Page 2025 of 3383

FFD-2
PRECAUTIONS
Revision: November 20092006 QX56
PRECAUTIONSPFP:00001
Precautions for Servicing Front Final DriveEDS0044X
Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
Check for the correct installation status prior to removal or disassembly. When matching marks are
required, be certain they do not interfere with the function of the parts they are applied to.
Overhaul should be done in a clean work area, a dust proof area is recommended.
Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
Always use shop paper for cleaning the inside of components.
Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace
them with new ones if necessary.
Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
Clean and flush the parts sufficiently and blow them dry.
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil,
and foreign materials from the application and mating surfaces.
In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
During assembly, observe the specified tightening torque.
Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.
Page 2026 of 3383

PREPARATIONFFD-3
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FFD
Revision: November 2009 2006 QX56
PREPARATIONPFP:00002
Special Service ToolsEDS0044Y
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
ST35271000
(—)
Drift Installing drive pinion front bearing outer
race.
a: 72 mm (2.83 in) dia.
b: 36 mm (1.42 in) dia.
KV38100500
(J-25273)
Drift Installing front oil seal.
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
ST30021000
(—)
Puller
Removing side bearing inner race.
Removing drive pinion rear bearing inner
race.
KV38100300
(J-25523)
Drift Installing side bearing inner race.
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
ST30901000
(—)
Drift Installing drive pinion rear bearing outer race.
A: 79 mm (3.11 in) dia.
B: 45 mm (1.77 in) dia.
C: 35.2 mm (1.39 in) dia.
KV40104810
(—)
Drift Installing drive pinion front bearing outer
race.
a: 68 mm (2.68 in) dia.
b: 55 mm (2.17 in) dia.
KV38102200
(—)
Drift Installing front oil seal.
a: 90 mm (3.54 in) dia
.
b: 55.3 mm (2.18 in) dia.
ZZA0702D
ZZA0811D
ZZA0700D
ZZA1046D
SDIA0217J
ZZA1003D
NT660
Page 2027 of 3383
FFD-4
PREPARATION
Revision: November 20092006 QX56
ST33081000
(—)
AdapterRemoving and installing side bearing inner
race.
a: 43 mm (1.69 in) dia
.
b: 33.5 mm (1.32 in) dia.
KV38108300
(J-44195)
Companion flange wrench Removing and installing drive pinion nut.
ST3127S000
(J-25765-A)
Preload gauge
1. GG91030000
(J-25765)
Torque wrench
2. HT62940000
( — )
Socket adapter (1/2 ″)
3. HT62900000
( — )
Socket adapter (3/8 ″) Inspecting drive pinion bearing preload and
total preload
—
(C-4040)
Installer Installing drive pinion rear bearing inner race.
KV40105230
(—)
Drift Installing drive pinion rear bearing outer race.
a: 92 mm (3.62 in) dia.
b: 85.5 mm (3.37 in) dia.
—
(C-4171)
Handle
Removing drive pinion front bearing outer
race
Removing drive pinion rear bearing outer
race
Tool number
(Kent-Moore No.)
Tool name
Description
ZZA1000D
NT771
NT124
SDIA2607E
ZZA0898D
LDIA0134E
Page 2028 of 3383
PREPARATIONFFD-5
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FFD
Revision: November 2009 2006 QX56
Commercial Service ToolsEDS0044Z
—
(D-103)
Remover Removing drive pinion front bearing outer
race
—
(C-4307)
Remover Removing drive pinion rear bearing outer
race
Tool number
(Kent-Moore No.)
Tool name
Description
LDIA0135E
LDIA0135E
(Kent-Moore No.)
Tool name
Description
(SP8P)
Slide hammer
Removing front oil seal
Removing side oil seal
Power tool Loosening bolts and nuts
LDIA0133E
PBIC0190E
Page 2029 of 3383
FFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: November 20092006 QX56
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS00450
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
FFD-23FFD-16FFD-16FFD-17FFD-17FFD-7
PR-3, "
NVH Troubleshooting Chart
"
FAX-4, "
NVH Troubleshooting Chart
"
FSU-4, "
NVH Troubleshooting Chart
"
WT-4, "
NVH Troubleshooting Chart
"
WT-4, "
NVH Troubleshooting Chart
"
FAX-4, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Incorrect backlash
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
FRONT AXLE
FRONT SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom
Noise××××××××××××××
Page 2030 of 3383

DIFFERENTIAL GEAR OILFFD-7
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Revision: November 2009 2006 QX56
DIFFERENTIAL GEAR OILPFP:KLD30
Changing Differential Gear OilEDS00451
DRAINING
1. Stop the engine.
2. Remove the drain plug from the front final drive assembly to drain the differential gear oil.
3. Install the drain plug with sealant applied on the threads to the front final drive assembly. Tighten to the
specified torque. Refer to FFD-14, "
COMPONENTS" .
Use High Performance Thread Sealant or equivalent. Refer to GI-46, "Recommended Chemical Prod-
ucts and Sealants" .
FILLING
1. Remove the filler plug from the front final drive assembly.
2. Fill the front final drive assembly with new differential gear oil
until the level reaches the specified level near the filler plug hole.
3. Install the filler plug with sealant applied on the threads to the front final drive assembly. Tighten to the specified torque. Refer
to FFD-14, "
COMPONENTS" .
Use High Performance Thread Sealant or equivalent. Refer to
GI-46, "
Recommended Chemical Products and Sealants" .
Checking Differential Gear OilEDS00452
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL
1. Make sure that differential gear oil is not leaking from the front final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as
shown.
CAUTION:
Do not start engine while checking differential gear oil level.
3. Install the filler plug with sealant applied on the threads to the front final drive assembly. Tighten to the specified torque. Refer
to FFD-14, "
COMPONENTS" .
Use High Performance Thread Sealant or equivalent. Refer to
GI-46, "
Recommended Chemical Products and Sealants" .
Differential gear oil
grade and capacity
: Refer to
MA-11, "
Fluids
and Lubricants" .
LDIA0176E
LDIA0176E
Page 2031 of 3383
FFD-8
FRONT OIL SEAL
Revision: November 20092006 QX56
FRONT OIL SEALPFP:38189
Removal and InstallationEDS00453
REMOVAL
1. Remove the drive shafts from the front final drive assembly. Refer to FA X - 7 , "Removal and Installation" .
2. Remove the front propeller shaft from the front final drive assembly. Refer to PR-4, "
Removal and Installa-
tion" .
3. Measure the total preload torque. Refer to FFD-15, "
Total Preload Torque" .
NOTE:
Record the total preload torque measurement.
4. Remove the drive pinion lock nut using Tool.
5. Put matching marks on the companion flange and drive pinion using paint.
CAUTION:
Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.
6. Remove companion flange using suitable tool.
7. Place a small hole in the front oil seal case using suitable tool.
8. Remove the front oil seal using Tool as shown. Tool number : KV38108300 ( — )
BDIA0001E
LDIA0171E
LDIA0129E
Tool number : SP8P
LDIA0130E
Page 2032 of 3383

FRONT OIL SEALFFD-9
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Revision: November 2009 2006 QX56
INSTALLATION
1. Apply multi-purpose grease to the lips of the new front oil seal.
Then drive the new front oil seal in evenly to the gear carrier
using Tool.
CAUTION:
Do not reuse front oil seal.
Do not incline the new front oil seal when installing.
Apply multi-purpose grease to the lips of the new front oil
seal.
2. Install the companion flange to the drive pinion while aligning the matching marks.
3. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using Tool A, and check
the total preload torque using Tool B.
The total preload torque should be within the total preload
torque specification. When not replacing the collapsible
spacer, it should also be equal to the measurement taken dur-
ing removal plus an additional 0.56 N·m (0.06 Kg-m, 5 in-lb).
If the total preload torque is low, tighten the drive pinion lock
nut in 6.8 N·m (0.69 Kg-m, 5ft-lb) increments until the total
preload torque is met.
CAUTION:
Do not reuse drive pinion lock nut.
Apply anti-corrosive oil to the threads of the drive pinion
and the seating surface of the new drive pinion lock nut.
Adjust the drive pinion lock nut tightening torque to the
lower limit first. Do not exceed the drive pinion lock nut
specified torque. Refer to FFD-14, "
COMPONENTS" .
Do not loosen drive pinion lock nut to adjust the total preload torque. If the drive pinion lock nut
torque or the total preload torque exceeds the specifications, replace the collapsible spacer and
tighten it again to adjust. Refer to FFD-14, "
Disassembly and Assembly" .
After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
4. Installation of the remaining components is in the reverse order of removal. CAUTION:
Check the differential gear oil level after installation. Refer to FFD-7, "
DIFFERENTIAL GEAR OIL" .
Tool number : KV38100500 (J-25273)
BDIA0003E
Tool number A: KV38108300 ( — )
B: ST3127S000 (J-25765-A)
Total preload torque: Refer to FFD-15, "
To ta l P r e -
load Torque" .
WDIA0381E