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Lubricat e the oi l s eal .
Refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial,
Speci fi cat ions ).
Us ing t he s peci al t ool, i ns t all a new oi l seal.
Speci al Tool (s ): 205-862-1 Tap i n the seal unti l the head of t he drift is
agains t the act ive on-demand coupl ing hous ing. 2.
Inst all t he different ial dri ve fl ange.
Refer t o: Dri ve Pinion Fl ange (205-02 Rear Dri ve Axl e/Di fferenti al,
Removal and Ins tall ati on).
3.
Inst all t he exhaus t sys t em.
Refer t o: Exhaus t Sys t em (309-00B Exhaus t Sys t em - TD4 2.2L
Di es el, Removal and Ins tal lat ion).
4.
Page 338 of 3229
Publi s hed: 11-May-2011
Rear Drive Axle/Differential - Differential Case
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he LH rear wheel and ti re.
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
2.
W it h ass i st ance, remove the rear muffler.
Refer t o: Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol ,Removal and Ins tall ati on).
3.
4. W ARNING: Do not lever the driveshaft joint s t orel ease from t he power trans fer unit or t he reardifferent ial flanges .
• CAUTIONS:
Mark t he components to ai d ins t al lat ion.
Make s ure that t he dri ves haft i s s upport ed wi ths uit abl e ret aini ng st raps .
Di scard the bolt s .
4.
5.
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6.
Remove t he LH rear halfs haft.
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).
7.
Us ing a transmis si on jack, s upport t he different ial case.8.
9. CAUTION: Mark the component s t o aidi ns t allat ion.
Di scard the bolt s .
9.
10. CAUTION: Mark the component s t o aidi ns t allat ion.
Di scard the bolt s .
10.
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Carefully releas e t he RH i nboard halfs haft joint fromt he different ial and ti e as ide.11.
12.
Carefully lower and remove t he different ial case.13.
14. NOTE: Do not dis ass emble further if t he componenti s removed for acces s onl y.14.
Page 341 of 3229

15.
Installation 1. CAUTION: Make s ure that the area around t he component is
clean and free of foreign materi al.
Inst all a new O-ring s eal to the acti ve on-demand coupl ing.
1.
2. CAUTIONS: Make s ure that t he area around the component i s clean and
free of foreign mat eri al. Make s ure that new bolt s are ins t al led.
Ali gn t he act ive on-demand coupli ng to the di fferenti al and t ight en
t he bolt s.
T orque: 24 Nm 2.
Inst all t he rear different ial s upport bracket .
T orque: 35 Nm 3.
Us ing a transmis si on jack, carefull y rai s e the as s embly.
4.
Connect t he different ial breather l ines.
5.
Secure t he RH i nner halfs haft joi nt t o t he different ial .
6.
7. CAUTIONS: Make s ure that t he ins tal lat ion marks are al igned.
Make s ure that new bolt s are ins t al led.
Inst all t he rear different ial front bus h retai ni ng bolt s.
T orque: 175 Nm 7.
8. CAUTIONS: Make s ure that t he ins tal lat ion marks are al igned.
Make s ure that new bolt s are ins t al led.
8.
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Inst all t he rear different ial rear bus h ret aining bol ts .
T orque: 110 Nm Inst all t he LH halfshaft.
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removal
and Inst all at ion).
9.
Connect t he Act ive On-demand Coupl ing modul e electrical connect or.
10.
Inst all t he dri ves haft rear s upport bracket .
T orque: 35 Nm 11.
12. CAUTION: Make s ure t hat new bol ts are
ins tal led.
Connect the drives haft t o the rear fl ange.
T orque: 40 Nm 12.
Inst all t he rear muffler.
Refer t o: Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol ,
Removal and Ins tall ati on).
13.
Inst all t he LH rear wheel and ti re.
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
14.
Check and top-up the acti ve on-demand coupl ing fluid level.
Refer t o: Act ive On-Demand Coupl ing Fi lli ng (205-02 Rear Drive
Axle/Different ial, General Procedures).
15.
Fil l the di fferenti al cas e wit h flui d.
Refer t o: Different ial Drai ni ng and Fil ling (205-02 Rear Drive
Axle/Different ial, General Procedures).
16.
Page 343 of 3229
Publi s hed: 11-May-2011
Rear Drive Axle/Differential - Differential Support Insulator
Removal and Inst all ati on
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he exhaus t sys t em.
Refer t o: Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol ,
Removal and Ins tall ati on).
2.
3. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Support the rear different ial usi ng a t rans mis s ion jack.
3. 4. CAUTION: Mark the component s t o aid
i ns t allat ion.
Di scard the bolt s . 4.
5.
Installation Inst all t he rear different ial ins ulat or t o t he rear di fferenti al .
T orque: 35 Nm 1.
2. CAUTIONS: Make s ure that new bolt s are ins t al led.
2.
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Make s ure that t he ins tal lat ion marks are al igned.
Inst all t he rear different ial front bus h retai ni ng bolt s.
T orque: 175 Nm Inst all t he exhaus t sys t em.
Refer t o: Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol ,
Removal and Ins tall ati on).
3.