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RFD-2
PREPARATION
Revision: October 20052005 QX56
PREPARATIONPFP:00002
Special Service ToolsEDS003Q6
The actual shapes of the tools may differ from those of the special service tools illustrated here.
Tool name
Tool numberDescription
Drift
ST15310000
Installing front oil seal
Installing drive pinion rear bearing outer
race.
a: 96 mm (3.77 in) dia.
b: 84 mm (3.30 in) dia.
Drift
ST35271000Installing side oil seal
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.
Protector
KV38107900Installing side flange
Attachment
KV38100800 Fixing unit assembly
a: 541 mm (21.30 in) dia.
b: 200 mm (7.87 in) dia.
Differential side bearing puller set
ST3306S001
1.ST33051001
2.ST33061000Removing side bearing inner race
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
Drift
ST30621000Installing drive pinion front bearing outer race
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
Drift
KV38100200Installing side bearing inner race
a: 65 mm (2.55 in) dia.
b: 49 mm (1.92 in) dia.
ZZA0811D
ZZA1143D
S-NT129
SDIA0267E
NT072
ZZA0810D
ZZA1143D
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PREPARATION
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Drive pinion flange wrench
KV40104000Removing and installing drive pinion nut
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.
Slide hammer
ST36230000Removing side flange
Axle stand
KV40104100Removing side flange
Slide hammer
HT72400000Removing differential case assembly
Drift
ST35325000Installing drive pinion rear bearing outer race
(use with ST30621000)
Preload gauge
ST3127S000
1. Torque wrench
GG91030000
2. Socket adapter (1/2 in)
HT62940000
3. Socket adapter (3/8 in)
HT62900000Measuring pinion bearing preload and total
preload
Side bearing outer race puller
ST33290001Removing front oil seal Tool name
Tool numberDescription
NT659
ZZA0803D
ZZA0804D
S-NT125
S-NT090
NT124
ZZA0601D
Page 2851 of 3419
RFD-4
PREPARATION
Revision: October 20052005 QX56
Commercial Service ToolsEDS003Q7
Drift
ST33081000Installing side bearing
a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.31 in) dia.
Bearing puller
ST30021000Removing drive pinion rear bearing inner
race
Drift
ST30022000Installing drive pinion rear bearing inner race
a: 110 mm (4.33 in) dia.
b: 46 mm (1.81 in) dia. Tool name
Tool numberDescription
ZZA0810D
ZZA0700D
ZZA0920D
Tool nameDescription
Power toolRemoving bolts and nuts
PBIC0190E
Page 2852 of 3419

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS003Q8
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: Applicable Reference page
RFD-18RFD-14RFD-14RFD-13—
MA-11, "
Fluids and Lubricants
"
PR-3, "
NVH Troubleshooting Chart
"
FAX -4
(FAX), RAX-4
(RAX)
FSU-4
(FSU), RSU-5
(RSU)
WT-4, "
NVH Troubleshooting Chart
"
WT-4, "
NVH Troubleshooting Chart
"
FAX -4, "
NVH Troubleshooting Chart
"
RAX-4, "
NVH Troubleshooting Chart
"
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
SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom FINAL DRIVE Noise××××××××××××××
Page 2853 of 3419

RFD-6
FRONT OIL SEAL
Revision: October 20052005 QX56
FRONT OIL SEALPFP:38189
Removal and InstallationEDS003Q9
REMOVAL
1. Remove the drive shaft inside flange bolts to disconnect the rear drive shafts from the rear final drive.
Support the rear drive shafts using suitable wire.
NOTE:
Disconnecting the rear drive shafts is necessary to measure the total preload accurately.
2. Remove the rear propeller shaft. Refer to PR-9, "
REMOVAL" .
CAUTION:
Do not damage the propeller shaft tube.
3. Check the total preload. Refer to RFD-13, "
TOTAL PRELOAD" .
4. Put a mark on the end of the drive pinion corresponding to the
position mark “B” on the companion flange as shown.
CAUTION:
Use paint to make the matching mark “B” on the drive
pinion. Never damage the drive pinion.
The mark “B” on the companion flange indicates the
maximum vertical runout position.
5. Remove drive pinion nut using Tool as shown.
Discard the drive pinion nut and use a new drive pinion nut for
installation.
6. Remove the companion flange using suitable tool as shown.
SDIA0270E
Tool number : KV40104000
LDIA0105E
LDIA0106E
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FRONT OIL SEAL
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7. Remove the front oil seal using Tool as shown.
INSTALLATION
1. Apply multi-purpose grease to the sealing lips of the new oil
seal, then press the front oil seal into the carrier using Tool as
shown.
CAUTION:
Keep the new oil seal even when installing, do not tilt the
oil seal when pressing it in.
Discard the old oil seal, always install a new oil seal.
2. Align the matching mark of the drive pinion with the matching
mark “B” of the companion flange as shown, then install the
companion flange.
3. Apply oil or multi-purpose grease on the drive pinion threads
and the seating surface of drive pinion nut.
4. Install new drive pinion nut using Tool.
Tighten the drive pinion nut to the minimum specified torque.
Final drive pinion nut torque will be determined when adjust-
ing the total preload. Refer to RFD-13, "
TOTAL PRELOAD" .
CAUTION:
The drive pinion nut is not reusable. Use a new drive pinion
nut for installation.
5. Install the rear propeller shaft. Refer to PR-9, "
INSTALLATION" .
6. Connect the rear drive shafts to the rear final drive. Tighten the drive shaft inside flange bolts to specifica-
tion.
7. Check the rear final drive fluid and add fluid as necessary. Refer to MA-25, "
Checking Final Drive Oil" . Tool number : ST33290001
LDIA0107E
Tool number : ST15310000
LDIA0108E
SDIA0270E
Tool number : KV40104000
Drive pinion nut : 167 - 372 N·m (17 - 38 kg-m,
124 - 274 ft-lb)
LDIA0105E
Drive shaft inside flange bolt : 118 N·m (12 kg-m, 87 ft-lb)
Page 2855 of 3419

RFD-8
SIDE OIL SEAL
Revision: October 20052005 QX56
SIDE OIL SEALPFP:33142
Removal and InstallationEDS003QA
REMOVAL
1. Remove the drive shaft inside flange bolts to disconnect the rear drive shafts from the rear final drive.
Support the rear drive shaft using a suitable wire.
2. Remove the side flange using Tools as shown.
a. Install Tool “A” on the side flange.
b. Pull the side flange out using Tool “B” as shown.
3. Remove the side oil seal using a suitable tool as shown.
INSTALLATION
1. Apply multi-purpose grease to the sealing lips of the new side oil seal.
2. Install the new side oil seal until the front surface of the side oil
seal is level with the end surface of the housing using tool.
CAUTION:
Keep the side oil seal even when installing, do not tilt the
side oil seal when pressing it in.
Discard the old side oil seal, always install a new side oil
seal.
3. Install the side flange using Tool.
a. Attach Tool to the side oil seal as shown.
b. After the side flange is inserted and the serrated part of the side
gear has engaged the serrated part of the flange, remove Tool.
c. Position a suitable drift on the center of the side flange, then
drive it in until the sound changes.
NOTE:
When the installation is complete, the driving sound of the side
flange turns into a sound which seems to affect the whole final
drive.Tool number A: KV40104100
Tool number B: ST36230000
Circlip installed position : Final drive side
LDIA0110E
LDIA0109E
Tool number : ST35271000
LDIA0111E
Tool number : KV38107900
SDIA0822E
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SIDE OIL SEAL
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4. Check measurement “A” after the side flange installation is com-
plete as shown.
5. Connect the rear drive shafts to the rear final drive. Tighten the drive shaft inside flange bolts to specifica-
tion.Measurement “A” : approx. 339.5 mm (13.37 in)
SDIA1039E
Drive shaft inside flange bolts : 118 N·m (12 kg-m, 87 lb-ft)