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FFD-26
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
14. 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 inner race
except it is replaced.
15. For proper reinstallation, paint matching mark on one differential case assembly.
CAUTION:
For matching mark, use paint. Do not damage differential
case and drive gear.
16. Remove drive gear mounting bolts.
17. Tap drive gear off differential case assembly with a soft hammer. CAUTION:
Tap evenly all around to keep drive gear from bending.
18. Remove lock pin of pinion mate shaft with a punch from drive gear side.
19. Remove pinion mate shaft. Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
SPD920
PDIA0496E
SPD025
SDIA0031J
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FRONT FINAL DRIVE ASSEMBLY FFD-27
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20. Turn pinion mate gear, then remove pinion mate gears, pinion
mate thrust washers, side gears and side gear thrust washers
from differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to FFD-24, "Differential Assembly" .
2. Remove drive pinion lock nut with a flange wrench.
3. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion
flange.
CAUTION:
For matching mark, use paint. Do not damage companion
flange and drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
4. Remove companion flange using the suitable puller.
SDIA0032J
PDIA0741E
PDIA0675E
SDIA1132E
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FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
5. Press drive pinion assembly out of gear carrier.
CAUTION:
Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove pinion front bearing inner race.
8. Remove drive pinion bearing adjusting washer and drive pinion adjusting washer.
9. Remove pinion rear bearing inner race and drive pinion height adjusting washer with replacer.
10. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.
CAUTION:
Be careful not to damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
PDIA0676E
Tool number : ST30031000 (J-22912-01)
S-PD179
PDIA0677E
Content Conditions and Measures
Hypoid gear
If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing
If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
is observed, replace as a bearing assembly (as a new set).
Side gear and Pinion mate
gear
If any cracks or damage on the surface of the tooth is found, replace.
If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
pinion mate thrust washer
If it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal
Whenever disassembled, replace.
If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case
If any wear or crack on the contact sides of the differential case is found, replace.
Companion flange
If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
companion flange is found, replace.
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FRONT FINAL DRIVE ASSEMBLY FFD-29
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ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS (SHIMS)
Differential Side Gear Clearance
Assemble the differential parts if they are disassembled. Refer to FFD-34, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea- sured comes upward.
2. Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well.
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/ thinner side gear thrust washer to adjust. Refer to FFD-39, "
Side
Gear Thrust Washer" .
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
Side Bearing Preload
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Press-fit side bearing outer race into side retainer with tool.
CAUTION:
At first, using a hammer, tap bearing outer race until it
becomes flat to side retainer.
Do not reuse side bearing outer race.
PDIA0460E
Side gear back clearance specification:
0.2 mm (0.008 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)
When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.
PDIA0576E
Tool number A: KV31103000 ( — ) B: ST30611000 (J-25742-1)
PDIA0679E
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FFD-30
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
3. Press-fit side bearing outer race into gear carrier with tool.
CAUTION:
At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
Do not reuse side bearing outer race.
4. Place the differential case assembly into gear carrier.
5. Install side bearing adjusting shim before disassembling or shim which thickness is the same as the one before disassembling.
6. Install side retainer assembly to gear carrier.
CAUTION:
Do not install O-ring.
7. Install side retainer mounting bolts to the specified torque. Refer to FFD-16, "
COMPONENTS (VQ35DE MODELS)" , FFD-18,
"COMPONENTS (VK45DE MODELS)" .
8. Measure the turning torque of the gear carrier at the drive gear mounting bolts with a spring gauge. Tool number A: KV31103000 ( — )
B: ST30611000 (J-25742-1)
PDIA0824E
PDIA0671E
PDIA0678E
PDIA0669E
Tool number : — (J-8129)
Specification:
0.78 - 1.08 N (0.08 - 0.11 kg, 0.57 - 0.80 lb) of pulling
force at the drive gear bolt
SPD194A
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FRONT FINAL DRIVE ASSEMBLY FFD-31
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9. If the turning torque is outside the specification, use a thicker/
thinner side bearing adjusting shim to adjust. Refer to FFD-40,
"Side Bearing Adjusting Shim" .
10. Record the total amount of shim thickness required for the cor- rect carrier side bearing preload.
Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Substitute these values into the equation to calculate the thick- ness of the washer.
2. Select the proper pinion height adjusting washer. Refer to FFD-40, "
Pinion Height Adjusting Washer" .
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated
value.
Pinion Bearing Preload
Assemble the drive pinion parts if they are disassembled. Refer to FFD-32, "Drive Pinion Assembly" .
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Install companion flange. NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange. If the turning torque is less than the specified range:
Decrease the side bearing adjusting shim thickness.
If the turning torque is greater than the specification:
Increase the side bearing adjusting shim thickness.
SPD772
Washer selection equation:
T = T
0 + (t1 - t2 )
T: Correct washer thickness
T
0 : Removed washer thickness
t
1 : Old drive pinion head letter “H × 0.01”
(“H”: machined tolerance 1/100 mm × 100)
t
2 : New drive pinion head letter “H × 0.01”
(“H”: machined tolerance 1/100 mm × 100)
Example:
T = 3.21 + [(2 × 0.01) - (-1 × 0.01)] = 3.24
T
0 :3.21
t
1 :+2
t
2 :-1
Example: Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
SDIA0249J
PDIA0675E
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FFD-32
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
3. Temporarily tighten removed drive pinon lock nut to drive pinion.
NOTE:
Use removed drive pinon lock nut only for the preload measure-
ment.
4. Rotate drive pinion at least 20 times to check for smooth opera- tion of the bearing.
5. Tighten to drive pinon lock nut, while adjust pinion bearing pre- load torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
6. If the pinion bearing preload torque is outside the specification, use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust.
Refer to FFD-40, "
Drive Pinion Bearing Adjusting Washer" and FFD-40, "Drive Pinion Adjusting Washer" .
7. Remove companion flange, after adjustment.
ASSEMBLY
Drive Pinion Assembly
1. Install front and rear bearing outer races using drifts.
CAUTION:
At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
Do not reuse pinion front and rear bearing outer race. Tool number : ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 127.4 - 245.0 N·m (13 - 25 kg-m, 94 - 181 ft-lb)
Pinion bearing preload: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
When the preload torque is large: Decrease the drive pinion bearing adjusting washer and drive pinion adjusting
washer thickness.
When the preload is small: Increase the drive pinion bearing adjusting washer and drive pinion adjusting
washer thickness.
PDIA0778E
Tool number : ST37820000 ( — )
PDIA0680E
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FRONT FINAL DRIVE ASSEMBLY FFD-33
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2. Temporarily install pinion height adjusting washer.
When hypoid gear set has been replaced
Select pinion height adjusting washer. Refer to FFD-31, "Pin-
ion Gear Height" .
When hypoid gear set has been reused
Temporarily install the removed pinion height adjusting
washer or same thickness washer to drive pinion.
3. Install selected drive pinion height adjusting washer to drive pin- ion. Press pinion rear bearing inner race to it, using drift.
CAUTION:
Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.)
Do not reuse pinion rear bearing inner race.
4. Temporarily assemble removed drive pinion adjusting washer and drive pinion bearing adjusting washer or same thickness
them to drive pinion.
5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.
CAUTION:
Do not reuse pinion front bearing inner race.
7. Using suitable spacer, press the pinion front bearing inner race to drive pinon as far as drive pinion nut can be tightened.
8. Adjust pinion bearing preload. If necessary, select the appropri- ate drive pinion adjusting washer and drive pinion bearing
adjusting washer. Refer to FFD-31, "
Pinion Bearing Preload" .
9. Using the drift, install front oil seal as shown in figure. CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
SDIA1666E
Tool number : ST30032000 (J-26010-01)
SDIA0048E
PDIA0681E
PDIA0682E
Tool number A: ST33400001 (J-26082)
B: KV38102510 ( — )
PDIA0683E