Rear Drive Axle/Differential,
Removal and Installation).

3. Check and top-up the differential case.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Rear Halfshaft Seal
Removal and Installation

Special Tool(s)
205-863
Installer, Halfshaft Seal

Removal
NOTES:

Left-hand shown, right-hand similar.

Some variation in the illustrations may occur, but the essential information is always correct.

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1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal

and Installation).

4. CAUTIONS:

Take extra care not to damage the mating faces.

Take extra care not to damage the edges of the

component.

Installation
 1. CAUTIONS:

Make sure that the seal is correctly located.

Take extra care not to damage the seal.

Special Tool(s): 205-863

2. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal

and Installation).

3. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

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 Published: 09-Jun-2011
Rear Drive Axle/Differential - Active On-Demand Coupling Vehicles With:
M66 6-Speed Manual Transmission AWD
Removal and Installation

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise the vehicle on a lift.

2. Remove the exhaust system.

Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

3. CAUTION: Make sure that the driveshaft is

supported with suitable retaining straps.

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4.
 5. CAUTIONS:

Be prepared to collect escaping oil.

Remove and discard the O-ring seal.

Installation

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1. CAUTIONS:

Make sure that the area around the component is

clean and free of foreign material.

A new O-ring seal is to be installed

Lubricate the O-ring seals.

Only use the specified material to lubricate the

seals.

Torque: 24 Nm
 2.

3. CAUTION: Make sure that new bolts are installed.

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NOTE: Tighten the retaining bolts working
diagonally.

Torque: 40 Nm

4. Check and top-up the active on-demand coupling fluid level.

Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

5. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).
 Published: 09-Jun-2011
Rear Drive Axle/Differential - Drive Pinion Flange Vehicles With: M66
6-Speed Manual Transmission AWD
Removal and Installation

Special Tool(s)
205-053
Retainer, Drive Flange

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

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3. CAUTION: Make sure that the driveshaft is
supported with suitable retaining straps.
 4. CAUTIONS:

Discard the nut.

Be prepared to collect escaping oil.

Special Tool(s): 205-053

Installation

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1. WARNING: Make sure that a new nut is installed.

Special Tool(s): 205-053

Torque: 130 Nm
 2. CAUTION: Make sure that new bolts are installed.

NOTE: Tighten the retaining bolts working

diagonally.

Torque: 40 Nm

3. Check and top-up the active on-demand coupling fluid level.

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Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive
Axle/Differential, General Procedures).

4. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).
 Published: 11-May-2012
Rear Drive Axle/Differential - Differential Case Vehicles With: M66 6-Speed
Manual Transmission AWD
Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Remove the LH rear wheel and tire.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

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4. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal
and Installation).

5. CAUTION: Make sure that the driveshaft is

supported with suitable retaining straps.
 6.

7.

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8. Using a transmission jack, support the differential case.
 9.

10.

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11.
Carefully release the RH inboard halfshaft joint
from the differential and tie aside.
Carefully lower and remove the differential case.
 12. NOTE: Do not disassemble further if the
component is removed for access only.

13. NOTE: Remove and discard the O-ring seal.

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Installation
1. CAUTIONS:

Make sure that the area around the component is

clean and free of foreign material.

A new O-ring seal is to be installed.

Make sure that new bolts are installed.

Torque: 24 Nm

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2. Torque: 35 Nm
3. Using a transmission jack, carefully raise the assembly.

4. Torque: 110 Nm

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5. Torque: 175 Nm
6. CAUTION: Make sure that new bolts are installed.

NOTE: Tighten the retaining bolts working

diagonally.

Torque: 40 Nm

7.

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8.
 9. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal
and Installation).

10. Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L
Diesel, Removal and Installation).

11. Install the LH rear wheel and tire.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

12. Check and top-up the active on-demand coupling fluid level.

Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

13. Fill the differential case with fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

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 Published: 18-Jul-2011
Rear Drive Axle/Differential - Rear Drive Axle and Differential
Diagnosis and Testing

Principles of Operation
For a detailed description of the driveline systems, refer to the relevant Description and Operation section in the workshop
manual.

Inspection and Verification

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does
not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor
vehicle.

NOTE: Certain driveline symptoms are also common to the engine, transmission, wheel bearings, tires, and other
parts of the vehicle. For this reason, ensure that the cause of the trouble is in the driveline before adjusting, repairing, or
installing any new components.

1. Verify the customer concern.

2. Visually inspect for system integrity and obvious signs damage.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step

Visual inspection

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Mechanical Electrical
Differential oil leakage Power
Sensor installation Fuse(s)
Wiring harness physical damage or water ingress
Loose or corroded electrical connectors
Controller area network (CAN) circuits
Sensors
Rear differential control module

4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.

Identify the Condition

Gear Howl and W hine

Howling or whining of the ring gear and pinion is due to an incorrect gear pattern, gear damage or incorrect bearing
preload.

Bearing Whine

Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings, which
are operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from gear whine which is
speed dependent.

As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however there is only one pinion
bearing that is worn/damaged, the noise may vary in different driving phases.

A wheel bearing noise can be mistaken for a pinion bearing noise.

Chuckle

Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub
and the differential case bore.
Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the
edge of a tooth can cause the noise.

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Knock

Knock, which can occur on all driving phases, has several causes including damaged teeth or gearset.

A gear tooth damaged on the drive side is a common cause of the knock.

Clunk

Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE. The noise may also
occur when the throttle is applied or released. Clunk is caused by transmission calibration, backlash in the driveline or
loose suspension components and is felt or heard in the vicinity of the rear drive axle.

Bearing Rumble

Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a worn/damaged wheel bearing.
The lower pitch is because the wheel bearing turns at only about one-third of the driveshaft speed. Wheel bearing noise
also may be high-pitched, similar to gear noise, but will be evident in all four driving modes.

Symptom Chart

Symptom Possible Cause Action

Noise is at constant tone Rear drive axle For additional information. GO to Pinpoint Test
over a narrow vehicle speed A.
range. Usually heard on
light drive and coast
conditions
Noise is the same on drive Road noise Normal condition (road noise)
or coast Worn or damaged driveshaft Check and install new components a required.
joint
Driveshaft center bearing
W heel bearing

Noise is produced with the Engine For additional information. REFER to:
vehicle stationary and when Transmission Engine (303-01A Engine - TD4 2.2L
driving Diesel, Diagnosis and Testing),
Diagnostics (307-01 Automatic
Transmission/Transaxle - Vehicles With:
AWF21 6-Speed Automatic Transmission,
Diagnosis and Testing).

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Loud clunk in the driveline Transmission calibration Using the manufacturer approved diagnostic
when shifting from reverse Transmission Mount system, re-configure the Transmission Control
to forward Transmission Module (TCM) with the latest available
Suspension components calibration
Backlash in the driveline Inspect and install new transmission mounts
Engine idle speed set too high as required
Engine mount For transmission diagnostics.
REFER to: Diagnostics (307-01 Automatic
Transmission/Transaxle - Vehicles W ith: AWF21
6-Speed Automatic Transmission, Diagnosis
and Testing).
Inspect and install new suspension
components as required
Inspect and install new driveline components
as required
Check and adjust the idle speed as required
Inspect and install new engine mounts as
required

Clicking, popping, or Inadequate or contaminated Inspect, clean and lubricate with new grease
grinding noises lubrication in the front/rear as required
drive halfshaft constant velocity Ensure all other components are clear from
(CV) joint front/rear drive halfshaft
Another component contacting Inspect and install new components as
the front/rear drive halfshaft required
W heel bearings, brakes or
suspension components

Vibration at highway Out of balance wheel(s) or Balance and install new wheel(s) and tire(s) as
speeds tire(s) required.
Driveshaft misaligned/out of Check driveshaft alignment. Check driveshaft
balance balance using manufacturer approved
Driveshaft center bearing diagnostic system
touching body mounting point Check driveshaft alignment

Shudder, Vibration During Powertrain/driveline Check for powertrain/driveline misalignment

Acceleration misalignment and rectify as required. Install new components
High constant velocity (CV) joint as required
operating angles caused by Check the ride height and verify the correct
incorrect ride height spring rate. Install new components as
required

Lubricant Leak Rear drive axle breather Check oil level and correct as necessary
Damaged seal Install new driveshaft/pinion seal as required
Rear drive axle filler plug Check and install new filler plug as required
Rear drive axle cover/active Re-seal leaking joints as required
on-demand coupling joint

Pinpoint Tests

PINPOINT TEST A : EXCESSIVE DRIVELINE NOISE

 TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: CHECK NOISE FROM VEHICLE ON ROAD TEST
1 Road test vehicle to determine load and speed conditions when noise occurs.
2 Assess the noise with different gears selected.
Does the noise occur in different gears at the same vehicle speed?
Yes
INSTALL a new rear drive axle/differential assembly.
REFER to: Differential Case - Vehicles W ith: AWF21 6-Speed Automatic Transmission (205-02 Rear
Drive Axle/Differential, Removal and Installation) /
Active On-Demand Coupling - Vehicles With: M66 6-Speed Manual Transmission AWD (205-02 Rear
Drive Axle/Differential, Removal and Installation).
RE-TEST the system for normal operation.
No
REFER to: Engine (303-01A Engine - TD4 2.2L Diesel, Diagnosis and Testing) / Diagnostics (307-01
Automatic Transmission/Transaxle - Vehicles W ith: AWF21 6-Speed Automatic Transmission,
Diagnosis and Testing).
For a list of diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - DTC: Active On-demand Coupling Control Module (100-00 General
Information, Description and Operation).

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