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RFD-20
REAR FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
6. Remove the side bearing caps.
7. Lift the differential case assembly out using Tool.
CAUTION:
Keep side bearing outer races together with inner race.
Do not mix them up.
Keep side bearing adjusting washers together with side
bearings.
S-PD343
Tool number : HT72400000 ( — )
S-PD344
SPD919
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REAR FINAL DRIVE ASSEMBLYRFD-21
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8. Remove the side bearing inner races using Tools.
CAUTION:
Engage Tool jaws in bearing groove to prevent damage.
Place copper plates between the side bearing and drive
gear and the vise to prevent damage.
Do not remove side bearing inner race unless it is being
replaced.
9. For proper reinstallation, paint matching marks on the differential case and drive gear.
CAUTION:
Use paint for matching marks. Do not damage differential
case or drive gear.
10. Remove the drive gear bolts.
11. Tap the drive gear off the differential case using suitable tool. CAUTION:
Tap evenly all around to keep drive gear from bending.
12. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.
13. Remove the pinion mate shaft. Tool number A: ST3306S001 ( — )
B: ST33061000 (J-8107-2)
SPD920
PDIA0496E
WDIA0132E
SDIA0031J
Page 2827 of 3383
RFD-22
REAR FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
14. Turn the pinion mate gear, then remove the pinion mate gear,
pinion mate thrust washer, side gear and side gear thrust
washer from the differential case.
Drive Pinion Assembly
1. Remove the differential assembly. Refer to RFD-19, "Differential Assembly" .
2. Remove the drive pinion lock nut using Tool.
3. 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.
4. Remove the companion flange using suitable tool.
5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.
CAUTION:
Do not drop drive pinion assembly.
6. Remove the front oil seal. CAUTION:
Do not damage gear carrier.
7. Remove the drive pinion front bearing inner race.
SDIA0032J
Tool number : KV40104000 ( — )
SDIA1144E
SDIA1132E
SPD892
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REAR FINAL DRIVE ASSEMBLYRFD-23
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8. Remove the drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.
9. Remove the drive pinion front and rear bearing outer races by tapping them uniformly using suitable tool.
CAUTION:
Do not damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, follow
the measures below.
Drive Pinion and Drive Gear
If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,
repair, or replace as necessary.
If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably,
replace with new drive pinion and drive gear.
Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and
drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the
numbers of each drive pinion and drive gear before proceeding with assembly.
Bearing
If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bear-
ing, replace with new bearing assembly (as a new set).
Bearing must be replaced with a new one whenever disassembled.
Side Gear and Pinion Mate Gear
If any cracks or damage are found on the surface of the teeth, replace with new one.
If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact
the thrust washer, replace with new one.
Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.
Side Gear Thrust Washer and Pinion Mate Thrust Washer
If any chips (by friction), damage, or unusual wear are found, replace with new one.
Gear Carrier
If any wear or cracks are found on the contact sides of gear carrier, replace with new one.
Companion Flange
If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the
front oil seal lips are found, replace with new one.Tool number: : ST30021000 ( — )
S-PD179
SDIA0817E
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RFD-24
REAR FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
ADJUSTING AND SELECTING WASHERS
Side Gear Back Clearance
Assemble the differential parts if they are disassembled. Refer to RFD-28, "Differential Assembly" .
1. Place the differential case straight up so that the side gear to be measured is upward.
2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while
rotating the side gear. Average the three readings to calculate
the clearance. (Measure the clearance of the other side as well.)
If the side gear back clearance is outside of the specification,
use a thicker or thinner side gear thrust washer to adjust.
Refer to RFD-32, "
Side Gear Thrust Washer" .
CAUTION:
Insert feeler gauges with the same thickness on both
sides to prevent side gear from tilting.
Each gear should rotate smoothly without excessive
resistance during differential motion.
Select a side gear thrust washer for right and left individ-
ually.
NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear
backlash.
Side Bearing Preload Torque
A selection of side bearing adjusting washers is required for successful completion of this procedure.
1. Apply differential gear oil to the side bearings, and install the dif- ferential case assembly with the side bearing outer races into
the gear carrier.
CAUTION:
Do not reuse side bearing outer race when replacing side
bearing inner race (replace as a set).
PDIA0460E
Side gear back clearance: 0.20 mm (0.0079 in) or less.
If the side gear back clearance is greater than
specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than
specification: Use a thinner side gear thrust washer.
PDIA0576E
SPD527
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REAR FINAL DRIVE ASSEMBLYRFD-25
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2. Insert the left and right original side bearing adjusting washers in
place between side bearings and gear carrier.
3. Align the matching mark on the side bearing cap with the match- ing mark on the gear carrier.
4. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque. Refer to RFD-15, "
COMPO-
NENTS" .
5. Turn the differential assembly several times to seat the side bearings.
6. To determine side bearing preload torque, measure the pulling force of the differential assembly at the drive gear bolt using
To o l .
NOTE:
If pulling force of the differential assembly at the drive gear bolt
is within specification, side bearing preload torque will also be
within specification. Refer to RFD-32, "
PRELOAD TORQUE" .
7. If the pulling force is outside the specification, use a thicker or thinner side bearing adjusting washer to adjust. Refer to RFD-
33, "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 side bearing preload torque.
SPD924
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 pulling force is less than the specification:
Use a thicker side bearing adjusting washer.
If the pulling force is greater than the specification: Use a thinner side bearing adjusting washer.
SPD772
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RFD-26
REAR FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
ASSEMBLY
Drive Pinion Assembly
1. Install the drive pinion front and rear bearing outer races using
To o l s .
CAUTION:
Do not reuse drive pinion front and rear bearing outer race.
2. Select a drive pinion height adjusting washer. Refer to RFD-33, "
Drive Pinion Height Adjusting Washer" .
3. Install the selected drive pinion height adjusting washer to the drive pinion. Press the drive pinion rear bearing inner race to it
using Tool.
CAUTION:
Install the drive pinion height adjusting washer in the
proper direction as shown.
Do not reuse drive pinion rear bearing inner race.
4. Assemble the collapsible spacer to the drive pinion. CAUTION:
Do not reuse collapsible spacer.
5. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
6. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion
assembly.
CAUTION:
Do not reuse drive pinion front bearing inner race.Tool number A: ST15310000 ( — )
B: ST35325000 ( — )
C: ST30621000 ( — )
SPD992
Tool number : ST30022000 ( — )
SPD377
PDIA0492E
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7. Press the drive pinion front bearing inner race to the drive pinion
as far as drive pinion lock nut can be tightened using suitable
spacer.
8. Apply multi-purpose grease to the lips of the new front oil seal. Then drive the new front oil seal in evenly until it becomes flush
with 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.
9. Install the companion flange to the drive pinion while aligning the matching marks.
10. 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 drive pinion bearing preload torque using Tool B.
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 RFD-15, "
COMPONENTS" .
If the drive pinion bearing 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 drive pinion bearing preload torque.
After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
11. Check companion flange runout. Refer to RFD-18, "
Companion Flange Runout" .
12. Install the differential case assembly. Refer to RFD-28, "
Differential Assembly" .
SPD896
Tool number : ST15310000 ( — )
PDIA0563E
Tool number A: KV40104000 ( — )
B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque: 1.77 - 2.64 N·m (0.18 - 0.26 kg-m, 16 - 23 in-lb)
WDIA0379E