Page 3033 of 4449
FAX-24
[AWD]
FRONT DRIVE SHAFT
Revision: 2004 November 2004 FX35/FX45
Secure boot band so that dimension “M” shown bellow right
satisfies the following:
9. After installing joint sub-assembly and shaft, rotate boot to check
whether or not the actual position is correct. If boot position is
not correct, secure boot with new boot bands again.Large diameter side : 3.0 mm (0.118 in)
Small diameter side : 2.0 mm (0.079 in)
DSF0047D
Page 3034 of 4449
SERVICE DATA
FAX-25
[AWD]
C
E
F
G
H
I
J
K
L
MA
B
FA X
Revision: 2004 November 2004 FX35/FX45
SERVICE DATAPFP:00030
Wheel BearingADS000OR
Drive ShaftADS000OS
Tightening TorqueADS000OT
Axial end play 0.05 mm (0.002 in) or less
Joint type (Wheel side) (Transaxle side)
Grease quantity 95 − 115 g (3.35 − 4.06 oz)95 − 105 g (3.35 − 3.70 oz) (LH side)
11 3 − 123 g (3.99 − 4.34 oz) (RH side)
Boots installed length 136 mm (5.35 in)95 − 97 mm (3.74 − 3.82 in) (LH side)
157.8 − 159.8 mm (6.21 − 6.29 in) (RH side)
Drive shaft - Side flange 44.5 N·m (4.5 kg-m, 33 lb)
Hub lock nut 275 N·m (28 kg-m, 203 lb)
Page 3035 of 4449
FAX-26
[AWD]
SERVICE DATA
Revision: 2004 November 2004 FX35/FX45
Page 3036 of 4449

FFD-1
FRONT FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
C
E
F
G
H
I
J
K
L
M
SECTION FFD
A
B
FFD
Revision: 2004 November 2004 FX35/FX45
FRONT FINAL DRIVE
PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
FRONT OIL SEAL ...................................................... 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSTALLATION ..................................................... 8
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
FRONT FINAL DRIVE ASSEMBLY .......................... 10
Removal and Installation (VQ35DE) ...................... 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Removal and Installation (VK45DE) ........................ 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Front Final Drive Breather Hose ............................ 12
REMOVAL AND INSTALLATION (VQ35DE) ....... 12
REMOVAL AND INSTALLATION (VK45DE) ....... 13
Components ........................................................... 14
COMPONENTS (VQ35DE) ................................. 14
COMPONENTS (VK45DE) ................................. 16Side Shaft ............................................................... 18
BEARING AND OIL SEAL REPLACEMENT ....... 18
EXTENSION TUBE REPLACEMENT ................. 19
PRE-DISASSEMBLY INSPECTION .................... 19
DISASSEMBLY AND ASSEMBLY ...................... 21
Differential Case Assembly .................................... 24
Installation Drive Pinion Assembly ......................... 27
DIFFERENTIAL CASE INSTALLATION .............. 28
TOOTH CONTACT INSPECTION ....................... 30
TOOTH CONTACT PATTERN AND HEIGHT
ADJUSTING WASHER SELECTION .................. 31
TOOTH CONTACT ADJUSTMENT ..................... 31
TOTAL PRELOAD INSPECTION ........................ 33
DRIVE PINION PRELOAD ADJUSTMENT ......... 33
After Inspection ....................................................... 35
Carrier Cover Installation ........................................ 36
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 37
General Specifications ............................................ 37
Drive Gear Runout .................................................. 37
Side Gear Adjustment ............................................ 37
Available Side Gear Thrust Washers ...................... 37
SIDE BEARING PRELOAD ADJUSTING SHIMS ... 37
Drive Pinion Height Adjustment .............................. 38
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 38
Drive Pinion Preload Adjustment ............................ 38
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 38
Total Preload Adjustment ........................................ 38
Page 3037 of 4449

FFD-2
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
PrecautionsADS000N3
CAUTION:
Before starting diagnosis of the vehicle, understand symptoms well. Perform correct and system-
atic operations.
Check for the correct installation status prior removal or disassembly. When mating marks are
required, be sure they do not interfere with the function of the parts they are applied to.
Carry out an overhaul in a clean work place, Using a dust proof room is recommended.
Before disassembly, using steam or white gasoline, completely remove sand and mud from the
exterior the unit, preventing them from entering into the unit during disassembly or assembly.
Check appearance of the disassembled parts for damage, deformation, and abnormal wear. If a
malfunction is detected, replace it with a new one.
Normally replace lock pins, oil seals, and bearings with new ones every times they are removed.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-
side. If tightening sequence is specified, observe it.
Clean and flush the parts sufficiently and blow them dry.
Be careful not to damage the sliding surfaces and mating surface.
When applying sealant, remove the old sealant from the mounting surface; then remove any mois-
ture, oil, and foreign materials from the application and mounting surfaces.
Always use shop paper for cleaning the inside of components.
Avoid using cotton gloves or a shop cloth to prevent entering of lint.
During assembly, observe the specified tightening torque, and new differential oil, Vaseline, or
multi-purpose grease, as specified for each vehicle, when necessary.
Page 3038 of 4449

PREPARATION
FFD-3
C
E
F
G
H
I
J
K
L
MA
B
FFD
Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsADS000N4
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore No.)
Tool nameDescription
ST33400001 (J26082)
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Drift
Installing front oil seal
Installing right side oil sea
KV38100500 (J25273)
ST3620000 ( – )
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
DriftInstalling drive pinion oil seal
Installing side shaft oil seal (retainer side)
ST33290001 (J34286)
Outer race puller
Removing side bearing outer race
Removing side oil seal
Removing front oil seal
ST3306S001 ( – )
ST33051001 (J22888-20) body
ST33061000 (J8107-2) adapter.
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
Puller setRemoving side bearing
ST30031000 (J22912-01)
PullerRemoving drive pinion bearing
ST33230000 ( – )
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28mm (1.10 in) dia.
DriftInstalling side bearing
ST33220000 ( – )
a: 32 mm (1.26 in) dia.
b: 31.5 mm (1.24 in) dia.
c: 21 mm (0.83 in) dia.
DriftInstalling side shaft bearing
ZZA0702D
ZZA0811D
NT713
NT072
ZZA0700D
ZZA1046D
ZZA1046D
Page 3039 of 4449
FFD-4
PREPARATION
Revision: 2004 November 2004 FX35/FX45
KV31100300 ( – )
Pin punch Removing and installing pinion mate shaft
lock pin
ST30032000 ( – )
A: 80mm (3.15 in) dia.
B: 38 mm (1.50 in) dia.
C: 31 mm (1.22 in) dia.
Inner race adaptorInstalling drive pinion bearing
Installing side shaft and retainer
KV38102510 ( – )
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
DriftInstalling front oil seal
ST33210000 ( – )
a: 44 mm (1.73 in) dia.
b: 34.5 mm (1.36 in) dia.
c: 22 mm (0.87 in) dia.
Drift
Removing side shaft bearing
Installing left side oil seal
ST37820000 ( – )
a: 39 mm (1.54 in) dia.
b: 72 mm (2.83 in) dia.
DriftInstalling drive pinion bearing
KV31103000 ( – )
a: 49 mm (1.93 in) dia.
b: 70 mm (2.76 in) dia.
DriftInstalling drive pinion bearing
ST1982000 ( – )
a: 70 mm (2.76 in) dia.
b: 50 mm (1.97 in) dia.
DriftInstalling side shaft oil seal Tool number (Kent-Moore No.)
Tool nameDescription
ZZA0515D
SDIA0217J
ZZA0838D
ZZA1046D
ZZA0836D
ZZA1113D
ZZA0838D
Page 3040 of 4449
PREPARATION
FFD-5
C
E
F
G
H
I
J
K
L
MA
B
FFD
Revision: 2004 November 2004 FX35/FX45
Commercial Service ToolsADS000N5
ST35321000 ( – )
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
DriftInstalling side bearing
KV40104000 ( – )
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.
Drive pinion flange wrenchRemoving and installing drive pinion lock
nut
ST3127S000 (see J25765-A)
1. GG91030000
Torque wrench (J25765)
2. HT62940000 ( – )
Socket adapter (1/2″)
3. HT62900000 ( – )
Socket adapter (3/8″)
Preload gaugeInspecting pinion bearing preload and total
preload Tool number (Kent-Moore No.)
Tool nameDescription
ZZA1000D
NT659
NT124
Tool nameDescription
Power toolLoosening bolts and nuts
PBIC0190E