Rear Axle

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

Remove the rear wheels and hubs. See the Wheels and Hubs topic for more information.

Drain the final drive gear oil. See the Final Gear Case Oil topic for more information.

Remove the under cover and the trailer hitch bracket if equipped.

Remove the four left final gear case cover bolts. These would already be removed for the trailer hitch bracket.

Slide off the rubber cover.

Slide off the left final gear case cover.

Slide the rubber cover off the right side of the axle.

Tap the right end of the rear axle with a rubber mallet.

Slide the rear axle out from the left and remove it.

Remove the O-ring from the left side of the final gear case. Discard the O-ring if it is in poor condition.

Inspection

The left final gear case cover has two oil seals. If the seals need to be replaced- drive them out from the outside of the cover.

Drive in the new seals from the inside of the cover. Both seals have a C shaped cross-section. Position the seals so that the closed end of the C faces the other seal. Use a suitable driver that is the same outside diameter as the seal. Drive in the smaller diameter seal first. The inside edge of the smaller diameter seal must sit 31.5 – 32.5 mm (1.24 – 1.28 in.) below the inside surface of the cover. Drive in the larger diameter seal so that it sits 21.3 – 22.3 mm (0.84 – 0.88 in.) below the inside surface of the cover.

Special Tool – Oil Seal Driver Dia. 47.5: 57001-1487

Turn the rear axle bearing by hand. If the bearing doesn’t turn smoothly the axle must be replaced as a whole.

Place the rear axle on V-blocks and measure the runout at the center of the rear axle with a dial gauge. The runout is the difference between the minimum and maximum readings of the dial gauge.

Rear Axle Shaft Runout Limit: TIR 2 mm (0.08 in.)
Rear Axle Shaft Runout: TIR 1 mm (0.04 in.) or less

Installation

Coat the O-ring in grease and fit it into place on the left side of the final gear case.

Slide the rear axle into place. Engage the splines on the axle with the ring gear inside the final gear case.

Coat the left final gear case cover oil seal lips in grease. Slide the left final gear case cover on over the axle.

Apply a non-permanent thread locking agent to the threads of the left final gear case cover bolts. Install the four bolts and tighten them to specification.

Rear Final Gear Case Left Cover Bolts: 49 N-m, 5.0 kgf-m, 36 ft-lb

These bolts are also used to mount the trailer hitch bracket if equipped or the under cover bracket if not.

Install the rubber covers to the final gear case.

Install the under cover and the trailer hitch bracket if equipped. Tighten the under cover bolts securely.

Apply a non-permanent thread locking agent to the threads of right final gear case cover/trailer hitch bracket and tighten them to specification.

Rear Final Gear Case Right Cover Bolts
(M8): 24 N-m, 2.4 kgf-m, 17 ft-lb
(M10): 49 N-m, 5.0 kgf-m, 36 ft-lb

Fill the final drive gear oil. See the Final Gear Case Oil topic for more information.

Install the rear hubs and wheels. See the Wheels and Hubs topic for more information.