Page 2017 of 3371
FFD-6
PREPARATION
Revision: August 20072004 QX56
Commercial Service ToolsEDS0035H
—
(C-4171)
HandleRemoving drive pinion front bearing outer
race
Removing drive pinion rear bearing outer
race
—
(D-103)
RemoverRemoving drive pinion front bearing outer
race
—
(C-4307)
RemoverRemoving drive pinion rear bearing outer
race Tool number
(Kent-Moore No.)
Tool nameDescription
LDIA0134E
LDIA0135E
LDIA0135E
Tool nameDescription
Slide hammer
Removing front oil seal
Removing side oil seal
Power toolLoosening bolts and nuts
LDIA0133E
PBIC0190E
Page 2018 of 3371

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
FFD-7
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Revision: August 20072004 QX56
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS0035I
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
FFD-15FFD-15
FFD-15
FFD-16
FFD-16
MA-24, "
Checking Final Drive Oil
"
PR-3, "
NVH Troubleshooting Chart
"
FSU-4, "
NVH Troubleshooting Chart
" (FSU) and RSU-5, "
NVH Troubleshooting Chart
" (RSU)
WT-3, "
NVH Troubleshooting Chart
"
WT-3, "
NVH Troubleshooting Chart
"
FAX -4, "
NVH Troubleshooting Chart
" (FAX) and RAX-4, "
NVH Troubleshooting Chart
" (RAX)
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible cause and suspected parts
Rough gear tooth
Improper gear contact
Tooth surfaces worn
Incorrect backlash
Companion flange excessive runout
Improper gear oil
Propeller shaft
Axle and suspension
Tires
Road wheel
Drive axle
Brakes
Steering
Symptom Differential Noise×××××××××××××
Page 2019 of 3371
FFD-8
FRONT OIL SEAL
Revision: August 20072004 QX56
FRONT OIL SEALPFP:38189
Removal and InstallationEDS0035J
REMOVAL
1. Remove front propeller shaft. Refer to PR-5, "REMOVAL" .
2. Separate the RH and LH drive shafts from the front final drive. Refer to FA X -7 , "
REMOVAL" .
3. Measure the drive pinion bearing preload with front oil seal resistance using Tool.
NOTE:
Record the preload measurement.
4. Loosen drive pinion nut while holding the companion flange
using Tool.
5. Remove companion flange using a suitable puller.
6. Place a small hole in seal case, using a suitable punch or drill.
7. Install slide hammer tool as shown and remove seal.Tool number : ST3127S000 (J-25765-A)
Tool number : KV38108300 (J-44195)
BDIA0001E
LDIA0129E
LDIA0130E
Page 2020 of 3371

FRONT OIL SEAL
FFD-9
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FFD
Revision: August 20072004 QX56
INSTALLATION
1. Apply multi-purpose grease to cavity at sealing lips of front oil
seal. Press front oil seal into gear carrier using suitable tool.
2. Install companion flange and a new drive pinion nut. Tighten
drive pinion nut while holding the companion flange using Tool
until there is no end play.
3. Measure the drive pinion bearing preload with front oil seal
resistance using Tool.
NOTE:
Drive pinion bearing preload should equal the measurement
taken during removal plus an additional 0.56 N·m (0.06 Kg-m,
5 in-lb).
If drive pinion bearing preload is low, tighten drive pinion nut in 6.8 N·m (0.69 Kg-m, 5ft-lb) increments
until drive pinion preload is met.
CAUTION:
Never loosen the drive pinion nut to decrease drive pinion bearing preload. Do not exceed speci-
fied preload. If preload torque is exceed a new collapsible spacer must be installed. If maximum
torque is reached prior to reaching the required preload, the collapsible spacer may have been
damaged. Replace the collapsible spacer.
4. Attach the RH and LH drive shafts. Refer to FAX-8, "
INSTALLATION" .
5. Install the front propeller shaft. Refer to PR-5, "
INSTALLATION" .
BDIA0003E
Tool number : KV38108300 (J-44195)
Tool number : ST3127S000 (J-25765-A)
Drive pinion nut : 298 - 678 N·m (31 - 69Kg-m, 220 - 500 ft-lb)
BDIA0001E
Page 2021 of 3371
FFD-10
SIDE OIL SEALS
Revision: August 20072004 QX56
SIDE OIL SEALSPFP:33142
Removal and InstallationEDS0035K
REMOVAL
1. Remove front final drive. Refer to FFD-12, "REMOVAL" .
2. Remove differential side shaft and side flange using suitable
tool.
3. Place a small hole in seal case, using suitable tool.
4. Install slide hammer tool as shown and remove seal.
5. Installation is in the reverse order of removal.
BDIA0006E
LDIA0129E
LDIA0130E
Page 2022 of 3371
REAR COVER GASKET
FFD-11
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FFD
Revision: August 20072004 QX56
REAR COVER GASKETPFP:38320
Removal and InstallationEDS0035L
REMOVAL
1. Remove front final drive. Refer to FFD-12, "REMOVAL" .
2. Drain gear oil. Refer to MA-25, "
Changing Final Drive Oil" .
3. Remove rear cover using Tool.
INSTALLATION
1. Apply 3.2mm (0.126 in) bead of sealant to the rear cover using
Tool.
Use Genuine Silicone RTV sealant or equivalent. Refer to. GI-
45, "Recommended Chemical Products and Sealants" .
2. Install rear cover and tighten rear cover bolts in the order shown
FFD-11, "
INSTALLATION" .
3. Fill final drive with recommended gear oil. Refer to GI-45, "
Rec-
ommended Chemical Products and Sealants" .
4. Install front final drive. Refer to FFD-13, "
INSTALLATION" . Tool number : KV10111100 (J-37228)
Tool number :WS39930000 ( — )
SDIA3204E
WDIA0290E
Page 2023 of 3371
FFD-12
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
FRONT FINAL DRIVE ASSEMBLYPFP:38500
Removal and InstallationEDS0035M
REMOVAL
1. Remove front propeller shaft. Refer to PR-5, "REMOVAL" .
CAUTION:
Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft.
2. Separate LH and RH drive shafts from front final drive. Refer to FAX-7, "
REMOVAL" .
3. Remove front cross member.
4. Disconnect the vent hose.
1. Gear carrier assembly 2. Front cross member 3. Skid plate (If equipped)
SDIA3220E
Page 2024 of 3371
FRONT FINAL DRIVE ASSEMBLY
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Revision: August 20072004 QX56
5. Support the front final drive with suitable jack and remove the
front final drive bolts. Carefully remove front final drive.
INSTALLATION
1. Install front final drive assembly.
2. Connect the vent hose.
3. Install the front cross member.
4. Install LH and RH drive shaft. Refer to FAX-8, "
INSTALLATION"
.
5. Install front propeller shaft. Refer to PR-5, "
INSTALLATION" .
BDIA0008E
Front final drive bolts : 182.5 N·m (19 kg-m, 135 ft-lb)
BDIA0008E