Drive Unit - Rear - Large - Remove And Install: Installation

Installation procedure is the reverse of removal, except for the following:

CAUTION: Ensure that the new halfshaft has a snap-ring already installed. If it does not, then install a different halfshaft that has a snap-ring already installed. Return any halfshafts without a snap-ring using the MRB process. Do not remove or reuse snap-rings.

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• When installing the halfshaft(s) into the drive unit:
  • Make sure that the opening of the snap ring is facing towards the bottom of the drive unit.
  • Do not damage or displace the oil seal.
  • Verify that the halfshaft is fully seated:
    • Carefully push the halfshaft into the drive unit until there is an audible "click" from the halfshaft stub contacting the pinion shaft.
    • There will be a slight pulling sensation on the halfshaft as the halfshaft circlip locks into place.
    • Pull on the inner halfshaft cup to confirm that the circlip is locked into place. If the halfshaft detaches from the drive unit then reinstall the halfshaft and then test that it is fully seated.

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• Ensure that the drive unit is equipped with a bracket that correctly routes the HV cables. If necessary, install a screw and bracket to correctly route the HV cables (torque 8 N.m).
  NOTE: Components have been removed in this graphic to aid clarity.

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• If both the front and rear drive units were removed at the same time, the vacuum refill tool must be used to refill the cooling system Cooling System - Vacuum Refill .
• If only the rear drive unit was removed, bleed the cooling system Cooling System - Partial Refill And Bleed .
• Refill the gearbox with the recommended fluid.
• Transfer the vehicle to a 4 post lift Raise Vehicle - 4 Post Lift .
• Air suspension only:  Set the suspension height to "Normal".
• CAUTION: Only fully tighten suspension nuts and bolts when the vehicle is on a 4-post lift and the suspension is in the ride height position.