19/11/2021 08:15:24

Gearbox Fluid - Rear Small Drive Unit (Drain and Refill)

Correction Code 40300402

Special tools required for this procedure:

Part Number Description
1498673-00-A KIT, CABLE AXLE REMOVER, MS/MX/M3
1082171-00-A S-hook
1454928-00-A TOOL, SEAL PULLER, ADJUSTABLE, MS/MX/M3
Informational PurposesAn informational icon, calling your attention
Note
Technicians may use this tool or equivalent.
1051509-00-A Output Seal Installation Tool

Drain

  1. Put the vehicle into "Tow" mode.
  2. Remove the LH rear wheel (refer to procedure).
  3. Release the bolts (x2) that secure the brake caliper to the knuckle (torque 120 Nm). Release the caliper and use the S-hook to support it.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To avoid damage to the brake line, the brake caliper must be supported at all times.
  4. Release the ABS harness from the bracket on the knuckle.
  5. Release the bolt that secures the upper link to the knuckle (torque 140 Nm).
  6. Disconnect the harness from the electric park brake (EPB) caliper.
  7. Use the park brake caliper release tool to release the park brake calipers (refer to procedure).
  8. Release the bolt that secures the toe link to the knuckle (torque 130 Nm).
  9. Release the nut and bolt that secure the damper to the knuckle (torque 140 Nm).
  10. Remove the mid aero shield (refer to procedure).
  11. Prepare a drain pan to catch the gearbox fluid.
  12. On the LH side of the gearbox, release the drain plug. Allow the fluid to completely drain, then reinstall the drain plug (torque 28 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not attempt to fill the drive unit through the upper plug.

Fill

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not attempt to fill the drive unit through the upper plug.
  1. Position the axle remover cable around the inner joint of the LH rear drive unit halfshaft, and then use a cable tie to hold the axle remover cable in position.
    Figure 1. Axle removed from drive unit for demonstration purposes
  2. Hook the axle remover slide hammer on the 2 axle remover cable loops, and then use the slide hammer to remove the halfshaft from the drive unit.
  3. Use the seal puller or an equivalent tool to remove the seal from the drive unit.
  4. Slowly fill the gearbox through the axle opening.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the gearbox is filled too quickly, fluid will spill out onto the drive unit casing.
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    Note
    Use the fluid specified in Fluids.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the amount specified in Fluid Capacities.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use exactly the specified amount of gearbox fluid. Do not fill to the top of the axle opening.
  5. Inspect the axle seal for damage and replace if necessary. Use the seal installation tool to install the seal.
  6. Reinstall the axle to the drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    • 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.
  7. Reinstall the components that were removed for access.
  8. Check the vehicle wheel alignment, and adjust if necessary. See Four Wheel Alignment Check.