DRIVELINE/AXLE

RFD
A

B
SECTION
REAR FINAL DRIVE C

RFD

E
CONTENTS
C200 Component ..............................................................11 F
Pre-Inspection .........................................................13
SERVICE INFORMATION ............................ 2 Disassembly and Assembly .....................................14
G
PREPARATION ................................................... 2 SERVICE DATA AND SPECIFICATIONS
Special Service Tool ................................................. 2 (SDS) ................................................................. 36
General Specifications .............................................36
NOISE, VIBRATION AND HARSHNESS Inspection and Adjustments ....................................36 H
(NVH) TROUBLESHOOTING ............................. 5 M216
NVH Troubleshooting Chart ...................................... 5
SERVICE INFORMATION ........................... 39 I
DIFFERENTIAL GEAR OIL ................................. 6
Changing Differential Gear Oil .................................. 6 REAR COVER GASKET ................................... 39
Checking Differential Gear Oil ................................... 6 Removal and Installation .........................................39
J
FRONT OIL SEAL ............................................... 7 REAR FINAL DRIVE ASSEMBLY .................... 40
Removal and Installation ........................................... 7 Removal and Installation .........................................40
REAR COVER GASKET ..................................... 9 K
SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................... 9 (SDS) ................................................................. 41
REAR FINAL DRIVE ASSEMBLY .....................10 General Specification ..............................................41
L
Removal and Installation ......................................... 10

Revision: March 2008 RFD-1 2009 D22 LCV

 PREPARATION
< SERVICE INFORMATION > [C200]

SERVICE INFORMATION
PREPARATION
Special Service Tool INFOID:0000000003491792

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
ST3127S000 Measuring pinion bearing preload and total
(See J-25765-A) preload
Preload gauge
1 GG91030000
(J-25765)
Torque wrench
2 HT62940000
( — )
Socket adapter
3 HT62900000 NT124
( — )
Socket adapter
KV38108300 Removing and installing propeller shaft lock
(J-44195) nut and drive pinion lock nut
Companion flange wrench

NT771

ST3090S000 Removing and installing drive pinion rear in-

( — ) ner cone
Drive pinion rear inner race puller set a: 79 mm (3.11 in) dia.
1 ST30031000 b: 45 mm (1.77 in) dia.
(J-22912-01) c: 35 mm (1.38 in) dia.
Puller
2 ST30901000
(J-26010-01)
Base NT527

ST3306S001 Removing and installing differential side bear-

Differential side bearing puller set ing inner cone
1 ST33051001 a: 28.5 mm (1.122 in) dia.
(J-22888-20) b: 38 mm (1.50 in) dia.
Body
2 ST33061000
(J-8107-2)
Adapter
NT072

ST33230000 Installing side bearing inner cone

(J-25805-01) a: 51 mm (2.01 in) dia.
Differential side bearing drift b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.

NT085

Revision: March 2008 RFD-2 2009 D22 LCV

 PREPARATION
< SERVICE INFORMATION > [C200]
Tool number
(Kent-Moore No.) Description A
Tool name
ST33081000 Installing side bearing inner cone and remov-
( — ) ing and installing differential case couple B
Side bearing puller adapter bolts·
a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.319 in) dia.
C

NT073

KV38100600 Installing side bearing spacer RFD

(J-25267) a: 8 mm (0.31 in)
Side bearing spacer drift b: R42.5 mm (1.673 in)

NT528 F
ST30611000 Installing pinion rear bearing outer race
(J-25742-1)
Drift
G

H
NT090

ST30621000 Installing pinion rear bearing outer race

(J-25742-5) a: 79 mm (3.11 in) dia. I
Drift b: 59 mm (2.32 in) dia.

NT073
K
ST30613000 Installing pinion front bearing outer race
(J-25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.
L

M
NT073

KV38100500 Installing front oil seal

(J-25273) a: 85 mm (3.35 in) dia.
Gear carrier front oil seal drift b: 60 mm (2.36 in) dia. N

NT115

(J-34309) Adjusting bearing pre-load and gear height P

Differential shim selector

NT134

Revision: March 2008 RFD-3 2009 D22 LCV

 PREPARATION
< SERVICE INFORMATION > [C200]
Tool number
(Kent-Moore No.) Description
Tool name
(J-25269-4) Selecting pinion height adjusting washer
Side bearing discs
(2 Req'd)

NT136

(J-8129) Measuring carrier turning torque

Spring gauge

NT127

KV381051S0 Checking differential torque on limited slip dif-

( — ) ferential
Rear axle shaft dummy
1 KV38105110
( — )
Torque wrench side
2 KV38105120
( — )
Vise side NT142

KV10112100 Tightening side bearing cap bolts

(BT-8653-A)
Angle wrench

S-NT014

Revision: March 2008 RFD-4 2009 D22 LCV

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [C200]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting Chart INFOID:0000000003491793

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. B

FAX-4,RAX-5, FSU-5, RSU-4

C

RFD-14, RFD-14

RFD-14

RFD-14

RFD-13

RAX-5
MA-9

WT-2
PR-3

BR-4

PS-5
Reference page

—
RFD

Companion flange excessive runout

F

AXLE AND SUSPENSION

Improper gear contact

PROPELLER SHAFT
Possible cause and SUSPECTED PARTS
G

Tooth surface worn

Incorrect backlash
Rough gear tooth

Improper gear oil

ROAD WHEEL

DRIVESHAFT

STEERING
H

BRAKES
TIRES
I
Symptom DIFFERENTIAL Noise × × × × × × × × × × × × ×
×: Applicable

Revision: March 2008 RFD-5 2009 D22 LCV

 DIFFERENTIAL GEAR OIL
< SERVICE INFORMATION > [C200]
DIFFERENTIAL GEAR OIL
Changing Differential Gear Oil INFOID:0000000004068379

DRAINING
1. Stop engine.
2. Remove the drain plug from the rear final drive assembly to
drain the differential gear oil.
3. Install the drain plug with a new gasket to the rear final drive
assembly. Tighten to the specified torque. Refer to RFD-11,
"Component".
CAUTION:
Do not reuse gasket.

LDIA0187E

FILLING
1. Remove the filler plug from the rear final drive assembly.
2. Fill the rear final drive assembly with new differential gear oil
until the level reaches the specified level near the filler plug hole.

Differential gear oil : Refer to MA-9, "Fluids and

grade and capacity Lubricants".
3. Install the filler plug with sealant applied on the threads to the
rear final drive assembly. Tighten to the specified torque. Refer
to RFD-11, "Component".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-43, "Recommended Chemical Product and Sealant".
LDIA0127E

Checking Differential Gear Oil INFOID:0000000004068380

DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL

1. Make sure that differential gear oil is not leaking from the rear final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as
shown.
CAUTION:
Do not start engine while checking differential gear oil level.
3. Install the filler plug with sealant applied on the threads to the
rear final drive assembly. Tighten to the specified torque. Refer
to FFD-10, "Component".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-43, "Recommended Chemical Product and Sealant".

LDIA0127E

Revision: March 2008 RFD-6 2009 D22 LCV

 FRONT OIL SEAL
< SERVICE INFORMATION > [C200]
FRONT OIL SEAL
A
Removal and Installation INFOID:0000000003491794

1. Remove propeller shaft. Refer to PR-8, "Removal and Installation". B

2. Loosen drive pinion nut while holding companion flange using
Tool.
C
Tool number : KV38108300 (J-44195)

RFD

E
APD032

3. Remove companion flange using a suitable tool.

F
4. Remove ABS sensor and rear wheel sensor rotor.

SPD737
I
5. Remove front oil seal.

L
WPD013

6. Apply multi-purpose grease to cavity at sealing lips of oil seal. M

Press front oil seal into carrier using Tool.

Tool number : KV38100500 (J25273) N

7. Install ABS sensor and rear wheel sensor rotor. Refer to RFD-
11.
8. Install companion flange. O

WPD014 P

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 FRONT OIL SEAL
< SERVICE INFORMATION > [C200]
9. Hold the companion flange using Tool and tighten drive pinion
nut. Refer to RFD-11.

Tool number : KV38108300 (J-44195)

APD032

10. Install rear propeller shaft. Refer to PR-8, "Removal and Installation".

Revision: March 2008 RFD-8 2009 D22 LCV

 REAR COVER GASKET
< SERVICE INFORMATION > [C200]
REAR COVER GASKET
A
Removal and Installation INFOID:0000000003491795

1. Drain gear oil. Refer to MA-38, "Changing Rear Final Drive Oil - C200 (Rear Differential Gear Oil)". B
2. Remove rear cover and rear cover gasket.
3. Install new rear cover gasket and rear cover.
4. Tighten rear cover bolts. Refer to RFD-11. C
5. Fill final drive with recommended gear oil. Refer to MA-9, "Fluids and Lubricants".

RFD

Revision: March 2008 RFD-9 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
REAR FINAL DRIVE ASSEMBLY
Removal and Installation INFOID:0000000004052084

REMOVAL C200
CAUTION:
• Do not damage spline, companion flange and front oil seal when removing propeller shaft.
• Before removing final drive assembly or rear axle assembly, disconnect ABS sensor harness con-
nector from the assembly and move it away from final drive/rear axle assembly area. Failure to do so
may result in sensor wires being damaged and sensor becoming inoperative.
1. Drain the differential gear oil. Refer to MA-38, "Changing Rear Final Drive Oil - C200 (Rear Differential
Gear Oil)".
2. Remove the rear propeller shaft. Refer to PR-8, "Removal and Installation".
3. Remove the axle shaft. Refer to RAX-7, "Removal".
4. Disconnect the following components from the rear final drive assembly.
• Brake tube block connectors. Refer to BR-10, "Front and Rear Brake Piping and Hose".
• ABS sensor wire harness (if equipped). Refer to BRC-35, "Rear Wheel Sensor and Sensor Rotor" 2WD,
or BRC-72, "Rear Wheel Sensor" 4WD.
• Parking brake cables. Refer to PB-5, "Removal and Installation".
• Remove LSV. Refer to BR-15, "2WD : Removal and Installation" 2WD, or BR-17, "4WD : Removal and
Installation" 4WD.

5. Disconnect brake hose from brake tube at the clip on top of rear final drive assembly. Then remove the
metal clip to disconnect brake line from the clip on the rear final drive assembly.
6. Support rear final drive assembly using a suitable jack.
7. Remove rear shock absorber lower bolts. Refer to RSU-8, "Removal and Installation".
8. Remove leaf spring U-bolt nuts. Refer to RSU-9, "Removal".
9. Remove rear final drive assembly.
CAUTION:
Secure rear final drive assembly to the jack while removing it.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Fill the rear final drive assembly with differential gear oil after installation. Refer to MA-38, "Changing
Rear Final Drive Oil - C200 (Rear Differential Gear Oil)".
• Bleed the air from brake system. Refer to BR-7, "Bleeding Brake System".

Revision: March 2008 RFD-10 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Component INFOID:0000000003491797

RFD

LDIA0019E
P
1. Axle case 2. Front oil seal 3. ABS sensor unit
4. Rear wheel sensor rotor 5. Companion flange 6. Inner cone
7. Outer race 8. Drive pinion front bearing 9. Drain plug
10. Collapsible spacer 11. Washer 12. Pinion height adjusting washer
13. Pinion mate thrust washer 14. Thrust block 15. Side gear
16. Side gear thrust washer 17. Side bearing adjusting shim 18. Side bearing spacer

Revision: March 2008 RFD-11 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
19. Outer race 20. Inner cone 21. Side bearing
22. Lock pin 23. Pinion mate shaft 24. Pinion mate gear
25. Drive pinion 26. Ring gear 27. Hypoid gear set
28. Filler plug 29. Carrier cover bolt 30. Carrier cover
31. Carrier cover gasket 32. Differential case 33. Inner cone
34. Outer race 35. Drive pinion rear bearing 36. Side bearing cap

LDIA0020E

Revision: March 2008 RFD-12 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]

1. Axle case 2. Front oil seal 3. Companion flange A

4. Inner cone 5. Outer race 6. Drive pinion front bearing
7. Drain plug 8. Collapsible spacer 9. Washer
10. Pinion height adjusting washer 11. Pinion mate thrust washer 12. Pinion mate gear B
13. Pinion mate thrust washer 14. Side gear 15. Side bearing adjusting shim
16. Outer race 17. Inner cone 18. Side bearing
19. Differential case A 20. Side gear thrust washer 21. Pinion mate shaft C
22. Drive pinion 23. Ring gear 24. Hypoid gear set
25. Filler plug 26. Carrier cover bolt 27. Carrier cover
28. Carrier cover gasket 29. Side bearing spacer 30. Differential case B RFD
31. Inner cone 32. Outer race 33. Drive pinion rear bearing
34. Side bearing cap
E
Pre-Inspection INFOID:0000000003491798

Before disassembling final drive, perform the following inspections.

F
TOTAL PRELOAD
1. Turn drive pinion in both directions several times to set bearing rollers.
2. Check total preload using Tool. Refer to RFD-36, "Inspection G
and Adjustments".

Tool number : ST3127S000 (J-25765-A) H

PD245 J

RING GEAR-TO-DRIVE PINION BACKLASH

Check backlash of ring gear with a dial indicator at several points.
K
Refer to RFD-36, "Inspection and Adjustments".

SPD196
N
RING GEAR RUNOUT
Check runout of ring gear with a dial indicator. Refer to RFD-36,
"Inspection and Adjustments". O

SPD702

TOOTH CONTACT

Revision: March 2008 RFD-13 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Check tooth contact. Refer to RFD-14, "Disassembly and Assembly".
SIDE GEAR-TO-PINION MATE GEAR BACKLASH
Measure clearance between side gear thrust washer and differential
case with a feeler gauge. Refer to RFD-36, "Inspection and Adjust-
ments".

SPD198

Disassembly and Assembly INFOID:0000000003491799

REMOVAL OF DIFFERENTIAL CASE

1. Remove rear cover and rear cover gasket.
2. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during reas-
sembly.
• Bearing caps are line-bored during manufacture and
should be put back in their original places.

SPD714

3. Remove side bearing caps.

SPD202

4. Remove differential case assembly with pry bar.

SPD193

NOTE:

Revision: March 2008 RFD-14 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Keep the side bearing outer races together with their respective
inner cones — do not mix them up. A

SPD745

RFD
REMOVAL OF DRIVE PINION ASSEMBLY
1. Remove pinion nut while holding the companion flange using
Tool.
E
Tool number : KV38108300 (J-44195)

APD032

2. Remove companion flange with puller. H

3. Remove ABS sensor and sensor rotor.

SPD014
K

4. Remove drive pinion with soft hammer.

5. Remove front oil seal and pinion front bearing inner cone. L

SPD206

O
6. Remove pinion bearing outer races with a brass drift.

PD349

Revision: March 2008 RFD-15 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
7. Remove pinion rear bearing inner cone and pinion height adjust-
ing washer.

Tool number : ST30031000 (J-22912-01)

PD179

DISASSEMBLY OF DIFFERENTIAL CASE (WITHOUT LSD)

1. Remove side gears, pinion mate gears and thrust washers into differential case
2. Remove side bearing inner cones using Tool.
• To prevent damage to bearing, engage puller jaws in
grooves.

Tool number A : ST33051001 (J-22888-20)

Tool number B : ST33061000 (J-8107-2)

SPD529

NOTE:
Be careful not to confuse the right-hand and left-hand parts.

SPD022

3. Loosen ring gear bolts in a crisscross fashion.

Revision: March 2008 RFD-16 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
4. Tap ring gear off the differential case with a soft hammer.
• Tap evenly all around to keep ring gear from binding. A

SPD024

RFD
5. Punch off pinion mate shaft lock pin from differential case.
• Lock pin is caulked at pinhole mouth on differential case.
E

G
SPD025

6. Disassemble the LH and RH differential case (4WD models).

H

SPD643
K
DISASSEMBLY OF DIFFERENTIAL CASE (WITH LSD)
Checking Differential Torque
L
• Measure differential torque with Tool. Refer to RFD-36, "Inspection
and Adjustments".

Tool number A : KV38105110 ( — ) M

Tool number B : KV38105120 ( — )
• If it is not within the specifications, inspect components of limited
N
slip differential.

O
SPD415

Revision: March 2008 RFD-17 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Disassembly

WDIA0014E

1. Pinion mate shaft 2. Thrust block 3. Differential case couple bolt

4. Differential case B 5. Pinion mate thrust washer 6. Pinion mate gear
7. Side gear 8. Friction plate 9. Spring plate
10. Differential case A 11. Friction plate guide 12. Spacer
13. Friction disc 14. Friction plate

1. Remove side bearing inner cones.

• To prevent damage to bearing, engage puller jaws in
groove.

Tool number A : ST33051001 (J-22888–20)

Tool number B : ST33061000 (J-8107–2)

SPD529

2. Loosen ring gear bolts in a crisscross pattern.

Revision: March 2008 RFD-18 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
3. Tap ring gear off gear case with a soft hammer.
• Tap evenly all around to keep ring gear from binding. A

SPD552A

RFD
4. Remove couple bolts on differential cases A and B with a press.

Tool number : ST33081000 ( — ) E

5. Separate differential case A and B.
6. Remove component parts (discs and plates, etc.).
• Put matchmarks on gears and pressure rings so that they F
can be reinstalled in their original positions from which
they are removed.
G
SPD276

INSPECTION
H
Ring Gear and Drive Pinion
Check gear teeth for scoring, cracking or chipping. If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).
I
Differential Case Assembly (Non LSD)
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, thrust block and thrust washers.
J

SPD584

Bearing M
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, N
replace outer race and inner race as a set.

P
SPD715

Contact Surfaces (With LSD)

Revision: March 2008 RFD-19 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.
1 Differential case B
2 Differential case A
3 Side gear
4 Pinion mate gear
5 Pinion mate shaft
6 Thrust block (2WD and 4WD without ABS only)
7 Friction plate guide

SPD291

Disc and Plate (With LSD)

1. Clean the discs and plates in suitable solvent and blow dry with compressed air.
2. Inspect discs and plates for wear, nicks and burrs.
3. Check friction discs or plates for warpage. Refer to RFD-36,
"Inspection and Adjustments".
• If it exceeds limits, replace with a new plate or disc to eliminate
possibility of clutch slippage or sticking.

SPD279

Revision: March 2008 RFD-20 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
4. Measure frictional surfaces and projected portions of friction
disc, friction plate, spring plate, and determine each part's differ- A
ences to see if the specified wear limit has been exceeded.
Refer to RFD-36, "Inspection and Adjustments".
• Measuring points:
B
- A: Projected portion
- B: Frictional surface
• If any part has worn beyond the wear limit, and is deformed or
fatigued, replace it with a new one that is the same thickness C
as the projected portion.

RFD

G
SPD551A

ADJUSTMENT OF DIFFERENTIAL CASE (WITH LSD)

1. End play of friction disc and friction plate can be calculated by H
using following equation and should be adjusted within following
range.
• Adjustment can be made by selecting friction disc having two dif- I
ferent thicknesses.

E = A − (B + C)
J
End play E : 0.05 - 0.15 mm (0.0020 - 0.0059 in)
A: Length of differential case contact surface to differential case
inner bottom. K
SPD545A
B: Total thickness of friction discs, friction plates, spring disc and
spring plate in differential case on one side.
C: Length of differential case contact surface to back side of side gear.
L
2. Measure values of the length of the differential case contact sur-
face to the differential case inner bottom.

Standard length A : 49.50 - 49.55 mm M

(1.9488 - 1.9508 in)

O
SPD417

Revision: March 2008 RFD-21 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
3. Measure thickness of each disc and plate. Number of discs and
plates (One side), Friction disc 5, Friction plate 6 and Spring
plate 2. Refer to RFD-36, "Inspection and Adjustments".

No. of discs and plates (One side)

Friction discs :2
Friction plates :5
Spring plate :2
Spacer :1
SPD420

4. Measure the length of differential case contact surface to back

side of side gear.
a. Attach a dial indicator to the base plate.
b. Place differential case B on rear of the base plate, and install a
master gauge on case B.
Then adjust the dial indicator scale to zero with its tip on
the master gauge.

SPD418

c. Install pinion mate gears, side gears and pinion mate shaft in dif-
ferential case B.
d. Set dial indicator tip on the side gear, and read the indication.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C
49.15 (D) = 19.45 (B) + 29.7 (C)
E=A−D SPD419
0.37 (E) = 49.52 (A) − 49.15 (D)
From the above equation, end play of 0.37 mm exceeds the specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.
SIDE BEARING PRELOAD
A selection of side bearing adjusting shims is required for successful completion of this procedure.
1. Make sure all parts are clean. Also make sure the bearings are
well lubricated with light oil or “DEXRONTM” automatic transmis-
sion fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

SPD919

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
3. Put the side bearing adjusting shim in place.
CAUTION: A
Side bearing adjusting shim is placed on either the right or
left depending upon final drive gear ratio. Be sure to place it
on the correct side.
B

SPD894

RFD
4. Use Tool to place original carrier side bearing adjusting shims on
the carrier end, opposite the ring gear.
E
Tool number : KV38100600 (J-25267)

G
SPD986

5. Install the side bearing caps in their correct locations using the
matchmarks made during removal, and tighten the bearing cap H
bolts to specification. Refer to RFD-11, "Component".
6. Turn the carrier several times to seat the bearings.
I

SPD526
K
7. Measure the turning resistance of the differential carrier assem-
bly at the ring gear retaining bolts with Tool. Refer to RFD-36,
"Inspection and Adjustments". L

Tool number : J-8129

M

N
WDIA0013E

8. If the turning resistance is not within the specification, correct as O

follows:
• If the turning resistance is less than the specified range, install
thicker side bearing adjusting shims.
• If the turning resistance is greater than the specification, install P
thinner side bearing adjusting shims.

Side bearing adjustment Refer to RFD-36, "Inspection

and Adjustments".
9. Record the total amount of shim thickness required for the cor-
SPD772
rect carrier side bearing preload.

Revision: March 2008 RFD-23 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
10. Remove the carrier from the final drive housing. Save the
selected adjusting shims for later use during the assembly of the
final drive unit.

PD344

PINION GEAR HEIGHT

1. Make sure all parts are clean and that the bearings are well
lubricated.

SPD769

2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J-34309.
• Front pinion bearing — make sure the J-34309-3 front pinion
bearing seat is secured tightly against the J-34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.
• Rear pinion bearing — the rear pinion bearing pilot, J-34309-
8, is used to center the rear pinion bearing only. The rear pin-
ion bearing locking seat, J-34309-4, is used to lock the bearing
to the assembly.

SPD197A

3. Install the pinion rear bearing inner cone into the final drive
housing. Then place the pinion preload shim selector Tool, J-
34309-1, on gauge screw assembly.

SPD893

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
4. Assemble the front pinion bearing inner cone and the J-34309-2
gauge anvil. Assemble them together with the J-34309-1 gauge A
screw in the final drive housing. Make sure that the pinion height
gauge plate, J-34309-16, will turn a full 360 degrees. Tighten the
two sections together by hand.
B

SPD199A

RFD
5. Turn the assembly several times to seat the bearings.

G
SPD770

6. Measure the turning torque at the end of the J-34309-2 gauge

H
anvil using Tool. Refer to RFD-36, "Inspection and Adjust-
ments".

Tool number : ST3127S000 (J-25765-A) I

SPD234A
K
7. Place the J-34309-11 pinion height adapter onto the gauge plate
and tighten it by hand.
CAUTION: L
Make sure all machined surfaces are clean.

N
SPD208A

Pinion Height Adjusting Washer Selection O

Revision: March 2008 RFD-25 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
1. Now, position the side bearing discs, J-25269-4, and arbor firmly
into the side bearing bores.

SPD211A

2. Install the side bearing caps and tighten the side bearing cap bolts to proper torque. Refer to RFD-11,
"Component".
3. Select the correct standard pinion height adjusting washer thick-
ness. Select by using a standard gauge of 3 mm (0.12 in) and J-
34309-101 feeler gauge. Measure the distance between the J-
34309-11 pinion height adapter including the standard gauge
and the arbor.
4. Write down the exact measurement (the value of feeler gauge).

SPD204A

5. Correct the pinion height adjusting washer size by referring to

the “pinion head number”.
• There are two numbers painted on the pinion gear. The
first one refers to the pinion and ring gear as a matched
set. This number should be the same as the number on
the ring gear. The second number is the “pinion head
height number”. It refers to the ideal pinion height from
standard for quietest operation.
• Use the following chart to determine the correct pinion
height adjusting washer:
SPD542

Add or remove from the standard pin-

Pinion head height number ion height adjusting washer thick-
ness measurement
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in)
−4 Add 0.04 mm (0.0016 in)
−3 Add 0.03 mm (0.0012 in)
−2 Add 0.02 mm (0.0008 in)
−1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
6. Select the correct pinion height adjusting washer. Refer to RFD-36, "Inspection and Adjustments".

Revision: March 2008 RFD-26 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
7. Remove the J-34309 pinion preload shim selector Tool from the
final drive housing. Then disassemble to retrieve the pinion A
bearings.

SPD205A

RFD
TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin-
ion.
Hypoid gear set which is not positioned properly may be noisy, or have short life or both. With the checking or E
gear tooth contact pattern, the most desirable contact for low noise level and long life can be assured.
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or F
equivalent to 3 or 4 teeth of ring gear drive side.

SPD199
I
3. Hold companion flange steady and rotate the ring gear in both
directions.
J

L
SPD200

SPD007-B

Revision: March 2008 RFD-27 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
ASSEMBLY OF DIFFERENTIAL CASE (WITHOUT LSD)
1. Measure clearance between side gear thrust washer and differ-
ential case (4WD models). Refer to RFD-36, "Inspection and
Adjustments".
The clearance can be adjusted with side gear thrust washer.
Refer to RFD-36, "Inspection and Adjustments".
2. Install side gears, pinion mate gears and thrust washers into dif-
ferential case
3. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see that they turn properly.

SPD656

4. Install differential case LH and RH (4WD models).

SPD643

5. Place differential case on ring gear.

6. Apply Genuine Medium Strength Locking Sealant or equivalent
to ring gear bolts, and install them.
• Refer to MA-9, "Fluids and Lubricants", RFD-11, "Component".
• Tighten bolts in a crisscross pattern.

Tool number KV10112100 (BT-8653-A)

SPD746

Revision: March 2008 RFD-28 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
7. Press-fit side bearing inner cones on differential case with Tool.
A
Tool number A : ST33230000 (J-25805-01)
Tool number B : ST33061000 (J-8107-2)
B

PD353

RFD
ASSEMBLY OF DIFFERENTIAL CASE (WITH LSD)
• Prior to assembling discs and plates, properly lubricate them by dipping them in limited slip differential oil.
Refer to MA-9, "Fluids and Lubricants".
E
1. Alternately position specified number of friction plates and fric-
tion discs on rear of side gear.
• Always position a friction plate first on rear of side gear.
F
Friction discs :2
Fiction plates :5
G
Spacer :1

SPD546A

L
2. Install two spring plates.

O
SPD547A

Revision: March 2008 RFD-29 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
3. Install friction plate guides.
• Correctly align the raised portions of friction plates, and
apply LSD gear oil to inner surfaces of friction plate
guides to prevent them from falling.

SPD424

4. Install differential case B over side gear, discs, plates and fric-
tion plate guide assembly.
• Install differential case B while supporting friction plate
guides with your middle finger inserted through oil hole in
differential case.
• Be careful not to detach spring disc from the hexagonal
part of the side gear.

SPD425

5. Install pinion mate gears and pinion mate thrust washers on pin-
ion mate shaft, then install pinion mate shaft in differential case
B.
6. Install side gear to pinion mate gears.

SPD426

7. Install thrust block.

• Equipped on 2WD vehicle and 4WD without ABS only.

SPD427

Revision: March 2008 RFD-30 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
8. Install each disc and plate.
• Use same procedures as outlined in steps 1 through 4. A

SPD429

RFD
9. Install differential case A.
• Position differential cases A and B by correctly aligning
the matchmarks stamped on cases.
E

G
SPD430

10. Tighten differential case couple bolts. Refer to RFD-11, "Compo-

H
nent".
11. Place ring gear on differential case and tighten ring gear bolts.
Refer to RFD-11, "Component".
• Tighten bolts in a crisscross pattern. I

Tool number KV10112100 (BT-8653-A)

J
12. Install side bearing inner race.
13. Check differential torque. Refer to RFD-13, "Pre-Inspection".
SPD364A
K
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit front and rear bearing outer races with Tools.
L
Tool number A : ST30611000 (J-25742-1)
Tool number B : ST30621000 (J-25742-5)
M
Tool number C : ST30613000 (J-25742-3)

SPD679

Revision: March 2008 RFD-31 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
2. Select pinion height adjusting washer. Refer to RFD-14, "Disas-
sembly and Assembly".
3. Install pinion height adjusting washer in drive pinion, and press-
fit rear bearing inner cone in it, with press and Tool.

Tool number : ST30901000 (J-26010-01)

SPD377

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal.

Tool number : KV38100500 (J-25273)

SPD557

6. Place drive pinion bearing spacer, drive pinion bearing adjusting

washer and drive pinion in gear carrier.

SPD222

7. Install ABS sensor unit and sensor rotor. Refer to RFD-11,

"Component".

SPD708

Revision: March 2008 RFD-32 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
8. Insert companion flange onto drive pinion by tapping the companion flange with a soft hammer until fully
seated. A

9. Hold companion flange using Tool and tighten the pinion nut.
Refer to RFD-11, "Component".
The threaded portion of drive pinion and pinion nut should B
be free from oil or grease.

Tool number : KV38108300 (J-44195) C

RFD

APD032

10. Tighten the pinion nut by very small degrees until the specified E
preload is achieved. When checking the preload, turn the drive
pinion in both directions several times to set the bearing rollers.
Refer to RFD-36, "Inspection and Adjustments". F

Tool number : ST3127S000 (J-25765-A)

G

SPD241
H

INSTALLATION OF DIFFERENTIAL CASE

This procedure will have to be repeated if: I
• Maximum preload is achieved before the minimum pinion nut
torque is reached.
• Minimum preload is not achieved before maximum pinion nut
J
torque is reached.
1. Select side bearing adjusting shim. Refer to RFD-14, "Disas-
sembly and Assembly".
K
2. Install differential case assembly with side bearing outer races
into gear carrier.

SPD203 L

3. Insert left and right side bearing adjusting shims in place

between side bearing outer races and differential carrier asse-
M
bly.

SPD558

Revision: March 2008 RFD-33 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
4. Drive in side bearing spacer with Tool.

Tool number : KV38100600 (J-25267)

SPD709

5. Align matchmark on bearing cap with that on differential gear

carrier and install side bearing cap on gear carrier with soft ham-
mer. Refer to RFD-11, "Component".

SPD226

6. Measure ring gear-to-drive pinion backlash with a dial indicator.

Refer to RFD-36, "Inspection and Adjustments".
• If backlash is too small, decrease thickness of right shim and
increase thickness of left shim by the same amount.
• If backlash is too great, reverse the above procedure.
• Never change the total amount of shims as it will change
the bearing preload.

SPD196

7. Check total preload with Tool. Refer to RFD-36, "Inspection and

Adjustments".
• When checking preload, turn drive pinion in both direc-
tions several times to seat bearing rollers correctly.

Tool number : ST3127S000 (J-25765-A)

SPD241

• If preload is too great, remove the same amount of shim from

each side.
• If preload is too small, add the same amount of shim to each
side.
• Never add or remove a different number of shims for each
side as it will change ring gear-to-drive pinion backlash.
8. Recheck ring gear-to-drive pinion backlash because increase or
decrease in thickness of shims will cause change of ring gear-
to-pinion backlash.

SPD561

Revision: March 2008 RFD-34 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
9. Check runout of ring gear with a dial indicator. Refer to RFD-36,
"Inspection and Adjustments". A
• If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the
ring gear and the differential case. B
• If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
C
10. Check tooth contact. Refer to RFD-14, "Disassembly and
Assembly".
11. Install new rear cover gasket and rear cover. SPD702
RFD
12. Tighten rear cover bolts. Refer to RFD-11, "Component".

Revision: March 2008 RFD-35 2009 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [C200]
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000004053027

GENERAL SPECIFICATIONS
2WD Models
Engine KA24DE YD25DDTi
M/T
Optional Standard Optional
Rear final drive
C200
2 Pinion LSD 4 Pinion LSD
Gear ratio 4.111 3.700 4.625
Number of teeth (Ring gear drive pinion) 37/9 37/10 37/8

Oil capacity (Approx.) (US pt., Imp pt) 1.3 (2 3/4, 2 1/4)

4WD Model
Engine YD25DDTi
Transmission M/T
Standard Optional
Rear final drive
C200
4-Pinion LSD
Gear ratio 4.625
Number of teeth (Ring gear/drive pinion) 37/8

Oil capacity (Approx.) (US pt, lmp pt) 1.3 (2-3/4, 2-1/4)

Inspection and Adjustments INFOID:0000000004053028

RING GEAR RUNOUT

Ring gear runout limit mm (in) 0.05 (0.0020)

SIDE GEAR ADJUSTMENT (WITHOUT LSD)

Side gear backlash (Clearance between side gear thrust washer

Less than 0.15 (0.0059)
and differential case) mm (in)
Available side gear thrust washers (2wd)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-N3110
0.78 (0.0307) 38424-N3111
0.81 (0.0319) 38424-N3112
0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116
Available side gear thrust washers (4wd)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-0C000
0.78 (0.0307) 38424-0C001
0.81 (0.0319) 38424-0C002
0.84 (0.0331) 38424-0C003
0.87 (0.0343) 38424-0C004
0.90 (0.0354) 38424-0C005
0.93 (0.0366) 38424-0C006

Revision: March 2008 RFD-36 2009 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [C200]
*Always check with the Parts Department for the latest parts information.
A
SIDE BEARING ADJUSTMENT

Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
B
Thickness mm (in) Part number*
2.00 (0.0787) 38453-N3100
2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102 C
2.15 (0.0846) 38453-N3103
Available 2.20 (0.0866) 38453-N3104
side bearing 2.25 (0.0886) 38453-N3105
adjusting RFD
2.30 (0.0906) 38453-N3106
shims 2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N3109 E
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112
*Always check with the Parts Department for the latest parts information.
F

TOTAL PRELOAD ADJUSTMENT

G
Total preload N·m (kg-cm, in-lb) 1.4 - 2.9 (15 - 29, 13 - 25)
Gear ratio 3.700, 4.625 0.13 - 0.18 (0.0051 - 0.0071)
Ring gear-to-drive pinion backlash mm (in)
Gear ratio 4.111 0.10 - 0.15 (0.0041 - 0.0059) H

DRIVE PINION HEIGHT ADJUSTMENT

I
Thickness mm (in) Part number*
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
J
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022 K
3.27 (0.1287) 38154-P6023
Available 3.30 (0.1299) 38154-P6024
drive pinion 3.33 (0.1311) 38154-P6025
height ad- 3.36 (0.1323) 38154-P6026 L
justing 3.39 (0.1335) 38154-P6027
washers 3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030 M
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034 N
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
*Always check with the Parts Department for the latest parts information. O
DRIVE PINION PRELOAD ADJUSTMENT

Drive pinion bearing preload adjusting method Collapsible spacer

P

Drive pinion preload with front oil seal N·m (kg-cm, in-lb) 1.1 - 1.4 (12 - 14, 10 - 12)
Drive pinion preload without front oil seal N·m (kg-cm, in-lb) 1.0 - 1.3 (11 - 13, 9 - 11)

DIFFERENTIAL TORQUE ADJUSTMENT (WITH LSD)

Revision: March 2008 RFD-37 2009 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [C200]

Differential torque N·m (kg-m, ft-lb) 40 - 58 (4.0 - 6.0, 29 - 43)

Number of discs and plates
Friction disc 2
Friction plate 5
Spring plate 2
Spacer 1
Wear limit of plate and disc mm (in) 0.1 (0.004)
Allowable warpage of friction disc
0.08 (0.0031)
and plate mm (in)
Total thickness mm (in)) 18.57 - 20.43 (0.7311 - 0.8043)
Part name Thickness mm (in)) Part number*
38433-C6004
1.4 (0.055)
(adjusting type)
Friction disc
38433-C6002
1.5 (0.059)
(standard type)
38433-C6003
1.6 (0.063)
Available discs and plates (one side) (adjusting type)
1.4 (0.055) 38432-C6002
Friction plate 1.5 (0.059) 38432-C6001
1.6 (0.063) 38432-C6003
Spring plate 1.5 (0.059) 38435-S9200
Spacer 6.0 (0.236) 38454-S9200
*Always check with the Parts Department for the latest parts information.

Revision: March 2008 RFD-38 2009 D22 LCV

 REAR COVER GASKET
< SERVICE INFORMATION > [M216]

SERVICE INFORMATION A
REAR COVER GASKET
Removal and Installation INFOID:0000000004055264
B

1. Drain gear oil.

2. Remove rear cover and rear cover gasket. C
3. Install new rear cover gasket and rear cover.
4. Tighten rear cover bolts. Refer to RFD-11, "Component".
5. Fill final drive with recommended gear oil. Refer to MA-9, "Fluids and Lubricants". RFD

Revision: March 2008 RFD-39 2009 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [M216]
REAR FINAL DRIVE ASSEMBLY
Removal and Installation INFOID:0000000004055261

REMOVAL
CAUTION:
• Do not damage spline, companion flange and front oil seal when removing propeller shaft.
• Before removing final drive assembly or rear axle assembly, disconnect ABS sensor harness con-
nector from the assembly and move it away from final drive/rear axle assembly area. Failure to do so
may result in sensor wires being damaged and sensor becoming inoperative.
1. Drain the differential gear oil. .
2. Remove the rear propeller shaft. Refer to PR-8, "Removal and Installation".
3. Disconnect the following components from the rear final drive assembly.
• Brake tube block connectors. Refer to BR-10, "Front and Rear Brake Piping and Hose".
• ABS sensor wire harness (if equipped). Refer to BRC-35, "Rear Wheel Sensor and Sensor Rotor".
• Parking brake cables. Refer to PB-5, "Removal and Installation".
• Brake tubes. Refer to BR-10, "Front and Rear Brake Piping and Hose".
• Remove LSV. Refer to BR-15, "2WD : Removal and Installation".

4. Disconnect brake hose from brake tube at the clip on top of rear final drive assembly. Then remove the
metal clip to disconnect brake line from the clip on the rear final drive assembly.
5. Support rear final drive assembly using a suitable jack.
6. Remove rear shock absorber lower bolts. Refer to RSU-8, "Removal and Installation".
7. Remove leaf spring U-bolt nuts. Refer to RSU-9, "Removal".
8. Remove rear final drive assembly.
CAUTION:
Secure rear final drive assembly to the jack while removing it.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Fill the rear final drive assembly with differential gear oil after installation. Refer to MA-38, "Changing
Rear Final Drive Oil - C200 (Rear Differential Gear Oil)".
• Bleed the air from brake system. Refer to BR-7, "Bleeding Brake System".

Revision: March 2008 RFD-40 2009 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [M216]
SERVICE DATA AND SPECIFICATIONS (SDS)
A
General Specification INFOID:0000000003491808

GENERAL SPECIFICATIONS B

Engine KA25DE
Rear final drive M216 C
Gear ratio 4.273

RFD

Revision: March 2008 RFD-41 2009 D22 LCV