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FFD-22
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
REMOVAL OF DRIVE PINION ASSEMBLY
1. Hold the companion flange using cam sprocket wrench or flange wrench, remove the pinion lock nut.
2. Remove the companion flange using puller.
3. Temporarily install drive pinion lock nut.
CAUTION:
Install the drive pinion lock nut until it flash with the drive
pinion end.
4. Remove the drive pinion from the carrier case.
5. Remove the bearing outer race by tapping the race evenly.
6. On companion flange side, remove the bearing outer race with
bearing and oil seal.
7. Press out the drive pinion bearing from the drive pinion using
puller.
DIFFERENTIAL CASE DISASSEMBLY
1. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
CAUTION:
To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.
If is not necessary to remove side bearing except it is
replaced.Tool number : KV40104000 ( – )
Tool number : ST30031000 (J22912–01 )
SDIA1658E
SDIA1663E
Tool number
A: ST3305S001 (−)
B: ST33061000(J8107−2)
SPD920
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FRONT FINAL DRIVE ASSEMBLY
FFD-23
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Revision: 2004 November 2004 FX35/FX45
Be careful not to confuse left-hand and right-hand parts.
Keep bearing and bearing race for each side together.
2. Loosen drive gear mounting bolt in a crisscross fashion.
3. Tap drive gear off the differential case with a soft hammer.
Tap evenly all around to keep the drive gear from binding.
4. Disassembly the differential case.
a. Drive out the pinion mate shaft lock pin using punch.
b. Remove the pinion mate shaft.
c. Turn the pinion mate gear, then remove the pinion mate gear,
pinion mate thrust washer, side gear and side gear thrust
washer from the differential case.
SPD022
SDIA0246J
Tool number : KV31100300 ( – )
SDIA1664E
SDIA0031J
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FFD-24
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
d. Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.
INSPECTION
Clean up the disassemble parts. Then, inspect if the parts are wear or damaged. If so, follow the mea-
sures below.
Differential Case AssemblyADS000NO
1. Apply gear oil to contact surfaces of each gear, thrust washers
and differential case.
2. Install the removed thrust washer or same thickness washer to
side gear.
SDIA0187J
Content Measures
Drive gear and drive pinion
If the gear teeth do not mesh or line-up correctly, determine the cause and
adjust, repair, or replace as necessary.
If the gear are worn, cracked, damaged, pitted or chipped (by friction)
noticeably, replace with new gears.
Bearing
If found any chipped (by friction), pitted, worn, rusted, scratched mark, or
unusual noise from the bearing, replace with new bearing assembly (as a
new set).
Side gear and pinion mate gear
Replace with a new one if found any cracks or damage on the surface of
the tooth.
Replace with a new one if found any worn or chipped mark on the contact
sides of the thrust washer.
Side gear thrust washer and pinion mate thrust washer
Replace with a new one if found that it is chipped (by friction), damaged, or
unusual worn.
Oil seal
Oil seals must be replaced with a new one whenever disassembled.
Differential case
Replace with a new one if found any wear or cracks on the contact sides of
the differential case.
Companion flange
Replace with a new one if found any chipped marks (about 0.10 mm,
0.0038 in) or other damage on the contact sides of the lip of the companion
flange.
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FRONT FINAL DRIVE ASSEMBLY
FFD-25
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Revision: 2004 November 2004 FX35/FX45
3. Install the side gear, thrust washers, pinion mate gears and
thrust washers to differential case.
CAUTION:
Install the circlip equipped side gear to the side retainer
side.
4. Install pinion mate gears by placing the pair of gear facing each
other, and turning them.
5. Install the pinion mate shaft while aligning the lock pin holes
between the differential case and pinion mate shaft.
6. Place the differential gear case so that measurement point fac-
ing up as shown.
7. Use two feeler gauges to prevent leaning of side gear as shown.
8. Measure the clearance at 3 points by turning the side gear.
9. Select side gear thrust washer so that the clearance is within
standard.
CAUTION:
Check the smooth gear movement.
10. Place the differential gear case upside down, and measure the
opposite side clearance.
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SDIA1650E
Rear face of side gear and differential case clearance
: 0.20 mm (0.0079 in) or less
SDIA1654E
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FFD-26
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
11. If clearance exceed limit, adjust the clearance by selecting adjusting shim.
If clearance too large, increase thrust washer thickness.
If clearance too small, decrease thrust washer thickness.
12. Drive the lock pin into the pinion mate shaft using punch.
CAUTION:
Do not reuse the lock pin. Always replace the with a new
one.
13. Apply genuine medium strength locking agent or equivalent to
the drive gear bolt hole thread.
14. Assemble the drive gear and differential case.
15. Apply oil to the mounting bolt seating surface., tighten the bolt in
crisscross pattern to specified torque. Refer to FFD-16, "
COM-
PONENTS (VK45DE)" or FFD-14, "COMPONENTS (VQ35DE)"
.
16. Press-fit side bearing inner race on differential case with tool.Tool number : KV31100300 ( – )
SDIA1670E
SDIA0201J
SDIA0247J
Tool number A: ST33230000 ( – )
B: ST35321000 ( – )
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
Installation Drive Pinion AssemblyADS000NP
1. Press-fit the drive pinion bearing outer race into the carrier case
with tool.
CAUTION:
First lightly tap outer race using a hammer, place the carrier
case and outer race parallel. Then press-fit outer race with
press.
2. Temporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
3. If the hypoid gear set has been replaced, select the adjusting
washer.
Temporarily install washer to the drive pinion.
CAUTION:
Select the washer form the drive pinion height adjusting washer selecting table. Refer to FFD-38,
"AVAILABLE PINION HEIGHT ADJUSTING WASHERS" .
4. Press-fit the drive pinion bearing onto the drive pinion using drift
and press.
NOTE:
Note the direction of washer.
5. Install the drive pinion and drive pinion bearing as follows:
a. Apply gear oil to the bearing portion.
b. Install the drive pinion and drive pinion bearing (front side) into
the carrier case.Tool number : KV31103000 ( – )
SDIA1679E
SDIA1666E
Washer selection equation:
T = T0 + (t1 - t2)
T = Correct washer thickness
T0 = Removed washer thickness
t1 = Old drive pinion head letter
(machined tolerance 1/100 mm x 100)
t2 = New drive pinion head letter
(machined tolerance 1/100 mm x 100)
Example:
In case the T0 = 3.21, t1 = +2, t2 = -1
T = 3.21 + ((2 x 0.01) - (-1 x 0.01)) = 3.24
Tool number : ST30032000 ( – )
SDIA0249J
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FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:
Do not install the drive pinion adjusting washer and drive pinion bearing adjusting washer at this
time.
c. Install the companion flange without installing oil seal.
d. Apply oil drive pinion lock nut threads and seating surface, then temporarily install it.
e. Tighten the drive pinion lock nut until it reach standard preload.
CAUTION:
Tighten the drive pinion nut by very small degrees until the
specified preload in achieved. Do not tighten nut more than
necessary.
DIFFERENTIAL CASE INSTALLATION
1. Drive side bearing outer race into the carrier case with tool.
CAUTION:
Do not apply excessive force to the race.
2. Drive side bearing outer race into the side retainer with tool.
3. Apply oil to the bearing portion.
4. Install the deferential case assembly to the carrier case.
CAUTION:
Be careful not to damage the carrier cover mating surface.
5. Install the side bearing adjusting shim to the side retainer, tighten the bolt to specified torque.
CAUTION:
Install removed adjusting shim or same thickness shim.
NOTE:
Do not install O-ring.Tool number : KV40104000(−)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
SDIA1669E
Tool number : KV31103000 ( – )
SDIA1680E
Tool number : KV31103000 ( – )
SDIA1679E
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
6. Turn the companion flange more than 20 times, measure the
preload using preload gauge.
If the preload value is out of standard, adjust preload by changing adjusting shim thickness (side
retainer side).Tool number : ST3127S000(see J25765-A)
Total preload standard (without oil seal)
: 1.56 - 2.65 N·m (0.16 - 0.27 kg-m, 14 - 23 in-lb)
SDIA1649E
If preload too large, decrease side bearing adjusting shim thickness.
If preload too small, increase side bearing adjusting shim thickness.