Rear Axle Replacement

WARNING:
^ When lowering or repositioning axle, an additional two persons are required.
^ Before commencing work, depressurize air suspension.

REMOVAL
1. Raise the vehicle.

WARNING: Support on safety stands.

2. Support axle with hydraulic jack.
3. Remove rear road wheels.
4. Mark differential and propeller shaft flanges to aid reassembly.






5. Remove 4 nuts and bolts securing propeller shaft-to differential. Release shaft and tie aside; discard nuts.
6. Remove 2 nuts securing shock absorbers to axle.
7. Remove 'R' clips retaining air springs to axle.
8. Remove bolt securing panhard rod to axle. Release rod. Tie aside.





9. Release ABS multiplug from body bracket. Disconnect plug. Release lead from body clips.
10. Disconnect brake pipes from body bracket. Plug pipes and connections.
11. Remove 2 clips securing brake pipes to body bracket.
12. Remove banjo bolt and strap securing breather hose to axle. Plug hose and connection.





13. Release height sensors from trailing arms.





14. Slacken 2 nuts and bolts securing trailing arms to chassis.
15. Remove 4 nuts and bolts securing trailing arms to axle.
16. With assistance lower axle. Release suspension units.
17. Remove axle from vehicle.

INSTALLATION
18. With assistance, position axle and align suspension units.
19. Raise axle up to trailing arms.
20. Secure axle to trailing arms with nuts and bolts.
M16 with 8.8 strength grade-Tighten to 160 Nm (118 ft. lbs.).
M16 with 10.9 strength grade-Tighten to 240 Nm (177 ft. lbs.),
M12-Tighten to 125 Nm (92 ft. lbs.).
21. Remove safety stands. Lower vehicle.
22. Tighten bolts securing trailing arms to chassis. Tighten to 160 Nm (118 ft. lbs.).
23. Retain air springs with 'R' clips.
24. Secure height sensors to trailing arms.
25. Position shock absorbers on axle. Secure with nuts. Tighten to 45 Nm (33 ft. lbs.).
26. Ensure all pipes and connections are clean.
27. Using new sealing washers, connect breather hose to axle with banjo bolt.
28. Secure hose to axle with strap.
29. Position-brake pipes to body bracket. Remove plugs. Connect pipes.
30. Secure pipes with clips.
31. Connect ABS multiplug. Secure plug to body bracket. Secure lead to body clips.
32. Position panhard rod to axle. Secure with bolt. Tighten to 200 Nm (148 ft. lbs.).
32. Position propeller shaft. Align marks on flanges.
34. Secure shaft with bolts and new nuts. Tighten to 48 Nm (35 ft. lbs.).
35. Replenish axle oil.
36. Bleed brakes.