Front Final Drive: Section
Front Final Drive: Section
Front Final Drive: Section
B
SECTION
FRONT FINAL DRIVE C
FFD
E
CONTENTS
PRECAUTIONS .......................................................... 2 REAR COVER GASKET ........................................... 13 F
Service Notice or Precautions .................................. 2 Removal and Installation ........................................ 13
PREPARATION ........................................................... 3 REMOVAL ........................................................... 13
Special Service Tools ............................................... 3 INSTALLATION ................................................... 13 G
Commercial Service Tools ........................................ 5 FRONT FINAL DRIVE ASSEMBLY .......................... 14
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ........................................ 14
TROUBLESHOOTING ................................................ 6 REMOVAL ........................................................... 14
H
NVH Troubleshooting Chart ..................................... 6 INSTALLATION ................................................... 15
DESCRIPTION ............................................................ 7 Disassembly and Assembly .................................... 16
Cross-Sectional View ............................................... 7 COMPONENTS ................................................... 16
DIFFERENTIAL GEAR OIL ........................................ 8 ASSEMBLY INSPECTION AND ADJUSTMENT... 17 I
Changing Differential Gear Oil ................................. 8 DISASSEMBLY ................................................... 20
DRAINING ............................................................. 8 INSPECTION AFTER DISASSEMBLY ................ 25
FILLING ................................................................. 8 ADJUSTMENT AND SELECTION ADJUSTING J
Checking Differential Gear Oil .................................. 8 WASHERS .......................................................... 26
OIL LEAKAGE AND OIL LEVEL ........................... 8 ASSEMBLY ......................................................... 29
FRONT OIL SEAL ...................................................... 9 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 36
K
Removal and Installation .......................................... 9 General Specifications ............................................ 36
REMOVAL ............................................................. 9 Inspection and Adjustment ..................................... 36
INSTALLATION ................................................... 10 DRIVE GEAR RUNOUT ...................................... 36
SIDE OIL SEAL ........................................................ 12 DIFFERENTIAL SIDE GEAR CLEARANCE ....... 36 L
Removal and Installation ........................................ 12 PRELOAD TORQUE ........................................... 36
REMOVAL ........................................................... 12 BACKLASH ......................................................... 36
INSTALLATION ................................................... 12 COMPANION FLANGE RUNOUT ....................... 36 M
SELECTIVE PARTS ............................................ 36
PRECAUTIONS PFP:00001
● Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
● Check for the correct installation status prior to removal or disassembly. When matching marks are
required, be certain they do not interfere with the function of the parts they are applied to.
● Overhaul should be done in a clean work area, a dust proof area is recommended.
● Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
● Always use shop paper for cleaning the inside of components.
● Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
● Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace
them with new ones if necessary.
● Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
● Clean and flush the parts sufficiently and blow them dry.
● Be careful not to damage sliding surfaces and mating surfaces.
● When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil,
and foreign materials from the application and mating surfaces.
● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
● During assembly, observe the specified tightening torque.
● Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.
PREPARATION PFP:00002
A
Special Service Tools EDS002NY
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
ST29020001 Separating the upper link ball joint stud
(J-24319-01) a: 34 mm (1.34 in) C
Gear arm puller b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)
FFD
NT694
NT771
G
KV381054S0 Removing front oil seal
(J-34286)
Puller
H
ZZA0601D
I
ST30720000 ● Installing front oil seal
(J-25405) ● Installing side oil seal
Drift J
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
K
ZZA0811D
ZZA1003D
( — )
Socket adapter (3/8″)
Tool number
(Kent-Moore No.) Description
Tool name
KV10111100 Removing rear cover
(J-37228)
Seal cutter
S-NT046
ZZA0700D
SDIA0429J
ZZA1000D
S-NT090
ZZA1143D
Tool number
(Kent-Moore No.) Description A
Tool name
ST30901000 Installing pinion rear bearing inner race
(J-26010-01) a: 79 mm (3.11 in) dia. B
Drift b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ZZA0978D
ZZA1002D
ZZA1046D H
— Adjusting bearing preload and pinion gear
(J-34309) height
Differential shim selector tool
I
J
NT134
L
NT135
PBIC0190E
×
×
Gear contact improper Refer to FFD-18, "Tooth Contact" .
FFD-6
×
Tooth surfaces worn Refer to FFD-25, "INSPECTION AFTER DISASSEMBLY" .
×
Backlash incorrect Refer to FFD-19, "Backlash" .
×
Gear oil improper Refer to FFD-8, "Checking Differential Gear Oil" .
×
×
PROPELLER SHAFT NVH in PR section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
×
TIRES NVH in WT section.
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
2005 Xterra
EDS002O0
DESCRIPTION
DESCRIPTION PFP:00000
A
Cross-Sectional View EDS002O1
FFD
PDIA0695E
DRAINING
1. Stop the engine.
2. Remove the drain plug and gasket. Drain the gear oil.
3. Install the drain plug with a new gasket to the final drive assem-
bly. Tighten to the specified torque. Refer to FFD-16, "COMPO-
NENTS" .
CAUTION:
Do not reuse gasket.
LDIA0175E
FILLING
1. Remove the filler plug and gasket. Fill with new gear oil until the
oil level reaches the specified level near the filler plug hole.
Oil grade and Viscosity:
Refer to MA-11, "Fluids and Lubricants" .
Oil capacity:
Approx. 0.85 (1-3/4 US pt, 1-1/2 Imp pt)
2. After refilling oil, check the oil level. Install the filler plug with a
new gasket on it to the final drive assembly. Tighten to the spec-
ified torque. Refer to FFD-16, "COMPONENTS" . LDIA0176E
CAUTION:
Do not reuse gasket.
Checking Differential Gear Oil EDS002O3
LDIA0176E
REMOVAL
1. Remove the front wheels and tires using power tool.
B
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer to BR-23, "Removal and Installation of
Brake Caliper and Disc Rotor" .
C
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
FFD
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
E
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
Tool number : ST29020001 (J-24319-01) F
CAUTION:
Support the lower link using a jack.
6. Remove the rear engine undercover using power tool. G
7. Remove the RH and LH drive shafts from the front final drive
using suitable tool. Refer to FAX-7, "Removal and Installation" .
CAUTION: H
Do not reuse the front final drive side oil seals. WEIA0119E
8. Disconnect the front propeller shaft from the front final drive. Then reposition the front propeller shaft
aside using suitable wire. Refer to PR-5, "Removal and Installation" . I
9. Measure the drive pinion bearing preload with the front oil seal resistance using Tool.
Tool number : ST3127S000 (J-25765-A)
J
NOTE:
Record the preload measurement.
10. Put a matching mark on the end of the drive pinion in line with
K
the matching mark B on the companion flange.
CAUTION:
Use paint to make the matching mark on the drive pinion.
Do not damage the companion flange or drive pinion. L
SDIA0270E
WDIA0259E
LDIA0171E
LDIA0172E
INSTALLATION
1. Apply multi-purpose grease to the front oil seal lips and gear oil onto the circumference of the oil seal.
2. Drive the front oil seal in evenly using Tools.
Tool number A A: ST30720000 (J-25405)
B: ST27863000 ( — )
CAUTION:
● Do not reuse oil seal.
● Do not incline oil seal when Installing.
● Apply multi-purpose grease onto oil seal lips and gear oil
onto the circumference of oil seal.
WDIA0147E
3. Align the matching mark of the drive pinion with the matching
mark B of the companion flange, then install the companion
flange.
4. Apply gear oil on the threads of the drive pinion and the seating
surface of the drive pinion lock nut.
SDIA0270E
5. Install the new drive pinion lock nut. Tighten to the specified
torque using Tool. Refer to FFD-16, "COMPONENTS" . A
Tool number : KV38108300 ( — )
6. Measure the drive pinion bearing preload with the front oil seal B
resistance using Tool.
Tool number : ST3127S000 (J-25765-A)
NOTE: C
● Drive pinion bearing preload should equal the measurement
taken during removal plus an additional 0.56 N·m (0.06 Kg-m, WDIA0259E
5 in-lb). FFD
● If the drive pinion bearing preload is low, tighten the new drive pinion lock nut in 6.8 N·m (0.69 Kg-m,
5ft-lb) increments until the drive pinion preload is met.
CAUTION: E
Never loosen the drive pinion nut to decrease drive pinion bearing preload. Do not exceed speci-
fied preload. If preload torque is exceeded a new collapsible spacer must be installed. If maximum
torque is reached prior to reaching the required preload, the collapsible spacer may have been
damaged. Replace the collapsible spacer. F
Drive pinion lock nut : 186 - 294 N·m (19 - 29 kg-m, 138 - 216 ft-lb)
7. Install new side oil seals into the front final drive assembly. Refer to FFD-12, "Removal and Installation" . G
8. Install the RH and LH drive shafts to the front final drive.
CAUTION:
When installing the drive shaft assembly into the front final drive assembly, do not damage the H
side oil seal.
9. Install the remaining components in the reverse order of removal.
CAUTION: I
Check the final drive gear oil level after installation. Refer to FFD-8, "Checking Differential Gear
Oil" .
● Tighten the upper link ball joint stud nut to specifications. Refer to FSU-5, "Components" . J
● Tighten the wheel nuts to specification. Refer to WT-7, "Rotation" .
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer to BR-23, "Removal and Installation of
Brake Caliper and Disc Rotor" .
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
Tool number : ST29020001 (J-24319-01)
CAUTION:
Support the lower link using jack.
6. Remove the rear engine undercover using power tool.
7. Remove the RH and LH drive shafts from the front final drive
using suitable tool. Refer to FAX-7, "Removal and Installation" .
WEIA0119E
LDIA0173E
INSTALLATION
Installation is the reverse order of removal.
● Drive the side oil seal in evenly until it becomes flush with the
case end using Tools.
Tool number A: ST30720000 (J-25405)
B: ST27863000 ( — )
CAUTION:
● Do not reuse oil seal.
● Apply multi-purpose grease onto oil seal lips and gear oil
onto the circumference of oil seal.
PDIA0826E
● When installing the drive shaft assembly into the front
final drive assembly, do not damage the side oil seal.
● Check the final drive gear oil level. Refer to FFD-8, "Checking Differential Gear Oil" .
● Tighten the upper link ball joint stud nut to specifications. Refer to FSU-5, "Components" .
● Tighten the wheel nuts to specification. Refer to WT-7, "Rotation" .
REMOVAL
1. Remove front final drive. Refer to FFD-14, "Removal and Installation" .
B
2. Remove the rear cover bolts, then remove the rear cover from the gear carrier.
INSTALLATION
1. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of C
the rear cover. Use Genuine Silicone RTV or equivalent. Refer
to GI-46, "Recommended Chemical Products and Sealants" .
CAUTION: FFD
Remove any old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering
to the application and mating surfaces.
E
2. Install the rear cover to the gear carrier. Tighten the bolts to the
specified torque. Refer to FFD-16, "COMPONENTS" .
3. Install the front final drive assembly. Refer to FFD-14, "Removal
and Installation" . PDIA0712E F
4. Fill the final drive with recommended gear oil. Refer to FFD-8, "Checking Differential Gear Oil" .
G
WDIA0303E
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer to BR-23, "Removal and Installation of
Brake Caliper and Disc Rotor" .
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
CAUTION:
Do not pull on the ABS sensor harness. A
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool. B
Tool number : ST29020001 (J-24319-01)
CAUTION:
C
Support the lower link using a jack.
6. Remove the rear engine undercover using power tool.
7. Drain the front final drive fluid. Refer to FFD-8, "Changing Differ- FFD
ential Gear Oil" .
8. Remove the RH and LH drive shafts from the front final drive
using suitable tool. WEIA0119E
E
CAUTION:
Do not reuse the front final drive side oil seals.
9. Remove the front crossmember.
F
10. Disconnect the front propeller shaft from the front final drive. Then reposition the front propeller shaft
aside using suitable wire. Refer to PR-5, "Removal and Installation" .
11. Disconnect the vent hose from the front final drive.
G
12. Support the front final drive using a suitable jack.
13. Remove the front final drive bolts, then remove the front final
drive assembly. H
CAUTION:
Support the front final drive using a jack.
I
WDIA0145E
INSTALLATION K
Installation is the reverse order of removal.
● Install new side oil seals into the front final drive assembly. Refer to FFD-12, "Removal and Installation" .
L
CAUTION:
● When installing the drive shaft assembly into the front final drive assembly, do not damage the
side oil seal.
● Make sure there are no pinched or restricted areas on the breather hose caused by bending or
M
winding when installing it.
● Fill the final drive with recommended gear oil after installation. Refer to FFD-8, "Changing Differ-
ential Gear Oil" .
● Tighten the upper link ball joint stud nut to specifications. Refer to FSU-5, "Components" .
● Tighten the wheel nuts to specification. Refer to WT-7, "Rotation" .
COMPONENTS
WDIA0265E
Tooth Contact
1. Remove rear cover. Refer to FFD-21, "Differential Assembly" .
2. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
SPD357
3. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
SDIA0570E
SDIA2549E
SDIA0517E
FFD
● If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washers to
move drive pinion closer to drive gear.
E
Refer to FFD-37, "Pinion Height Adjusting Washer" .
G
PDIA0440E
● If the tooth contact is near the flank (flank contact), or near the
H
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
Refer to FFD-37, "Pinion Height Adjusting Washer" .
I
PDIA0441E
K
Backlash
1. Remove rear cover. Refer to FFD-21, "Differential Assembly" .
2. Fit a dial indicator to the drive gear face to measure the back- L
lash.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
M
● If the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
When the backlash is greater than specification:
Make drive gear back side adjusting washer thicker,
and drive gear tooth side adjusting washer thinner by
the same amount. Refer to FFD-37, "Side Bearing SPD513
Adjusting Washer" .
When the backlash is less than specification:
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. Refer to FFD-37, "Side Bearing
Adjusting Washer" .
CAUTION:
Do not change the total amount of washers as it will change the bearing preload.
PDIA0713E
PDIA0714E
PDIA0715E
PDIA0718E
FFD
Differential Assembly
1. Remove side shaft assembly. Refer to FFD-20, "Side Shaft" .
2. Remove rear cover bolts. E
3. Separate the rear cover from the gear carrier using Tool.
Tool number : KV10111100 (J-37228)
F
CAUTION:
● Do not damage the mating surface.
H
PDIA0699E
PDIA0700E L
5. Remove bearing caps using suitable tool.
M
PDIA0701E
PDIA0547E
CAUTION:
● Keep side bearing outer races together with inner race.
Do not mix them up.
● Keep side bearing adjusting washers together with bear-
ings.
SPD919
PDIA0827E
12. Remove lock pin of pinion mate shaft from drive gear side using
suitable tool. A
SPD025
FFD
13. Remove pinion mate shaft.
G
SDIA0031J
14. Turn pinion mate gear, then remove pinion mate gear, pinion
H
mate thrust washer, side gear and side gear thrust washer from
differential case.
SDIA0032J
K
Drive Pinion Assembly
1. Remove side shaft assembly. Refer to FFD-20, "Side Shaft" .
2. Remove differential assembly. Refer to FFD-21, "Differential Assembly" . L
3. Remove drive pinion lock nut using Tool.
Tool number : KV38108300 (J-44195)
M
PDIA0702E
PDIA0703E
PDIA0704E
7. Remove pinion rear bearing inner race and drive pinion height
adjusting washer using Tool.
Tool number : ST30031000 (J-22912-01)
S-PD179
PDIA0716E
PDIA0705E
FFD
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If parts are worn or dam-
aged, follow the measures below.
E
Content Conditions and Measures
● If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
Hypoid gear F
● If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
● If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
Bearing G
is observed, replace as a bearing assembly (as a new set).
Side gear and Pinion mate ● If any cracks or damage on the surface of the tooth is found, replace.
gear ● If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
H
Side gear thrust washer and
● If it is chipped (by friction), damaged, or unusually worn, replace.
pinion mate thrust washer
● Whenever disassembled, replace. I
Oil seal ● If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case ● If any wear or crack on the contact sides of the differential case is found, replace. J
● If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
Companion flange
companion flange is found, replace.
PDIA0460E
ally.
Pinion Gear Height
1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the Tool.
Tool number : — (J-34309)
SPD769
G
SPD893
4. Assemble the pinion front bearing inner race and the J-34309-2 H
gauge anvil. Assemble them together with the J-34309-1 gauge
screw in gear carrier. Make sure that the pinion height gauge
plate, J-34309-16, will turn a full 360 degrees. Tighten the two
I
sections together by hand.
SPD199A K
SPD770
PDIA0566E
SPD208A
8. Position the side bearing discs, Tool, and arbor firmly into the
side bearing bores. Install the bearing caps and tighten bearing
cap bolts to the specified torque. Refer to FFD-16, "COMPO-
NENTS" .
Tool number : — (J-25269-18)
SPD211A
SPD204A
SPD775
11. Correct the pinion height washer size by referring to the “pinion
head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive 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 washer.
SPD542
SPD205A
ASSEMBLY I
Drive Pinion Assembly
1. Install front and rear bearing outer races using Tools.
Tool number A: ST30611000 (J-25742-1) J
B: ST30613000 (J-25742-3)
C: KV38100200 (J-26233) K
CAUTION:
● First tap the bearing outer race until it becomes flat to the
gear carrier. L
● Do not reuse pinion front and rear bearing outer race.
PDIA0707E
SDIA0048E
PDIA0708E
6. Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion assembly.
CAUTION:
Do not reuse pinion front bearing inner race.
SPD581
7. Press the pinion front bearing inner race to drive pinion as far as
drive pinion lock nut can be tightened using Tool.
Tool number : ST33200000 (J-26082)
PDIA0709E
8. Install front oil seal until it becomes flush with the case end using
Tools.
Tool number A: ST30720000 (J-25405)
B: ST27863000 ( — )
CAUTION:
● Do not reuse oil seal.
● Do not incline oil seal when installing.
PDIA0675E
FFD
10. Apply gear oil to the thread and seat of drive pinion lock nut, and
temporarily tighten drive pinion lock nut to drive pinion.
CAUTION: E
Do not reuse drive pinion lock nut.
11. Adjust the new drive pinion lock nut tightening torque and pinion
bearing preload torque using Tools.
F
Tool number A: KV38108300 (J-44195)
B: ST3127S000 (J-25765-A)
G
Drive pinion lock nut tightening torque:
186 - 294 N·m (19 - 29 kg-m, 138 - 216 ft-lb)
H
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
CAUTION: I
● Adjust the lower limit of the drive pinion lock nut tighten-
ing torque first.
● If the preload torque exceeds the specified value, replace J
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.
PDIA0710E
● After adjustment, rotate drive pinion back and forth 2 to 3 K
times to check for unusual noise, rotation malfunction, and other malfunctions.
12. Install differential case assembly. Refer to FFD-32, "Differential Assembly" .
CAUTION: L
Do not install rear cover yet.
13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to FFD-17, "Drive Gear Runout" , FFD-18, "Tooth Contact" , FFD-19, "Backlash" , M
FFD-20, "Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to FFD-17, "Total Preload Torque" .
15. Install rear cover. Refer to FFD-32, "Differential Assembly" .
16. Install side shaft assembly. Refer to FFD-35, "Side Shaft" .
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears.
SDIA0193J
SDIA2025E
4. Align the lock pin holes on differential case with shaft, and install
pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate
side gear thrust washers. Refer to FFD-26, "Differential Side
Gear Clearance" .
SDIA0195J
6. Drive a lock pin into pinion mate shaft, using suitable tool.
Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
SPD030
SDIA2593E
FFD
8. Apply thread locking sealant into the thread hole of drive gear.
● Use Genuine High Strength Thread Locking Sealant or
equivalent. Refer to GI-46, "Recommended Chemical E
Products and Sealants" .
CAUTION:
Make sure the drive gear back and threaded holes are
F
clean.
G
SDIA2594E
9. Install drive gear on the bolts, and then tighten to the specified
H
torque. Refer to FFD-16, "COMPONENTS" .
CAUTION:
● Tighten bolts in a crisscross pattern.
I
● After tightening the bolts to the specified torque, tighten
the bolts an additional 34 to 39 degrees.
SDIA0247J
K
10. Press side bearing inner races to differential case, using Tools.
Tool number A: ST33230000 (J-35867) L
B: ST33061000 (J-8107-2)
CAUTION:
Do not reuse side bearing inner race. M
SPD353
12. Apply gear oil to side bearings, and install differential case
assembly with side bearing outer races into gear carrier.
SPD527
13. Insert left and right original side bearing adjusting washers in
place between side bearings and gear carrier, using Tool.
Tool number : KV38100600 (J-25267)
PDIA0706E
14. Align matching mark on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap bolts to the speci-
fied torque. Refer to FFD-16, "COMPONENTS" .
PDIA0700E
16. Drive side oil seal until it becomes flush with the case end using
Tools.
Tool number A: ST30720000 (J-25405)
B: ST27863000 ( — )
CAUTION:
● Do not reuse oil seal.
● Do not incline oil seal when installing.
FFD
Side Shaft
1. Press side shaft bearing to side shaft.
CAUTION: E
Do not reuse bearing.
2. Install snap ring (shaft side).
3. Install side shaft assembly into gear carrier. F
4. Install snap ring (hole side).
PDIA0719E
5. Drive side oil seal until it becomes flush with the case end using H
Tools.
Tool number A: ST30720000 (J-25405)
I
B: ST27863000 ( — )
CAUTION:
● Do not reuse oil seal. J
● Do not incline oil seal when installing.
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
Item Specification
Pinion bearing (P1 ) 1.08 - 1.66 (0.11 - 0.16, 10 - 14)
Side bearing (P2 ) 0.59 - 1.08 (0.06 - 0.11, 6 - 9)
Side bearing to pinion bearing (Total preload)
1.67 - 2.74 (0.17 - 0.27, 15 - 24)
(Total preload = P1 + P2 )
BACKLASH
Unit: mm (in)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059)
SELECTIVE PARTS
Side Gear Thrust Washer
Unit: mm (in)
Thickness Part number* Thickness Part number*
0.75 (0.0295) 38424 W2010 0.87 (0.0343) 38424 W2014
0.78 (0.0307) 38424 W2011 0.90 (0.0354) 38424 W2015
0.81 (0.0319) 38424 W2012 0.93 (0.0366) 38424 W2016
0.84 (0.0331) 38424 W2013 0.96 (0.0378) 38424 W2017
*: Always check with the Parts Department for the latest parts information.
*: Always check with the Parts Department for the latest parts information.