Page 4025 of 4449
RF-28
SUNROOF
Revision: 2004 November 2004 FX35/FX45
Installation
1. Temporarily tighten the mounting bolts on the front/rear sunroof
brackets (RH/LH).
2. Bring sunroof unit assembly into passenger room and place the
rear end of the rail onto the sunroof brackets.
3. Tighten the mounting nuts on the front end.
4. Tighten the installation points diagonally excluding the installation point of the sunroof bracket around the
roof opening.
5. Tighten the bolts on the sunroof bracket to the vehicle side and
then tighten the bolt to the rail side.
6. Tighten the bolts on the curtain air bag bracket to the rail side.
Refer to SRS-43, "
Removal and Installation" .
GLASS LID
Removal
1. Tilt up glass lid.
2. Remove TORX bolts (T25) from remove glass lid.
Installation
1. Tighten bolts diagonally on the glass lid.
2. After installation, carry out fitting adjustment.
PIIA6193E
PIIA6191E
PIIA6193E
PIIA6192E
Page 4026 of 4449

SUNROOF
RF-29
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Revision: 2004 November 2004 FX35/FX45
SUNSHADE
Removal
NOTE:
Detaching is possible even with the sunshade attached on the vehicle.
1. Remove the headlining. Refer to EI-42, "
Removal and Installation" .
2. Remove sunshade stopper.
3. The protection tape is pasted to the sunshade knob.
4. Pull sunshade out of the rear end of the sunroof frame, and
remove it from the frame.
CAUTION:
Do not damage the sunshade and sunshade knob while lift-
ing up a little.
Installation
Install in the reverse order of removal.
WIND DEFLECTOR
Removal
NOTE:
Detaching is possible even with the wind deflector attached on the vehicle.
1. The sunroof is opened.
2. Remove spring hinge screws, then remove hinge from the
frame.
3. Remove the wind deflector.
Installation
Install in the reverse order of removal.
SUNROOF MOTOR ASSEMBLY
Removal
1. Remove headlining. Refer to EI-42, "Removal and Installation" .
2. Remove motor mounting screw.
3. Disconnect harness connector from sunroof motor assembly,
then remove sunroof motor assembly.
CAUTION:
When removing the sunroof motor assembly, be sure that
the sunroof is in the fully closed position.
Do not run the removed sunroof motor assembly as a
single unit.
Installation
1. Move the sunroof motor assembly laterally little by little so that the gear is completely engaged into the
wire on the sunroof unit assembly and the mounting surface becomes parallel. Then secure the sunroof
motor assembly with screws.
PIIA5064E
PIIA3510E
PIIA6189E
Page 4027 of 4449
RF-30
SUNROOF
Revision: 2004 November 2004 FX35/FX45
CAUTION:
1. Before installing the sunroof motor assembly, be sure to place the link and wire assembly in the
symmetrical and fully closed position.
2. Confirm the body ground of the noise cover is con-
nected.
3. Initialization of it after installing the sunroof motor. Refer to RF-12, "
INITIALIZATION PROCE-
DURE" .
PIIA5062E
PIIA5063E
Page 4028 of 4449

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTION RFD
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RFD
Revision: 2004 November 2004 FX35/FX45
REAR 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 ..................................................... 7
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 10
REAR FINAL DRIVE ASSEMBLY .............................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Components ........................................................... 12
R200 2-PINION ................................................... 12
Pre-Inspection ........................................................ 13
TOTAL PRELOAD ............................................... 13
DRIVE GEAR TO DRIVE PINION BACKLASH ... 13
DRIVE GEAR RUNOUT ...................................... 13
COMPANION FLANGE RUNOUT ...................... 14
TOOTH CONTACT .............................................. 14
Disassembly and Assembly ................................... 14
REMOVAL OF DIFFERENTIAL CASE ASSEM-BLY ...................................................................... 14
REMOVAL OF DRIVE PINION ASSEMBLY ........ 15
DISASSEMBLY OF DIFFERENTIAL CASE
ASSEMBLY ......................................................... 17
INSPECTION ...................................................... 18
ADJUSTMENT OF DIFFERENTIAL CASE ......... 19
SIDE BEARING PRELOAD ................................. 20
PINION GEAR HEIGHT ...................................... 21
TOOTH CONTACT .............................................. 24
ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
BLY ...................................................................... 25
INSTALLATION OF DRIVE PINION ASSEMBLY ... 26
INSTALLATION OF DIFFERENTIAL CASE
ASSEMBLY ......................................................... 28
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
General Specifications ............................................ 31
Drive Gear Runout .................................................. 31
Side Gear Adjustment ............................................ 31
AVAILABLE SIDE GEAR THRUST WASHERS ... 31
Drive Pinion Height Adjustment .............................. 31
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 31
Drive Pinion Preload Adjustment ............................ 31
Side Bearing Preload Adjustment ........................... 32
SIDE BEARING ADJUSTING WASHERS .......... 32
Total Preload Adjustment ........................................ 32
Companion Flange ................................................. 32
Page 4029 of 4449

RFD-2
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
PrecautionsADS000K2
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 matching 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 gear oil, Vaseline,
or multi-purpose grease, as specified for each vehicle, when necessary.
Page 4030 of 4449

PREPARATION
RFD-3
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RFD
Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsADS000JM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore No.)
Tool nameDescription
ST30720000 (J25405)
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
DriftInstalling front oil seal
KV38100200 (J26233)
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
DriftInstalling final drive side oil seal
KV38107900 (J39352)
ProtectorInstalling final drive side flange
KV38100800 (J25604-01)
a: 541 mm (21.30 in)
b: 200 mm (7.87 in)
Attachment Fixing unit assembly
ST3306S001 ( – )
1.ST3305S001 ( – )
2.ST33061000 (J8107–2)
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
Differential side bearing puller setRemoving and installing side bearing
ST30613000 (J25742-3)
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
DriftInstalling pinion front and rear bearing outer
race
KV38100300 (J25523)
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
DriftInstalling side bearing
ZZA0811D
ZZA1143D
S-NT129
SDIA0267E
NT072
ZZA0810D
ZZA1046D
Page 4031 of 4449

RFD-4
PREPARATION
Revision: 2004 November 2004 FX35/FX45
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
ST36230000 (J25840-A)
Sliding hammer Removing side flange
KV40104100 ( – )
Axle stand Removing side flange (VQ35DE engine)
KV40101000 ( – )
Axle standRemoving side flange (VK45DE engine)
HT72400000 ( – )
Sliding hammerRemoving differential case assembly
ST3090S000 ( – )
1. ST30031000 (J22912-01) Puller
2. ST30901000 ( – ) Base
Equivalent tool (J26010-01)
a : 90 mm (3.54 in) dia.
b : 80 mm (3.15 in) dia.
c : 50 mm (1.97 in) dia.
d : 79 mm (3.11 in) dia.
e : 45 mm (1.77 in) dia.
f : 35 mm (1.38 in) dia.
Drive pinion rear inner race puller setRemoving and installing drive pinion rear
bearing inner race
ST30611000 (J25742–1)
DriftInstalling pinion rear bearing outer race
(Use with ST30613000) Tool number (Kent-Moore No.)
Tool nameDescription
NT659
ZZA0803D
ZZA0804D
NT159
S-NT125
S-NT640
S-NT090
Page 4032 of 4449
PREPARATION
RFD-5
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Revision: 2004 November 2004 FX35/FX45
Commercial Service ToolsADS000JN
ST3127S000 (J25765-A)
1. GG91030000
Torque wrench (J25765)
2. HT62940000 ( – )
Socket adapter (1/2″)
3. HT62900000 ( – )
Socket adapter (3/8″)
Preload gaugeMeasuring pinion bearing preload and total
preload
ST33290001 (J34286)
Side bearing outer race pullerRemoving oil seal
Differential shim selection (J34309) Adjusting bearing preload gear height Tool number (Kent-Moore No.)
Tool nameDescription
NT124
NT713
NT134
Tool name Description
Power toolLoosening bolts and nuts
PBIC0190E