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FFD-14
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
Disassembly and AssemblyEDS0035N
COMPONENTS
1. Side bearing adjust nut 2. Side bearing 3. Side gear thrust washer
4. Side gear 5. Lock pin 6. Pinion mate thrust washer
7. Pinion mate gear 8. Pinion mate shaft 9. Drive pinion
10. Drive pinion height adjusting washer 11. Drive pinion rear bearing 12. Collapsible spacer
13. Breather tube 14. Differential side flange 15. Dust shield
16. Circular clip 17. Side oil seal 18. Drive pinion front bearing
19. Front oil seal 20. Companion flange 21. Drive pinion nut
22. Drain plug 23. Differential side shaft 24. Axle shaft bearing
25. Extension tube 26. O-ring 27. Gear carrier
28. Plate 29. Differential case 30. Drive gear
31. Side bearing cap 32. Filler plug 33. Rear cover
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ASSEMBLY INSPECTION AND ADJUSTMENT
Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload with preload gauge.
If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload
and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bear-
ing preload.
Tooth Contact
1. Remove rear cover. Refer to FFD-11, "REMOVAL" .
2. Thoroughly clean drive gear and drive pinion teeth.
3. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth of drive gear drive side.
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
34. Bushing 35. Bearing 36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload (with oil seal):
2.98 - 4.76 N·m (0.31 - 0.48 kg-m, 27 - 42 in-lb)
SDIA2220E
When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjust nuts at the same force on each side.
When the preload is small
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Tighten the side bearing adjust nuts at the same force on each side.
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FFD-16
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
Backlash
1. Remove carrier cover. Refer to FFD-11, "REMOVAL" .
2. Fit a dial indicator to the drive gear face to measure the back-
lash.
If the backlash is outside of the specified value, use each side
bearing adjust nut.
Companion Flange Runout
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout.
SDIA1796E
Backlash: 0.12 - 0.20 mm (0.0050 - 0.0079 in)
SDIA3203E
When the backlash is large:
Loosen adjust nut A and tighten adjust nut B.
When the backlash is small:
Loosen adjust nut B and tighten adjust nut A.
SDIA2262E
Runout limit: 0.10 mm (0.0039 in)
Runout limit: 0.13 mm (0.0051 in)
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5. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an
assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for
these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove differential side shaft with a soft hammer.
3. Remove differential side flange with a soft hammer.
4. Remove extension tube and O-ring.
5. Place a small hole in seal case, using a suitable punch or drill.
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SDIA2224E
SDIA3205E
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FFD-18
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
6. Install slide hammer tool as shown and remove seal.
7. Remove rear cover from gear carrier.
8. For proper reinstallation, paint matching mark on one side bear-
ing cap.
CAUTION:
For matching mark, use paint. Do not damage bearing
caps and gear carrier.
Bearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
9. Remove side bearing caps.
10. Remove side bearing adjust nuts.
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11. Keep the side bearing outer races together with inner race. Do
not mix them up.
12. 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.
It is not necessary to remove side bearing except it is
replaced.
Be careful not to confuse left-hand and right-hand parts.
Keep bearing and bearing race for each side together.
13. Loosen drive gear bolts in a crisscross fashion.
14. Tap drive gear off the differential case with a soft hammer.
Tap evenly all around to keep the drive gear from bending.
15. Drive out pinion mate shaft lock pin with suitable punch from
drive gear side.
SPD5 27
Tool number A: ST33081000 ( — )
B: ST30021000 ( — )
SDIA2237E
SPD0 22
SDIA2238E
SPD0 25
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FFD-20
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
16. Remove the pinion mate shaft.
17. 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.
Drive Pinion Assembly
1. Remove differential assembly. Refer to FFD-17, "Differential Assembly" .
2. Put matching marks on companion flange and drive pinion with
paint.
3. Loosen drive pinion nut using Tool.
4. Remove companion flange using a suitable puller.
SDIA0031J
SDIA0032J
Tool number : KV38108300 (J-44195)
SDIA2232E
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5. Remove drive pinion (together with rear bearing inner race, col-
lapsible spacer.)
6. Remove pinion front bearing inner race.
7. Place a small hole in seal case, using a suitable punch or drill.
8. Install slide hammer tool as shown and remove seal.
9. Turn nose of gear carrier down. Remove drive pinion front bear-
ing outer race using Tool. Locate driver on back edge of outer
race, then drive outer race out.
CAUTION:
Do not nick gear carrier.
10. Turn nose of gear carrier up. Remove drive pinion rear bearing
outer race using Tool. Locate driver on back edge of outer race,
then drive outer race out.
CAUTION:
Do not nick gear carrier.
SDIA2234E
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Tool number A: — C-4171
B: — D-103
LDIA0131E
Tool number A: — C-4171
B: — C-4307
LDIA0132E