Differential Output Shaft Bearing: Service and Repair
OUTPUT SHAFT BEARING
RENEW
- Jack up vehicle and place on two stands.
- Road wheel - One - remove and refit.
- Renew output shaft housing oil seal.
- Displace and remove the output shaft shims from final drive.
- Open vice and insert output shaft assembly, tightening to fit.
- Mark the bearing retaining collar with punch.
- Pilot drill the bearing retaining collar, then open out to 1/2" (1 Fig 1) taking care not to drill the output shaft.
- Using suitable chisel, break retaining collar at drilling (2 Fig 1).
- Undo vice.
- Place the output shaft assembly to press and remove (Fig 2).
- Close the vice.
- Reposition the press retaining plates under the seal housing.
- Using the press, displace shaft from the seal housing and collar.
- Remove the shaft, seal housing, bearing and retaining collar from the press.
- Place a suitable block of wood to the front, place seal/housing to the wood and using suitable drift, displace and remove seal from housing.
- Clean the shaft and seal housing, together with shims.
- Place the output seal housing to the press and place the seal replacer tool JD 550-1(1 Fig 3) and driver handle 18G 134 (2 Fig 3) to the front.
- Fit and align the new seal to the tool.
- Fit and align the tool/seal assembly to the housing using press.
- Fully seat the seal to the housing ensuring the seal is square to the housing when fitting.
- Remove the housing/tool assembly from the press and place tool JD 550-1 aside.
- Place output shaft to front and lubricate the seal.
- Fit and align the seal housing assembly to the output shaft.
- Place a new bearing to the front and lubricate the bearing.
- Align the bearing to the output shaft assembly and place a suitable block of wood to press fit and align output shaft assembly to press/wooden block.
- Ensure that the flange securing studs do not rest on the press plate.
- Place the bearing replacer tool SL 7 to output shaft/bearing.
- Press the bearing fully home and displace and remove tool SL 7.
- Fit a new bearing retaining collar to the shaft assembly and fit and align SL 7 to the collar.
- Press the retaining collar fully home and displace and remove SL 7.
- Remove the output shaft assembly from the press.
- Fit and align the original shims to the final drive casing.
- Offer up the output shaft assembly to the casing WITHOUT the 0 ring seal.
- Fit and fully seat the assembly.
- DO NOT fit the securing bolts.
- Measure the gap between the bearing housing and the casing.
- The correct gap should be 0.003 - 0.005 in.
- If the gap is correct, remove the shaft assembly, fit the 0 ring seal, and refit the assembly to the casing.
- Fit and tighten the securing bolts.
- If the gap is incorrect, remove the shaft assembly and re-shim until the correct clearance is obtained.
NOTE: There should always be three shims behind the bearing.
- When the clearance is correct, fit the 0 ring seal, and fit the assembly to the casing.
- Fit and tighten the securing bolts.
- Fit a magnetic dial gauge to the output flange and measure the end float (Fig 1).
- The correct end float should be 0.001 - 0.006in (this end float is pre-set, built into the bearing).
- If the end float is outside the given tolerances, the output shaft bearing must be replaced.
- Reconnect the half shaft.
- Fit and tighten the securing bolts.
- Refit the road wheel.
- Fit and tighten the wheel nuts.
- Remove the stands and lower the vehicle.
SERVICE TOOLS
SL7 Rear hub bearing cone and cup replacer
JD 550-1 Driveshaft oil seal remover/replacer adaptor
18G 134 Driver handle
TORQUE FIGURES
Oil seal housing to gear case 51 - 58 Nm
Halfshaft to differential output shaft 78 - 95 Nm
TOLERANCES
Output flange end float 0.004 in
SPANNER SIZES
17 mm
22 mm
11/16" AF