Page 2897 of 4555
REAR FINAL DRIVE SYSTEM
RFD-7
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RFD
REAR FINAL DRIVE SYSTEMPFP:38300
Sectional ViewEDS001ZL
SDIA0141E
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RFD-8
DIFFERENTIAL GEAR OIL
DIFFERENTIAL GEAR OILPFP:KLD30
Changing Differential Gear OilEDS0027G
DRAINING
1. Stop engine.
2. Remove drain plug and drain oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to RFD-16, "
Compo-
nents" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the
specified level near filler plug mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug, then
install it to final drive assembly. Refer to RFD-16, "
Components"
.
CAUTION:
Do not reuse gasket.
Checking Differential Gear OilEDS0027H
OIL LEAKAGE AND OIL LEVEL
Make sure that oil is not leaking from final drive assembly or around it.
Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.
Set a gasket on filler plug and install it on final drive assembly.
Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse gasket.
PDIA0454E
Oil grade and Viscosity:
Refer to MA-17, "
Fluids and Lubricants" .
Oil capacity:
Approx. 0.55 (1 Imp pt)
PDIA0453E
PDIA0453E
Page 2899 of 4555
FRONT OIL SEAL
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FRONT OIL SEALPFP:38189
Removal and InstallationEDS001Z2
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
3. Remove companion flange lock nut, using a flange wrench.
Then remove companion flange.
4. Remove front oil seal from coupling cover, using a flat-bladed
screwdriver.
CAUTION:
Be careful not to damage coupling cover.
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Install front oil seal until it becomes flush with the case end,
using the drifts.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
PDIA0455E
PDIA0456E
PDIA0457E
Tool number A: KV38100200
B: ST27861000
PDIA0038E
Page 2900 of 4555
RFD-10
FRONT OIL SEAL
3. Align the matching mark of electric controlled coupling with the
matching mark of companion flange, then install the companion
flange.
4. Install companion flange lock nut with a flange wrench, tighten
the to the specified torque. Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse companion flange lock nut.
5. Install propeller shaft. Refer to PR-4, "
Removal and Installation"
.
PDIA0455E
Page 2901 of 4555
SIDE OIL SEAL
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RFD
SIDE OIL SEALPFP:38343
Removal and InstallationEDS001Z3
REMOVAL
1. Remove rear drive shaft with power tool. Refer to RAX-14, "REAR DRIVE SHAFT" .
2. Remove side oil seal, using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage carrier case and rear cover.
INSTALLATION
1. Apply multi-purpose grease to side oil seal lips.
2. Install side oil seal until it becomes flush with the case end,
using the drift.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Install rear drive shaft. Refer to RAX-14, "
REAR DRIVE
SHAFT" .
PDIA0431E
Tool number : KV38100200
PDIA0432E
Page 2902 of 4555
RFD-12
ELECTRIC CONTROLLED COUPLING
ELECTRIC CONTROLLED COUPLINGPFP:38760
Removal and InstallationEDS0027J
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on the companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.
3. Remove companion flange lock nut, using a flange wrench.
4. Remove companion flange.
5. Disconnect 4WD solenoid harness connector and remove con-
nector bracket.
6. Remove electric controlled coupling breather hose from cou-
pling cover.
7. Remove coupling cover with electric controlled coupling from
carrier case.
8. Remove electric controlled coupling from coupling cover.
PDIA0455E
PDIA0456E
PDIA0458E
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ELECTRIC CONTROLLED COUPLING
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INSTALLATION
1. Install electric controlled coupling to spline of drive pinion inside
carrier case.
CAUTION:
Align the pin on electric controlled coupling with the
groove of carrier case.
Be careful not to damage center oil seal.
2. Set 4WD solenoid harness guide to carrier case.
3. Apply liquid gasket to mating surface of coupling cover. Overlap
both ends of the bead for at least 3 mm (0.12 in).
Use sealant (Three bound 1217 or equivalent).
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.
4. Install coupling cover to carrier case with arrow facing upward,
temporarily tighten reamer bolts to the positions shown in the
figure.
5. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque. Refer to RFD-16, "
Components" .
6. Install electric controlled coupling breather hose to coupling
cover.
7. Install connector bracket and connect 4WD solenoid harness
connector.
8. Install companion flange.
NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of
companion flange, then install companion flange.
9. Install companion flange lock nut with flange wrench, tighten to
the specified torque. Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse companion flange lock nut.
10. Install propeller shaft. Refer to PR-4, "
Removal and Installation"
.
PDIA0912E
PDIA0451E
SDIA0587E
PDIA0455E
Page 2904 of 4555
RFD-14
REAR FINAL DRIVE ASSEMBLY
REAR FINAL DRIVE ASSEMBLYPFP:38300
Removal and InstallationEDS001ZA
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Remove drive shaft with power tool. Refer to RAX-14, "
Removal and Installation" .
3. Disconnect 4WD solenoid harness connector.
4. Remove rear final drive breather hose and electric controlled coupling breather hose.
5. Support rear final drive assembly with a suitable jack.
6. Remove rear final drive mounting nut at rear suspension mem-
ber.
7. Remove rear final drive mounting bolts at final drive mounting
bracket, and then remove rear final drive assembly.
If necessary, remove final drive mounting bracket.
CAUTION:
Secure rear final drive assembly to a suitable jack while
removing it.
1. Rear suspension member 2. Final drive mounting bracket 3. Harness bracket
4. Drive shaft 5. Propeller shaft 6. Rear final drive assembly
PDIA0433E
PDIA0434E
PDIA0435E