Title: Differential Removal and Installation - Part 1 of 4
Owner: Don B , added Feb 27 2013 17:29:29
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3998x2234 228kb(If the image has failed to load, click on it to view large version) Description: In addition to its remarkable performance, the Jaguar Independent Rear Suspension (IRS) is renowned for the ease of dropping the entire unit from the car. See Brett Gadzinsky’s instructions in the online XJ40 e-book for a detailed account. The following photos may also be helpful.
2700x1923 230kb(If the image has failed to load, click on it to view large version) Description: If you intend to replace the rear wheel bearings while the IRS is out (it will never be easier), before you raise the car and support it on jack stands, put the gearbox in Park, set the emergency brake, then use a long breaker bar to loosen the rear axle nuts, which are torqued to 221-236 lb-ft.
2700x2038 226kb(If the image has failed to load, click on it to view large version) Description: Place a suitable container under the diff and use a ˝ in. socket extension and wrench to remove the differential drain plug.
1814x2962 202kb(If the image has failed to load, click on it to view large version) Description: Unless the diff oil is very new, you will want to replace it.
3000x2099 233kb(If the image has failed to load, click on it to view large version) Description: Tie the brake calipers, ABS sensors and brake pad wear sensor up and out of the way, ensuring that they will not catch on any part of the IRS as it is lowered.
2729x2237 232kb(If the image has failed to load, click on it to view large version) Description: Don’t even bother trying to disconnect the handbrake cables from the rear wheel hubs. It’s a fiddly, frustrating and unnecessary job. Instead, remove the cotter pin and clevis pin from the wishbone below the driveshaft…
2000x1533 229kb(If the image has failed to load, click on it to view large version) Description: Then disconnect this slip union in the cable that runs from wheel to wheel. On our ’93 car this union is to the left of the driveshaft when facing the rear of the car. You may need to clean gunk and grit from the union before the cable can be pressed toward the center of the joint and slipped out.
2991x2592 227kb(If the image has failed to load, click on it to view large version) Description: Each half of the handbrake cable is secured to the front differential mounting frame by a slide-on circlip (arrow).
1800x799 230kb(If the image has failed to load, click on it to view large version) Description: It’s not necessary to remove the axles if your jack can handle the weight. To remove them, put the trans in Neutral, rotate the axle to access one nut at the inner U-joint, put the trans in Park, use a thin-walled socket & long extension while kneeling outside the wheel well, and repeat 7 times.
3400x2195 221kb(If the image has failed to load, click on it to view large version) Description: Two screws secure each exhaust mount on either side of the diff mounting frame (white arrows). Note the crack in the Jurid flexible coupling, which will be replaced (blue arrow).
2200x1953 219kb(If the image has failed to load, click on it to view large version) Description: Remove the Jurid-to-Diff Pinion Flange bolts with a box end wrench on the back and a ratchet & socket or ratcheting wrench on the front.
1900x2533 234kb(If the image has failed to load, click on it to view large version) Description: I invested in this inexpensive transmission jack because I also need to replace the rear main engine oil seal. Note that the jack is set to balance the IRS with the axles removed. With the axles in place, the jack must be moved more forward to balance the entire IRS assembly.
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