Page 3065 of 4647

FFD-10
FRONT OIL SEAL
Revision: 2007 April2007 M35/M45
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Using the drifts, install front oil seal as shown in figure.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Align the matching mark (B) of drive pinion with the matching
mark (A) of companion flange, and then install the companion
flange (1).
4. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
5. Tighten to drive pinion lock nut, while adjust total preload torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
If measured value is out of the specification, remove final
drive assembly and disassemble drive pinion parts to check
and adjust each part. Refer to FFD-13, "
Removal and Installa-
tion" and FFD-15, "Disassembly and Assembly" .
6. Install front propeller shaft. Refer to PR-5, "
Removal and Installation" .
7. Install side shaft assembly.
8. Install front drive shaft both. Refer to FA X - 11 , "
Removal and Installation" .
9. Refill gear oil to the final drive and check oil level. Refer to FFD-8, "
FILLING" .
10. Check the final drive for oil leakage. Refer to FFD-8, "
OIL LEAKAGE AND OIL LEVEL" . Tool number A: ST33400001 (J-26082)
B: KV38102510 ( — )
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Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque:
127.4 - 245.0 N·m (13.0 - 25.0 kg-m, 94 - 181 ft-lb)
Total preload torque:
1.56 - 2.65 N·m (0.16 - 0.27 kg-m, 14 - 23 in-lb)
PDIA0969E
Page 3066 of 4647

SIDE OIL SEAL
FFD-11
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Revision: 2007 April2007 M35/M45
SIDE OIL SEALPFP:33142
Removal and InstallationNDS000ET
NOTE:
Left side oil seal is attached to engine assembly. Replace it after removing front final drive assembly
from vehicle.
REMOVAL
Right Side:
1. Remove the front drive shaft. Refer to FAX-11, "Removal and Installation" .
2. Remove the side oil seal using a puller.
CAUTION:
Be careful not to damage gear carrier.
Left Side:
1. Remove the front final drive assembly from vehicle with power tool. Refer to FFD-13, "Removal and Instal-
lation" .
2. Remove the side oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage gear carrier.
INSTALLATION
Right Side:
1. Apply multi-purpose grease to sealing lips of side oil seal.
2. Using the drift, press-fit side oil seal so that its surface comes
face to face with the end surface of the side retainer.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Install the front drive shaft. Refer to FAX-11, "
Removal and
Installation" .
4. When oil leaks while removing, check oil level after the installa-
tion. Refer to FFD-8, "
Checking Differential Gear Oil" .
Left Side:
1. Apply multi-purpose grease to sealing lips of side oil seal.
2. Using the drift, press-fit side oil seal so that its surface comes
face to face with the end surface of the gear carrier.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Install the front final drive assembly on vehicle. Refer toFFD-13,
"Removal and Installation" .
4. Install the front drive shaft. Refer to FAX-11, "
Removal and
Installation" . Tool number A: KV381054S0 (J-34286)
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Tool number A: ST33400001 (J-26082)
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Tool number A: KV38102100 (J-25803-01)
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Page 3067 of 4647
FFD-12
SIDE OIL SEAL
Revision: 2007 April2007 M35/M45
5. When oil leaks while removing, check oil level after the installation. Refer to FFD-8, "Checking Differential
Gear Oil" .
Page 3068 of 4647

FRONT FINAL DRIVE ASSEMBLY
FFD-13
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Revision: 2007 April2007 M35/M45
FRONT FINAL DRIVE ASSEMBLYPFP:38500
Removal and InstallationNDS000EU
COMPONENTS
REMOVAL
1. Remove front drive shaft both. Refer to FA X - 11 , "Removal and Installation" .
2. Remove front crossbar with power tool.
3. Separate steering outer socket and steering knuckle. Refer to PS-19, "
POWER STEERING GEAR AND
LINKAGE" .
4. Remove side shaft.
5. Remove three way catalyst (right bank) with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
6. Remove front propeller shaft. Refer to PR-5, "
Removal and Installation" .
7. Separate EPS solenoid valve connector.
8. Separate power steering hydraulic line.
9. Remove stabilizer assembly with power tool. Refer to FSU-36, "
Removal and Installation" .
10. Separate steering lower joint and steering gear assembly. Refer to PS-19, "
POWER STEERING GEAR
AND LINKAGE" .
11. Set a suitable jack to engine.
12. Remove front suspension member with power tool. Refer to FSU-27, "
Removal and Installation" .
13. Remove breather hose and tube.
14. Remove engine mounting bracket (RH) (Lower) and engine mounting insulator (RH) with power tool.
Refer to EM-119, "
Removal and Installation (AWD Models)" .
1. Front final drive assembly 2. Side shaft 3. Bushing
4. Front propeller shaft 5. Breather hose 6. Breather tube
7. Breather connector 8. Engine mounting bracket (RH)
(Lower)9. Engine mounting insulator (RH)
Refer to GI-11, "
Components" , for the symbols in the figure.
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FFD-14
FRONT FINAL DRIVE ASSEMBLY
Revision: 2007 April2007 M35/M45
15. Remove front final drive assembly with power tool.
INSTALLATION
Note the following, and installation is in the reverse order of removal.
Refer to FFD-13, "COMPONENTS" about each tightening torque.
When installing the side shaft, apply multi-purpose grease to contact surface of side shaft and side shaft
oil seal.
Tighten mounting bolts in the order as described below when
installing front final drive assembly: side of gear carrier (1),
upper side of gear carrier (2), part of carrier cover (3), lower part
of gear carrier (4).
CAUTION:
Align the mating faces of gear carrier and oil pan for instal-
lation.
When installing breather hoses (1) and tube (2), refer to the fig-
ure.
CAUTION:
Make sure there are no pinched or restricted areas on the
breather hose caused by bending or winding when install-
ing it.
–Make sure the paint mark facing up ( ).
–Securely install the hose until it seats the rounded portion of the
tube ( ).
–Install breather connector as shown in the figure.
–Seat the breather tube bracket end (A) to the machined face (B)
of gear carrier boss.
When oil leaks while removing final drive assembly, check oil
level after the installation. Refer to FFD-8, "
Checking Differential
Gear Oil" .
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Angle “A”: 0 - 30°
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FRONT FINAL DRIVE ASSEMBLY
FFD-15
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Revision: 2007 April2007 M35/M45
Disassembly and AssemblyNDS000EV
COMPONENTS
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Pinion front bearing 5. Drive pinion bearing adjusting
washer6. Drive pinion adjusting washer
7. Gear carrier 8. Pinion rear bearing 9. Pinion height adjusting washer
10. Drive pinion 11. Drive gear 12. Side oil seal (right side)
13. Side retainer 14. O-ring 15. Side bearing adjusting shim
16. Side bearing 17. Differential case 18. Breather connector
19. Dowel pin 20. Filler plug 21. Drain plug
22. Gasket 23. Carrier cover 24. Gear oil defence
25. Side gear thrust washer 26. Side gear 27. Circular clip
28. Pinion mate thrust washer 29. Pinion mate gear 30. Pinion mate shaft
31. Lock pin 32. Side bearing adjusting washer 33. Side oil seal (left side)
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FFD-16
FRONT FINAL DRIVE ASSEMBLY
Revision: 2007 April2007 M35/M45
ASSEMBLY INSPECTION AND ADJUSTMENT
Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
3. Measure total preload with 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.
34. Side shaft bearing 35. Extension tube retainer 36. Side shaft oil seal
37. Dust sealed 38. Side shaft
A: Oil seal lip
B: Screw hole
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
:Apply gear oil.
:Apply anti-corrosion oil.
:Apply Genuine Silicone RTV or equivalent. Refer to GI-47, "
Recommended Chemical Products and Sealants" .
:Apply Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to GI-47, "
Recommended Chemical
Products and Sealants" .
Tool number A: ST3127S000 (J-25765-A)
Total preload torque:
1.56 - 2.65 N·m (0.16 - 0.27 kg-m, 14 - 23 in-lb)
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When the preload torque is large
On pinion bearings: Decrease the drive pinion bearing adjusting washer and drive pinion
adjusting washer thickness. Refer to FFD-36, "
Drive Pinion Bearing
Adjusting Washer" and FFD-36, "Drive Pinion Adjusting Washer" .
On side bearings: Increase the side bearing adjusting shim thickness. Refer to FFD-36,
"Side Bearing Adjusting Shim" .
When the preload torque is small
On pinion bearings: Increase the drive pinion bearing adjusting washer and drive pinion
adjusting washer thickness. Refer to FFD-36, "
Drive Pinion Bearing
Adjusting Washer" and FFD-36, "Drive Pinion Adjusting Washer" .
On side bearings: Decrease the side bearing adjusting shim thickness. Refer to FFD-36,
"Side Bearing Adjusting Shim" .
Page 3072 of 4647

FRONT FINAL DRIVE ASSEMBLY
FFD-17
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FFD
Revision: 2007 April2007 M35/M45
Drive Gear Runout
1. Remove carrier cover. Refer to FFD-20, "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.
Tooth Contact
1. Remove carrier cover. Refer to FFD-20, "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.Runout limit: 0.05 mm (0.0020 in)
SPD886
SPD357
SDIA0570E