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REAR FINAL DRIVE ASSEMBLY RFD-19
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Revision: 2006 December 2006 FX35/FX45
ASSEMBLY INSPECTION AND ADJUSTMENT
Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Secure final drive assembly onto an attachment.
2. Remove side flanges.
3. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
4. Rotate drive pinion at least 20 times to check for smooth opera- tion of the bearing.
5. Measure total preload with the preload gauge.
NOTE:
Total preload torque = Pinion bearing preload torque + Side
bearing preload torque
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 bearing preload.
Drive Gear Runout
1. Remove rear cover. Refer to RFD-33, "Differential Assembly" .
2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.
If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive gear
may be deformed, etc.
CAUTION:
Replace drive gear and drive pinion gear as a set. Tool number A: KV38100800 (J-25604-01)
Tool number A: ST3127S000 (J-25765-A)
Total preload torque: 2.85 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)
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When the preload torque is large On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to each side. Refer to RFD-38, "
Side Bearing Adjusting Washer" .
When the preload is small On pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to each side. Refer to RFD-38, "
Side Bearing Adjusting Washer" .
Runout limit: 0.05 mm (0.0020 in)
SPD886
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RFD-20
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
Tooth Contact
1. Remove rear cover. Refer to RFD-33, "Differential Assembly" .
2. Apply red lead to drive gear. CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
3. 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.
SPD357
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REAR FINAL DRIVE ASSEMBLY RFD-21
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Revision: 2006 December 2006 FX35/FX45
4. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).
If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washers to
move drive pinion closer to drive gear.
Refer to RFD-38, "
Pinion Height Adjusting Washer" .
If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
Refer to RFD-38, "
Pinion Height Adjusting Washer" .
Backlash
1. Remove rear cover. Refer to RFD-33, "Differential Assembly" .
2. Fit a dial indicator to the drive gear face to measure the back- lash.
If the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
CAUTION:
Do not change the total amount of washers as it will change the bearing preload.
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Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is large: Make drive gear back side adjusting washer thicker,
and drive gear tooth side adjusting washer thinner by
the same amount. Refer to RFD-38, "
Side Bearing
Adjusting Washer" .
When the backlash is small: Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. Refer to RFD-38, "
Side Bearing
Adjusting Washer" .
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RFD-22
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
Companion Flange Runout
1. Fit a test indicator to the inner side of companion flange (socket diameter).
2. Rotate companion flange to check for runout.
3. If the runout value is outside the runout limit, follow the proce- dure 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 side flange.
3. Remove rear cover mounting bolts.
4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.
CAUTION:
Be careful not to damage the mating surface.
Do not insert flat-bladed screwdriver, this way damage
the mating surface.
5. Using two 45 mm (1.77 in) spacers, mount carrier on the attach- ment.
6. For proper reinstallation, paint matching marks on one side of the bearing cap.
CAUTION:
For matching marks, 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. Runout limit: 0.08 mm (0.0031 in)
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Tool number A: KV10111100 (J-37228)
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Tool number A: KV38100800 (J-25604-01)
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REAR FINAL DRIVE ASSEMBLY RFD-23
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Revision: 2006 December 2006 FX35/FX45
7. Remove bearing caps.
8. Lift differential case assembly out with a suitable tool.
Keep side bearing outer races together with inner race. Do
not mix them up.
Also, keep side bearing adjusting washers together with bear-
ings.
9. 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.
S-PD343
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SPD527
Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
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RFD-24
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
10. For proper reinstallation, paint matching marks on one differen- tial case assembly.
CAUTION:
For matching marks, use paint. Do not damage differential
case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer. CAUTION:
Tap evenly all around to keep drive gear from bending.
13. Remove lock pin of pinion mate shaft with a punch from drive gear side.
14. Remove pinion mate shaft.
15. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from
differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to RFD-33, "Differential Assembly" .
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REAR FINAL DRIVE ASSEMBLY RFD-25
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Revision: 2006 December 2006 FX35/FX45
2. Remove drive pinion lock nut with the flange wrench.
3. Put matching mark (B) on the end of drive pinion. The matching mark should be in line with the matching mark (A) on companion
flange (1).
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 (1)
indicates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
4. Remove companion flange using the suitable puller.
5. Press drive pinion assembly out of gear carrier. CAUTION:
Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.
10. Remove pinion rear bearing inner race and pinion height adjust- ing washer with the replacer.
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Tool number A: ST30031000 (J-22912-01)
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RFD-26
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
11. 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.
ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance
Assemble the differential parts if they are disassembled. Refer to RFD-33, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea- sured comes upward.
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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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