Page 2697 of 3833

REAR FINAL DRIVE ASSEMBLY
RFD-21
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3. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case assembly and side bearing
to remove carrier case assembly and rear cover.
CAUTION:
The pressure shall be as low as possible to remove carrier
case assembly and rear cover. The maximum pressure shall
be 10kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
The differential case assembly, side bearings, and adjusting
shims are compressed and integrated in the carrier case and
rear cover.
4. Remove side bearing adjusting shims and side bearing outer
race.
CAUTION:
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be
identified later.
5. Remove drive gear mounting bolts, and remove drive gear from the differential case.
6. Using a puller and a drift, remove side bearing inner race.
7. Using a pin punch, pull the lock pin out of the pinion mate shaft.
8. Remove pinion mate shaft, pinion mate gears, pinion mate
thrust washers, side gears, side gear thrust washers from the
differential case.
Removing Drive Pinion Assembly
1. Remove electronically controlled coupling assembly. Refer to
RFD-20, "
Removal of Electronically Controlled Coupling Assem-
bly" .
2. Remove differential case assembly. Refer to RFD-20, "
Removal
of Differential Assembly" .
3. Fit a drive pinion socket onto the drive pinion spline. Using a
pinion nut wrench, remove pinion nut.
4. Remove center oil seal.
SDIA0575E
SDIA0620E
PDG0219D
PDG0220D
Page 2698 of 3833

RFD-22
REAR FINAL DRIVE ASSEMBLY
5. Press the drive pinion gear assembly out of the carrier case.
6. Remove pinion front bearing inner race.
7. Remove collapsible spacer.
8. Using a puller, remove pinion rear bearing inner race from the
drive pinion.
9. Using a brass rod, tap the pinion front bearing outer race evenly
from the 2 cutouts on the carrier case, and remove pinion front
bearing outer race.
CAUTION:
Be careful not to damage the carrier case.
10. Using a brass rod, tap the drive pinion adjusting shim evenly
from the 2 cutouts on the carrier case, and remove drive pinion
adjusting shims and pinion rear bearing outer race.
CAUTION:
Be careful not to damage the carrier case.
ASSEMBLY
Assembly of Drive Pinion Assembly
1. Assemble with a drive pinion adjusting shim of the same thick-
ness as was installed prior to disassembly. Using a drift, press a
pinion rear bearing outer race into the carrier case.
CAUTION:
●At first, using a hammer, tap the bearing outer race until it
becomes square to the carrier case.
●Do not reuse the pinion rear bearing outer race.
SDIA0576E
SDIA0577E
SDIA0564E
SDIA0578E
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REAR FINAL DRIVE ASSEMBLY
RFD-23
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2. Using a drift, press a pinion front bearing outer race into the car-
rier case.
CAUTION:
●At first, using a hammer, tap the bearing outer race until it
becomes square to the carrier case.
●Do not reuse the pinion front bearing outer race.
3. Using a drift, press a pinion rear bearing inner race into the drive
pinion.
CAUTION:
Do not reuse the pinion rear bearing inner race.
4. After checking and adjusting the tooth contact and backlash of
the hypoid gear following the procedure below, assemble a col-
lapsible spacer to the drive pinion.
CAUTION:
●Be careful of the mounting orientation of the collapsible
spacer.
●Do not reuse the collapsible spacer.
a. Apply differential oil to the pinion bearing, and assemble the
drive pinion to the carrier case.
CAUTION:
Do not assemble a collapsible spacer.
b. Assemble a pinion front bearing inner race to the drive pinion.
Using a drift and press stand, press the pinion nut as far as it
can be tightened.
c. Temporarily tighten the removed pinion nut to the drive pinion.
NOTE:
Use the removed pinion nut only for the preload torque mea-
surement.
SDIA0579E
SDIA0580E
SDIA0581E
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RFD-24
REAR FINAL DRIVE ASSEMBLY
d. Fit the drive pinion socket onto the drive pinion spline. Using a
pinion nut wrench, tighten the pinion nut to the specified preload
torque.
CAUTION:
The pinion nut is tightened with no collapsible spacer. Be
careful not to overtighten it. While measuring the preload,
tighten it by 5° to 10°.
e. Apply differential oil to the side bearings, and install new side
bearing adjusting shims with the same thickness or re-install the
old ones to the same mounting position they were in prior to dis-
assembly. Install the differential case assembly to the carrier
case. Refer to RFD-25, "
Installation of Differential Assembly" .
f. Install a dummy cover set to check and adjust the tooth contact.
Refer to RFD-17, "
TOOTH CONTACT" .
g. Check and adjust the backlash. Refer to RFD-15, "
HYPOID
GEAR BACKLASH" .
h. Remove dummy cover set, and remove differential case assembly.
i. Remove pinion nut, pinion front bearing inner race, and remove
drive pinion gear.
5. Install the drive pinion gear with a collapsible spacer to the car-
rier case.
6. Using a drift and press stand, press the pinion front bearing
inner race to the drive pinion as far as a pinion nut can be tight-
ened.
7. Apply anti-corrosive oil to the thread and seat of the pinion nut,
and temporarily tighten the pinion nut and washer to the drive
pinion.
CAUTION:
Do not reuse the pinion nut.
PDG0229D
SDIA0576E
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REAR FINAL DRIVE ASSEMBLY
RFD-25
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8. Fit a drive pinion socket onto the drive pinion gear spline. Using
a pinion nut wrench, adjust the pinion nut tightening torque and
pinion bearing preload torque.
CAUTION:
●Do not reuse the pinion nut.
●Adjust the lower limit of the pinion nut tightening torque
first.
●If the preload torque exceeds the specified value, replace
the collapsible spacer and tighten it again to adjust. Never
loosen the pinion nut to adjust the preload torque.
●After adjustment, rotate the drive pinion gear back and forth
2 - 3 times to check for abnormal noise, rotation malfunc-
tion, and other malfunctions.
9. Install center oil seal.
10. Install the differential case assembly. Refer to RFD-25, "
Installa-
tion of Differential Assembly" .
CAUTION:
Do not install the rear cover.
11. Install a dummy cover set, and check backlash, drive gear back
runout, and tooth contact. Refer to RFD-17, "
TOOTH CON-
TA C T" .
12. Remove dummy cover, then install the rear cover, and drive in
the oil seal.RFD-25, "
Installation of Differential Assembly" Refer
to
13. Check overall preload torque. Refer to RFD-15, "
OVERALL PRELOAD TORQUE" .
14. Connect electronically controlled coupling assembly. Refer to RFD-28, "
Installation of Electronically Con-
trolled Coupling Assembly" .
15. Check companion flange runout. Refer to RFD-17, "
COMPANION FLANGE RUNOUT" .
Installation of Differential Assembly
1. Assemble new side gear thrust washers with the same thickness as the ones installed prior to disassem-
bly or reinstall the old ones on the side gears.
2. Assemble the side gears, side gear thrust washers, pinion mate gears, and pinion mate thrust washers to
the differential case, and temporarily assemble the pinion mate shaft. Pinion nut tightening torque:
99 - 431 N·m (10 - 43 kg-m, 73 - 317 ft-lb)
Pinion bearing preload torque:
0.69 - 1.17 N·m (0.07 - 0.11 kg-m, 7 - 10 in-lb)
PDG0229D
SDIA0146E
Page 2702 of 3833

RFD-26
REAR FINAL DRIVE ASSEMBLY
3. Measure the side gear endplay following the procedure below,
and select the appropriate side gear thrust washers.
●Using a thickness gauge, measure the clearance between
side gear back and the differential case at 3 different points,
while rotating the side gear. Average the 3 readings, and
select the appropriate side gear thrust washer so that the
mean value is within specifications below. (Measure the clear-
ance of the other side as well.)
CAUTION:
●Before measurement, place differential case straight up
so that side gear to be measured comes upward. To pre-
vent the side gear from tilting, insert thickness gauges
with the same thickness from both sides.
●Select a side gear thrust washer for right and left individ-
ually.
4. Assemble the selected side gear thrust washer to the differential case.
5. Using a pin punch, drive a lock pin into the pinion mating shaft.
CAUTION:
Do not reuse the lock pin.
6. Using a drift, press a side bearing inner race into the differential
case.
7. Apply locking sealant (Thread lock super 1303 or equivalent) onto the thread of the drive gear.
CAUTION:
The drive gear back, threaded holes, and drive gear bolts shall be cleaned and decreased suffi-
ciently.
8. Assemble the drive gear to the differential case, and tighten it with drive gear bolt. Side gear endplay standard:
0.2 mm (0.008 in) or less. Every gear shall rotate
smoothly with no abnormal feeling of drag.
Thickness Part No. Thickness Part No.
0.74 mm (0.0291 in)
0.77 mm (0.0303 in)
0.80 mm (0.0315 in)38424 4N200
38424 4N201
38424 4N2020.83 mm (0.0327 in)
0.86 mm (0.0339 in)38424 4N203
38424 4N204
SDIA0583E
PDG0219D
SDIA0584E
: 94 - 112 N·m (9.6 - 11 kg-m, 70 - 82 ft-lb)
Page 2703 of 3833

REAR FINAL DRIVE ASSEMBLY
RFD-27
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9. Apply differential oil to the side bearings, and assemble new side bearing adjusting shims (2 pieces for
one side) with the same thickness as the ones installed prior to disassembly or re-install the old ones, with
a side bearing outer race to the differential case.
If the side bearing adjusting shims have been already selected, use them.
10. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case assembly and side bearing
to install the carrier case assembly to differential case assembly.
CAUTION:
●A drift shall be placed on the center of the adjusting
shims.
●The pressure shall be as low as possible to install the
carrier case assembly into the differential assembly. The
maximum pressure shall be 1 ton.
●If the adjusting shims are installed by tapping, the carrier
case may be damaged. Avoid tapping.
11. Install a dummy cover set, check and adjust the backlash, drive gear back runout, tooth contact, and over-
all preload torque. Refer to RFD-15, "
Inspection Before Disassembly" .
12. Remove dummy cover set.
13. Apply sealant (Three bond 1217 or the equivalent) around the carrier case mounting surface on the rear
cover.Refer to
CAUTION:
Remove old sealant on the mounting surface, then remove any moisture, oil, and foreign material
on the application and mounting surfaces.
14. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case assembly and side bearing
to install the rear cover.
CAUTION:
●A drift shall be placed on the center of the adjusting
shims.
●The pressure shall be as low as possible to install the
rear cover. The maximum pressure shall be 10kN (1 ton,
1.1US ton, 1.0 Imp ton)
●If the rear cover is forced in by tapping, the rear cover
may be damaged by the adjusting shims. Avoid tapping.
15. Tighten rear cover mounting bolts to the specified torque.
16. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
●Oil seals are not reusable. Never reuse them.
●Apply multi-purpose grease onto the oil seal lips, and dif-
ferential oil onto the circumference of the oil seal.
17. Check overall preload torque. Refer to RFD-15, "
OVERALL PRELOAD TORQUE" .
SDIA0585E
SDIA0575E
Tightening torque
M8-bolt : 14 - 17 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb)
M10-bolt : 31 - 36 N·m (3.2 - 3.6kg·m, 23 - 26 ft-lb)
PDG0234D
Page 2704 of 3833

RFD-28
REAR FINAL DRIVE ASSEMBLY
Installation of Electronically Controlled Coupling Assembly
1. Using a drift, install the coupling front bearing to the electroni-
cally controlled coupling.
CAUTION:
At disassembly, be sure to install shim between electroni-
cally-controlled coupling and bearing. Chamfering side of
shim should be coupled to install.
2. Assemble the electronically controlled coupling assembly to the drive pinion.
3. Using a drift, drive an oil seal until it becomes flush with the case
end.
CAUTION:
●Oil seals are not reusable. Never reuse them.
●Apply multi-purpose grease onto the oil seal lips, and dif-
ferential oil onto the circumference of the oil seal.
4. Apply sealant (Three bond 1217 or the equivalent) around the
carrier case mounting surface on the coupling cover.Refer to
RFD-10, "
REAR COVER GASKET" .
CAUTION:
Remove old sealant on the mounting surface, then remove
any moisture, oil, and foreign material from the application
and mounting surfaces.
5. Assemble the coupling cover to the carrier case assembly with
the arrow facing upward, temporarily tighten reamer bolts to the
positions shown in the figure.
6. Tighten the reamer bolts and coupling cover mounting bolts to
the specified torque.
7. Assemble the companion flange.
8. Using a flange wrench, tighten the companion flange nut to the specified torque.
CAUTION:
Do not reuse the companion flange nut.
9. Check companion flange runout. Refer to RFD-17, "
COMPANION FLANGE RUNOUT" .
SDIA0586E
PDG0237D
SDIA0587E