Page 2569 of 3061
RFD-12
< SERVICE INFORMATION >
SIDE OIL SEAL
Check the differential gear oil level after installation. Refer to RFD-8, "Checking Differential Gear
Oil".
Page 2570 of 3061

CARRIER COVER
RFD-13
< SERVICE INFORMATION >
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CARRIER COVER
Removal and InstallationINFOID:0000000003532605
REMOVAL
1. Remove the rear final drive assembly. Refer to RFD-14, "Removal and Installation".
2. Remove the carrier cover bolts and separate the carrier cover
from the gear carrier using Tool.
CAUTION:
• Do not damage the mating surface.
• Do not insert flat-bladed screwdriver, this will damage the
mating surface.
INSTALLATION
1. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of
the carrier cover as shown.
• Use Genuine Silicone RTV or equivalent. Refer to GI-45,
"Recommended Chemical Product and Sealant".
CAUTION:
Remove any old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering
to the application and mating surfaces.
2. Install the carrier cover to the gear carrier. Tighten the bolts to
the specified torque. Refer to RFD-15, "
Disassembly and
Assembly".
3. Install the rear final drive assembly. Refer to RFD-14, "
Removal
and Installation".
CAUTION:
Fill the rear final drive assembly with recommended differential gear oil. Refer to RFD-8
. Tool number : KV10111100 (J-37228)
WDIA0123E
WDIA0282E
Page 2571 of 3061
RFD-14
< SERVICE INFORMATION >
REAR FINAL DRIVE ASSEMBLY
REAR FINAL DRIVE ASSEMBLY
Removal and InstallationINFOID:0000000003532606
REMOVAL
1. Remove the spare tire.
2. Drain the differential gear oil. Refer to FFD-7
.
3. Remove the rear stabilizer bar. Refer to RSU-21, "
Component".
4. Remove the rear propeller shaft. Refer to PR-8, "
Removal and Installation".
5. Remove the rear drive shafts from the rear final drive assembly
and support them using suitable wire. Refer to RAX-7, "
Removal
and Installation".
6. Disconnect the breather hose from the rear final drive assembly.
1. Breather hose 2. Rear final drive assembly 3. Rear propeller shaft
4. Washer 5. Lower stopper 6. Rear drive shaft
7. Rear final drive assembly 8. Upper stopper⇐Vehicle front
WDIA0375E
LDIA0164E
Page 2572 of 3061
REAR FINAL DRIVE ASSEMBLY
RFD-15
< SERVICE INFORMATION >
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7. Place a suitable jack under the rear final drive assembly.
CAUTION:
Do not place the jack on the carrier cover.
8. Remove the nuts and bolts and remove the rear final drive
assembly.
CAUTION:
Secure rear final drive assembly to the jack while removing
it.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• When installing the breather hose make sure the painted marking on the metal end of breather hose
is to the front of the vehicle and there are no pinched or restricted areas on the breather hose
caused by folding or bending when installing it.
• When installing the breather hose insert the plastic end of the breather hose into the hole in the sus-
pension member.
• Fill the rear final drive assembly with differential gear oil after installation. Refer to RFD-8
.
Disassembly and AssemblyINFOID:0000000003532607
COMPONENTS
WDIA0117E
Page 2573 of 3061
RFD-16
< SERVICE INFORMATION >
REAR FINAL DRIVE ASSEMBLY
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Drive pinion front bearing 5. Collapsible spacer 6. Drive pinion rear bearing
7. Drive pinion height adjusting washer 8. Drive pinion 9. Gear carrier
10. Drive gear 11. Pinion mate shaft 12. Lock pin
13. Pinion mate gear 14. Pinion mate thrust washer 15. Side gear
16. Side gear thrust washer 17. Differential case 18. Side bearing
WDIA0191E
Page 2574 of 3061

REAR FINAL DRIVE ASSEMBLY
RFD-17
< SERVICE INFORMATION >
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ASSEMBLY INSPECTION AND ADJUSTMENT
• Drain the differential gear oil before inspection and adjustment. Refer to RFD-8.
• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to RFD-13
.
Total Preload Torque
1. Remove the side flanges if necessary.
CAUTION:
The side flanges shaft must removed in order to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure the total preload torque using Tool.
NOTE:
Total preload torque = Drive pinion bearing preload torque +
Side bearing preload torque
• If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion
bearing preload torque first, then adjust the side bearing preload torque.
CAUTION:
Select a side bearing adjusting washer for right and left individually.
Drive Gear Runout
1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.
• If the runout is outside of the limit, check the condition of the drive
gear assembly. Foreign material may be caught between the drive
gear and differential case, or the differential case or drive gear may
be deformed.
CAUTION:
Replace drive gear and drive pinion as a set.
Tooth Contact
19. Side bearing adjusting washer 20. Bearing cap 21. Carrier cover
22. Filler plug 23. Drain plug 24. Side oil seal
Tool number : ST3127S000 (J-25765-A)
Total preload torque:
2.05 - 4.11 N·m (0.21 - 0.42 kg-m, 19 - 36 in-lb)
SPD884
If the total preload torque is greater than specification
On drive pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same
amount on each side. Refer to RFD-32, "
Inspection and Adjust-
ment".
If the total preload torque is less than specification
On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same
amount on each side. Refer to RFD-32, "
Inspection and Adjust-
ment".
Runout limit : 0.05 mm (0.0020 in) or less
SPD886
Page 2575 of 3061

RFD-18
< SERVICE INFORMATION >
REAR FINAL DRIVE ASSEMBLY
1. Apply red lead to the drive gear.
NOTE:
Apply red lead to both faces of three to four gears, at four loca-
tions evenly spaced on the drive gear.
2. Rotate the drive gear back and forth several times. Then check
for correct drive pinion to drive gear tooth contact as shown.
CAUTION:
Check tooth contact on drive side and reverse side.
3. If the 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), use a thicker drive pinion height adjusting washers
to move the drive pinion closer to the drive gear.
Refer to RFD-32, "
Inspection and Adjustment".
• If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), use a thinner drive pinion height adjusting washers to
move the drive pinion farther from the drive gear.
Refer to RFD-32, "
Inspection and Adjustment".
SPD357
SDIA0570E
SDIA0517E
PDIA0440E
PDIA0441E
Page 2576 of 3061

REAR FINAL DRIVE ASSEMBLY
RFD-19
< SERVICE INFORMATION >
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1. Fit a dial indicator to the drive gear face to measure the back-
lash.
• If the backlash is outside of the specification, change the thickness
of the side bearing adjusting washers.
CAUTION:
Do not change the total thickness of side bearing adjusting washers as it will change the side bearing
preload torque.
Companion Flange Runout
1. Rotate companion flange and check for runout on the outer face
of the companion flange using suitable tool.
2. If the runout is outside of the runout limit, follow the procedure
below to adjust.
a. Rotate the companion flange on the drive pinion by 90°, 180°
and 270° while checking for the position where the runout is
minimum.
b. If the runout is still outside of the runout limit after the companion
flange has been rotated on the drive pinion, possible cause
could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion
bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion
bearing or drive pinion bearing, replace the companion flange.
DISASSEMBLY
Side Flange
1. Drain the differential gear oil if necessary.
2. Remove the side flange using Tools.
3. Remove the side oil seal using suitable tool.
CAUTION:
Do not to damage gear carrier.
Differential Assembly
1. Remove the side flanges.
2. Remove the carrier cover bolts.Backlash : 0.13 - 0.18 mm (0.0051 - 0.0070 in)
If the backlash is greater than specification:
Make side bearing adjusting washer thicker on drive
gear back side, and side bearing adjusting washer
thinner on drive gear tooth side by the same amount.
Refer to RFD-32, "
Inspection and Adjustment".
If the backlash is less than specification:
Make side bearing adjusting washer thinner on drive
gear back side, and side bearing adjusting washer
thicker on drive gear tooth side by the same amount.
Refer to RFD-32, "
Inspection and Adjustment".
SPD513
Runout limit : 0.08 mm (0.0031 in) or less
WDIA0231E
Tool numbers A: KV40104100 ( — )
B: ST36230000 (J-25840-A)