Page 769 of 2890
7. Center Differential (AWD Model)
B3M0036A
1Ball bearing
2Snap ring (Inner-110)
3Center differential cover
4Needle bearing
5Adjusting washer
6Viscous coupling
7Pinion shaft
8Differential bevel pinion
9Retainer
10Differential bevel gear
11Washer
12Center differential case
13Snap ring
14Roller bearing
13
3-1COMPONENT PARTS
7. Center Differential (AWD Model)
Page 770 of 2890
8. Front Differential
G3M0515
1Drive pinion shaft
2Hypoid driven gear
3Pinion shaft
4Straight pin
5Washer
6Differential bevel gear
7Differential bevel pinion
8Snap ring (Outer)
9Roller bearing
10Differential case
11Oil seal
12Differential side retainer
13O-ring
14Axle drive shaft
15Retainer lock plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25±5 (2.5±0.5, 18.1±3.6)
T2: 62±5 (6.3±0.5, 45.6±3.6)
14
3-1COMPONENT PARTS
8. Front Differential
Page 771 of 2890
1. General
A: APPLICATION
Large titleModel
AWD FWD
1 General
2Transfer Case and Extension
(AWD Model)
3 Rear Case (FWD Model)
4 Transmission Case
5 Drive Pinion Assembly (AWD Model)
6 Drive Pinion Assembly (FWD Model)
7 Main Shaft Assembly
8 Center Differential (AWD Model)
9 Front Differential
The table above shows the titles of the main sections in
Service Procedures and the applicable vehicle models.
Carry out service operations by referring to the sections
applicable to the vehicle to be serviced.
15
3-1SERVICE PROCEDURE
1. General
Page 772 of 2890

B3M0037A
B: PRECAUTIONS
1) The following job should be followed before disassem-
bly:
(1) Clean oil, grease, dirt and dust from transmission.
(2) Remove drain plug
1to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44±3 N⋅m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
G3M0517
(3) Attach transmission to ST.
ST 499937100 TRANSMISSION STAND SET
2) Rotating parts should be coated with oil prior to assem-
bly.
3) All disassembled parts, if to be reused, should be rein-
stalled in the original positions and directions.
4) Gaskets and lock washers must be replaced with new
ones.
5) Liquid gasket should be used where specified to pre-
vent leakage.
6) Fill transmission gear oil through the oil level gauge
hole up to upper point level gauge.
C: INSPECTION
Disassembled parts should be washed clean first and then
inspected carefully.
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner races are
broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make abnormal
noise when turned after gear oil lubrication.
B3M0038A
The ball bearing3on the rear side of the drive pinion shaft
2should be checked for smooth rotation before the drive
pinion assembly is disassembled. In this case, because a
preload is working on the bearing, its rotation feels like it is
slightly dragging unlike the other bearings.
Bearings having other defects
16
3-1SERVICE PROCEDURE
1. General
Page 773 of 2890

2) Bushing (each gear)
Replace the bushing in the following cases:
(1) When the sliding surface is damaged or abnormally
worn.
(2) When the inner wall is abnormally worn.
3) Gears
(1) Replace gears with new ones if their tooth surfaces
are broken, damaged, or excessively worn.
(2) Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
(3) Correct or replace if the inner surface or end face
is damaged.
B3M0039A
4) Baulk ring
Replace the ring in the following cases:
When the inner surface and end face are damaged.
When the ring inner surface is abnormally or partially
worn down.
If the gap between the end faces of the ring and the gear
splined part is excessively small when the ring is pressed
against the cone.
Clearance
A:
0.5 — 1.0 mm (0.020 — 0.040 in)
When the contact surface of the synchronizer ring
4
insert is scored or abnormally worn down.
B3M0040A
5) Insert5(shifting)
Replace the insert if deformed, excessively worn, or defec-
tive in any way.
17
3-1SERVICE PROCEDURE
1. General
Page 774 of 2890
6) Oil seal
Replace the oil seal if the lip is deformed, hardened,
damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively
worn, bent, or defective in any way.
G3M0521
9) Differential gear
Repair or replace the differential gear in the following
cases:
(1) The hypoid drive gear and drive pinion shaft tooth
surface are damaged, excessively worn, or seized.
(2) The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
(3) There is damage, wear, or seizure of the differen-
tial bevel pinion, differential bevel gear, washer, pinion
shaft, and straight pin.
(4) The differential case has worn or damaged sliding
surfaces.
18
3-1SERVICE PROCEDURE
1. General
Page 775 of 2890
2. Transfer Case and Extension (AWD
Model)
A: REMOVAL
B3M0041A
1) Remove transfer cover1.
2) Remove shifter fork screw
2which secures selector
arm to shifter arm.
3) Remove transfer case
4with extension assembly3.
19
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 776 of 2890
B: DISASSEMBLY
1. SEPARATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
G3M0523
1) Separate transfer case1and extension assembly2.
2) Remove transfer driven gear
3and center differential
4as a set.
3) Remove thrust washer
5(52x61xt).
B3M0042A
2. TRANSFER CASE
1) Remove neutral switch
6.
NOTE:
Before removing shifter arm, disconnect neutral switch.
2) Draw out shifter arm
1and remove selector arm8.
3) Remove plug
2, spring3and reverse check ball4.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
20
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)