Frelander 2. Manual — part 82

Rear Drive Axle/Differential - Active On-Demand Coupling Filling

General Procedures

• NOTE: If installing a new active on-demand coupling, fill with 650 ml of fluid. It is not possible to completely drain the
active on-demand coupling fluid during service. The procedure below MUST be followed for both filling and topping up.

1.

CAUTION: Make sure the vehicle is on a flat level surface.

Raise and support the vehicle.

1.

No provision is made to fully drain the active on-demand coupling.
During repair procedures, fluid will be lost. A container should be
positioned to collect any spillage.

2.

3.

CAUTION: This is a filler plug only and must

not be used as a fluid level indicator.

Make sure the vehicle is level. Remove the filler plug
and discard the sealing washer.

3.

Fill the active on-demand coupling, until a thin thread of fluid runs
from the filler hole.

Refer to:

Specifications

(205-02 Rear Drive Axle/Differential,

Specifications).

4.

Install the active on-demand fluid filler plug.

5.

Turn the ignition on for 5 minutes.

6.

Turn the ignition off and remove the remote handset.

7.

Fill the active on-demand coupling, until a thin thread of fluid runs
from the filler hole.

8.

9.

CAUTION: This is a filler plug only and must not be used as

a fluid level indicator.

Using a syringe, remove exactly 70 ml of fluid.

9.

10.

CAUTION: Replace the washer.

Install and tighten the filler plug.

Torque: 35 Nm

10.

Rear Drive Axle/Differential - Active On-Demand Coupling

Removal and Installation

Removal

1.

WARNING: Make sure to support the vehicle with axle

stands.

Raise the vehicle on a lift.

1.

Remove the exhaust system.

Refer to:

Exhaust System

(309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

2.

3.

WARNING: Do not lever the driveshaft joints to

release from the power transfer unit or the rear
differential flanges.

• CAUTIONS:

Mark the components to aid installation.

Make sure that the driveshaft is supported with

suitable retaining straps.

Discard the bolts.

3.

4.

5.

Position a container to collect the oil spillage.
Discard the O-ring seal.

6.

Installation

Lubricate and install a new O-ring seal.

Refer to:

Specifications

(205-02 Rear Drive Axle/Differential,

Specifications).

1.

2.

CAUTION: Make sure that the area around the component is

clean and free of foreign material.

Install the active on-demand coupling.

Torque: 24 Nm

2.

Connect the electrical connector.

3.

4.

CAUTION: Make sure that new bolts are

installed.

• NOTE: Make sure that the component is installed to
the position noted on removal.

Install the driveshaft to the active on-demand
coupling.

Torque: 40 Nm

4.

Install the driveshaft rear support bracket.

Torque: 35 Nm

5.

Check and top-up the active on-demand coupling fluid level.

Refer to:

Active On-Demand Coupling Filling

(205-02 Rear Drive

Axle/Differential, General Procedures).

6.

Install the exhaust system.

Refer to:

Exhaust System

(309-00B Exhaust System - TD4 2.2L

Diesel, Removal and Installation).

7.