Page 4065 of 4462

REAR FINAL DRIVE ASSEMBLY RFD-27
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2006 December 2006 FX35/FX45
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 RFD-37,
"Side Gear Thrust Washer" .
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
Side Bearing Preload
Selecting carrier side bearing adjusting washers is required for successful completion of this procedure.
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Place the differential case, with side bearings and bearing races installed, into gear carrier.
3. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier. 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
SPD527
SPD558
Page 4066 of 4462

RFD-28
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
4. Install bearing caps in their correct locations and tighten bearing cap mounting bolts to the specified torque. Refer to RFD-18,
"COMPONENTS" .
5. Turn the carrier several times to seat the bearings.
6. Measure the turning torque of the carrier at the drive gear mounting bolts with a spring gauge.
7. If the turning torque is outside the specification, use a thicker/ thinner side bearing adjusting washer to adjust. Refer to RFD-
38, "Side Bearing Adjusting Washer" .
CAUTION:
Select a side bearing adjusting washer for right and left
individually.
8. Record the total amount of washer thickness required for the correct carrier side bearing preload.
Pinion Gear Height
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool.
SDIA1795E
Tool number : — (J-8129)
Specification:
34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force at
the drive gear bolt
SPD194A
If the turning torque is less than the specified range:
Use a thicker thrust washer.
If the turning torque is greater than the specification: Use a thinner thrust washer.
SPD772
Tool number : — (J-34309)
SPD769
Page 4067 of 4462

REAR FINAL DRIVE ASSEMBLY RFD-29
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2006 December 2006 FX35/FX45
Pinion front bearing; make sure the J-34309-3 pinion front
bearing seat is secured tightly against the J-34309-2 gauge
anvil. Then turn the pinion front bearing pilot, J-34309-5, to
secure the bearing in its proper position.
Pinion rear bearing; the pinion rear bearing pilot, J-34309-8,
is used to center the pinion rear bearing only. The pinion rear
bearing locking seat, J-34309-4, is used to lock the bearing to
the assembly.
Installation of J-34309-9 and J-34309-16; place a suitable
2.5 mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the pinion rear bearing inner race into gear carrier. Then place the pinion preload shim selector tool, J-34309-1, gauge
screw assembly.
4. Assemble the pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge
screw in gear carrier. Make sure that the pinion height gauge
plate, J-34309-16, will turn a full 360 degrees. Tighten the two
sections together by hand.
5. Turn the assembly several times to seat the bearings.
6. Measure the turning torque at the end of the J-34309-2 gauge anvil using preload gauge.
SPD197A
SPD893
SPD199A
SPD770
Tool number : ST3127S000 (J-25765- A)
Turning torque specification: 1.0 - 1.3 N·m (0.11 - 0.13 kg-m, 9 - 11 in-lb)
PDIA0566E
Page 4068 of 4462

RFD-30
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
7. Place the J-34309-11 “R200A” pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.
8. Position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the bearing caps and tighten bear-
ing cap mounting bolts to the specified torque. Refer to RFD-18,
"COMPONENTS" .
9. Select the correct standard pinion height adjusting washer thick- ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J-34309-101 feeler gauge. Measure the distance between
the J-34309-11 pinion height adapter including the standard
gauge and the arbor.
10. Write down exact measurement (the value of feeler gauge).
11. Correct the pinion height washer size by referring to the “pinion head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the “pinion head height
number”. It refers to the ideal pinion height from standard
for quietest operation. Use the following chart to determine
the correct pinion height washer.
SPD208A
SPD211A
SPD204A
SPD775
SPD542
Page 4069 of 4462

REAR FINAL DRIVE ASSEMBLY RFD-31
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2006 December 2006 FX35/FX45
12. Select the correct pinion height adjusting washer. Refer to RFD-38, "Pinion Height Adjusting Washer" .
13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.
ASSEMBLY
Drive Pinion Assembly
1. Install front bearing outer race (1) and rear bearing outer race (2) 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.
2. Select drive pinion height adjusting washer. Refer to RFD-28,
"Pinion Gear Height" .
Pinion head height number Add or remove from the standard pinion height
adjusting washer thickness measurement
- 6
- 5
- 4
- 3
- 2
- 1
0
+1
+2
+3
+4
+5
+6 Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)
Use the selected washer thickness Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)
SPD205A
Tool number A: ST30720000 (J-25405)
B: KV40105230 ( — )
C: ST30611000 (J-25742-1)
D: ST30613000 (J-25742-3)
PDIA0761J
Page 4070 of 4462

RFD-32
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
3. Install selected drive pinion height adjusting washer (2) to drive pinion. Press pinion rear bearing inner race (1) 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. Assemble collapsible spacer to drive pinion. CAUTION:
Do not reuse collapsible spacer.
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 (A), press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.
8. 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.
9. Install companion flange (1). NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange (1). Tool number A: ST30901000 (J-26010-01)
PDIA0805J
PDIA0492E
PDIA0762J
Tool number A: ST30720000 (J-25405)
PDIA0764J
PDIA0750J
Page 4071 of 4462

REAR FINAL DRIVE ASSEMBLY RFD-33
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2006 December 2006 FX35/FX45
10. Apply anti-corrosion oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.
After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
12. Install differential case assembly. Refer to RFD-33, "
Differential Assembly" .
CAUTION:
Do not install rear cover yet.
13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to RFD-19, "
Drive Gear Runout" , RFD-20, "Tooth Contact" , RFD-21, "Backlash" ,
RFD-22, "
Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to RFD-19, "
Total Preload Torque" .
15. Install rear cover. Refer to RFD-33, "
Differential Assembly" .
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears. Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 N·m (15 - 32 kg-m, 109 - 238 ft-lb)
Drive pinion bearing preload: 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)
PDIA0765J
SDIA0193J
Page 4072 of 4462

RFD-34
REAR FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
2. Install side gears and thrust washers into differential case. CAUTION:
Make sure that the circular clip is installed to side gears.
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust
washer to pinion mate gear.
4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to RFD-26, "
Differential Side
Gear Clearance" .
6. Drive a lock pin into pinion mate shaft, using a punch. Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
7. Align the matching mark of differential case with the mark of drive gear, then place drive gear.
8. Apply thread locking sealant into the thread hole of drive gear.
Use Genuine High Strength Thread Locking Sealant or
equivalent. Refer to GI-48, "
RECOMMENDED CHEMICAL
PRODUCTS AND SEALANTS" .
CAUTION:
Drive gear back and threaded holes shall be cleaned and
degreased sufficiently.
SDIA2025E
SDIA0195J
SPD030
SDIA2593E
SDIA2594E