Side Cover and Gasket Replacement LH

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the LH rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the LH wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
4. Remove the LH muffler assembly. Refer to Muffler Replacement in Engine Exhaust.
5. Drain the fluid from the rear axle differential. Refer to Lubricant Change .
6. Remove the bolts mounting the damper/tuned absorber to the differential LH side cover.
7. Remove the damper/tuned absorber.



8. Loosen the nut retaining the transmission to the transmission LH mounting stud.
9. Install a second nut onto the stud.
10. Remove the stud from the differential LH side cover.
11. Clean away any dirt or debris from around the edge of the differential LH side cover.
12. Remove the bolts retaining the differential LH side cover.
13. Remove the differential LH side cover from the differential.
14. Remove and discard the O-ring seal from the differential side cover.

1. Clean the O-ring sealing surface on the differential side cover and the differential housing.
2. Install a new O-ring seal to the differential side cover.
3. Install the differential side cover to the differential.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the differential side cover retaining bolts.

Tighten
Tighten the differential LH side cover retaining bolts to 25 N·m (18 lb ft).

5. Using two nuts installed on the stud, install the transmission mounting stud to the differential LH side cover.

Tighten
Tighten the transmission mounting stud to 42 N·m (31 lb ft).

6. Remove the second nut from the transmission mounting stud.
7. Tighten the nut retaining the transmission to the transmission LH mounting stud.

Tighten
Tighten the differential to transmission nut to 50 N·m (37 lb ft).




8. Install the damper/tuned absorber to the differential LH side cover.
9. Install the bolts mounting the damper/tuned absorber to the differential LH side cover.

Tighten
Tighten the damper/tuned absorber mounting bolts to 25 N·m (18 lb ft).

10. Fill the rear axle differential with the proper fluid and to the proper level. Refer to Lubricant Change .
11. Install the LH muffler assembly. Refer to Muffler Replacement in Engine Exhaust.
12. Install the LH wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
13. Install the LH rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
14. Lower the vehicle.

Side Cover and Gasket Replacement RH

Tools Required

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the RH rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the RH wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
4. Remove the RH muffler assembly. Refer to Muffler Replacement in Engine Exhaust.
5. Drain the fluid from the differential. Refer to Lubricant Change .
6. Clean any dirt or debris from around the edge of the differential cover (right).
7. Remove the bolts retaining the differential cover (right).
8. Remove the transmission vent tube retainer (automatic transmission).
9. Remove the differential cover (right) from the differential.



10. Remove and discard the axle seal (1), and O-ring seal (4) from the differential cover (right).



11. Install the J 42194 into the differential cover (right), in order to remove the bearing race and shims. Position the cover into a hydraulic press.



12. Using a hydraulic press, remove the bearing race (1) and shims (2). Mark or tag the shims for assembly.




Important: Whenever service requires the replacement of the right side differential cover, the covers MUST be measured and the right side shim pack adjusted to compensate for machining tolerances between the two components. Failure to perform this measurement procedure may result in improper differential bearing preload.

13. Use a caliper (2), a straight edge (1), and J 42168-16  (3) in order to measure the NEW differential cover bore dimension. Record the measurement as value A.
14. Use a caliper (2), a straight edge (1), and J 42168-16  (3) in order to measure the old differential cover bore dimension. Record the measurement as value B.
15. Subtract value B from value A. If the computation is a positive value, add shims equal to the value, to the existing shim pack. If the computation is a negative value, subtract shims equal to the value, from the existing shim pack.

1. Install the selected shims (2) and the bearing race (1) to the NEW cover (right).



2. Press the shims and bearing race into the NEW cover (right) using the J 42170 and a hydraulic press.



3. Clean the O-ring sealing surface on the differential cover (right) and the differential housing.
4. Install a new O-ring seal (4) to the differential cover (right).



5. Install the differential cover (right) to the differential.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the differential cover (right) retaining bolts.

Tighten
Tighten the differential cover (right) retaining bolts to 25 N·m (18 lb ft).




7. Install the axle seal into the differential cover (right) using J 36797-A .
8. Install the transmission vent tube retainer onto the vent tube, then position the retainer to receive the retaining bolt (automatic transmission).
9. Fill the rear axle differential with the proper fluids and to the proper level. Refer to Lubricant Change .
10. Install the RH muffler assembly. Refer to Muffler Replacement in Engine Exhaust.
11. Install the RH wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
12. Install the RH rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
13. Lower the vehicle.