FRONT OIL SEALDLN-159
< REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]
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3. 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, using flange wrench (commercial service tool).
CAUTION:
Never reuse drive pinion lock nut.
4. Tighten drive pinion lock nut within the limits of specified torque so as to keep the pinion bearing preload within a standard val-
ues, using preload gauge (A) [SST: ST3127S000 (J-25765-A)].
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 tighte n it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
5. Fit a dial indicator onto the companion flange face (inner side of the propeller shaft mounting bolt holes).
6. Rotate the companion flange to check for runout.
7. Fit a test indicator to the inner side of the companion flange (socket diameter).
8. Rotate the companion flange to check for runout.
9. If the runout value is outside the repair limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion gear by 90 ° step,
and search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible causes are be an
assembly malfunction of drive pinion and pinion bear ing and malfunction of pinion bearing. Check for
these items and repair if necessary.
c. If the runout value is still outsi de of the limit after the check and repair, replace companion flange.
10. Install front propeller shaft. Refer to DLN-129, "
Removal and Installation".
11. Install drive shaft. Refer to FAX-22, "
Removal and Installation".
12. Refill gear oil to the final drive and check oil level. Refer to DLN-155, "
Refilling".
13. Check the final drive for oil leakage. Refer to DLN-155, "
Inspection".
Total preload torque: A value
that add 0.1 – 0.4 N·m
(0.01 – 0.04 kg-m, 1 – 3 in-lb) to
the measured value when re-
moving.
PDIA1003E
Companion flange runout : Refer to DLN-185, "Com-
panion Flange Runout".
Companion flange runout : Refer to DLN-185, "
Com-
panion Flange Runout".
JSDIA0116ZZ
Revision: 2010 May2011 QX56
SIDE OIL SEALDLN-161
< REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]
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2. Install drive shaft. Refer to FAX-22, "Removal and Installation".
3. Refill gear oil to the final drive and check oil level. Refer to DLN-155, "
Refilling".
4. Check the final drive for oil leakage. Refer to DLN-155, "
Inspection".
Revision: 2010 May2011 QX56
DLN-162
< UNIT REMOVAL AND INSTALLATION >[FRONT FINAL DRIVE: R180A]
FRONT FINAL DRIVE ASSEMBLY
UNIT REMOVAL AND INSTALLATION
FRONT FINAL DRIVE ASSEMBLY
Exploded ViewINFOID:0000000006222385
Removal and InstallationINFOID:0000000006222386
REMOVAL
1. Drain the differential gear oil. Refer to
DLN-155, "Draining".
2. Remove the drive shafts. Refer to FAX-22, "
Removal and Installation".
3. Remove the front propeller shaft from the front final drive assembly. Refer to DLN-129, "
Removal and
Installation".
4. Disconnect the breather hose from the front final drive assembly.
5. Support the front final drive assembly using a suitable jack.
6. Remove the front final drive assembly bolts, then remo ve the front final drive assembly with a power tool.
CAUTION:
Secure the front final drive assembly to a suitable jack while removing it.
INSTALLATION
Note the following, and installation is in the reverse order of removal.
CAUTION:
Check that there are no pinched or restricted areas on the breather hose caused by bending or wind-
ing when installing it.
1. Front final drive assembly
Refer to GI-4, "
Components" for symbols in figure.
JPDID0388GB
Revision: 2010 May2011 QX56
FRONT FINAL DRIVE ASSEMBLYDLN-163
< UNIT REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]
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Install the breather hose (1) as shown in the figure.
- Install the breather hose (1) of final side with the paint mark (A) facing vehicle front, and insert the breather hose until dimension
(B) shown as follows.
CAUTION:
Never reuse hose clamp.
Install the hose clamp with th e tab facing vehicle front.
- Be sure to fix the breather hose in (C) position.
If remove the bracket (2), align stopper part (D) to part (E) of sus-
pension mounting bracket (3), and tighten the mounting bolt (4) to
specified torque.
When oil leaks while removing final drive assembly, check oil level after the installation. Refer to DLN-142, "
Inspection".
: Vehicle front
B: 20 mm (0.79 in)
Specified torque: 8.3 Nm (0.85 kg-m, 73 in-lb)
JPDID0389ZZ
Revision: 2010 May2011 QX56
DIFFERENTIAL ASSEMBLYDLN-171
< UNIT DISASSEMBLY AND ASSEMBLY > [FRONT FINAL DRIVE: R180A]
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10. Check and adjust drive gear runout, tooth contac t, backlash, and total preload torque. Refer to DLN-171,
"Adjustment".
Recheck above items. Readjust the above description, if necessary.
11. Apply sealant to match surface of carrier cover. Use Genuine Silicone RTV or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants".
CAUTION:
Remove any old sealant adheri ng to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering
to the application and mating surfaces.
12. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque.
13. Install side shaft. Refer to DLN-166, "
Assembly".
14. Install bushing with drift (commercial service tool).
AdjustmentINFOID:0000000006222394
TOTAL PRELOAD TORQUE
1. Install the differential side shaft. Refer to DLN-166, "Assembly".
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 total preload torque with the preload gauge [SST: ST3127S000 (J-25765-A)].
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.
DRIVE GEAR RUNOUT
1. Remove carrier cover. Refer to DLN-168, "Disassembly".
PDIA0712E
Total preload torque : Refer to DLN-185, "Pre-
load Torque".
PDIA0697E
When the preload torque is large
On drive pinion bear ings: Decrease the drive pinion bear ing adjusting washer and drive
pinion adjusting washer thi ckness. For selecting adjusting
washer, refer to the latest parts information.
On side bearings: Increase the side bear ing adjusting washer thickness. For se-
lecting adjusting washer, refer to the latest parts information.
When the preload torque is small On drive pinion bearings: Increase the drive pi nion bearing adjusting washer and drive
pinion adjusting washer thi ckness. For selecting adjusting
washer, refer to the latest parts information.
On side bearings: Decrease the side bear ing adjusting washer thickness. For se-
lecting adjusting washer, refer to the latest parts information.
Revision: 2010 May2011 QX56
DLN-180
< UNIT DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: R180A]
DRIVE PINION
7. Using drift [SST: ST33200000 (J-26082)], press the pinion front
bearing inner race to drive pinion as far as drive pinion nut can
be tightened.
8. Install front oil seal as shown in figure with the drifts (A and B). CAUTION:
Never reuse oil seal.
When installing, n ever 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).
10. Temporarily tighten drive pinion lock nut to drive pinion. CAUTION:
Apply anti-corrosion oil to th e thread and seat of the drive
pinion lock nut
Never reuse drive pinion lock nut.
11. Tighten to drive pinion lock nut using flange wrench (A), while adjusting pinion bearing preload torque using preload gauge (B).
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
After adjustment, rotate dri ve pinion back and forth 2 to 3
times to check for unusual no ise, rotation malfunction,
and other malfunctions.
12. Install differential case assembly. Refer to DLN-169, "
Assem-
bly".
CAUTION:
PDIA0709E
A: Drift [SST: ST30720000 (J-25405)]
B: Drift [SST: ST27863000 ( — )]
PDIA0717E
PDIA0799J
A: Flange wrench (commercial service tool)
B: Preload gauge [SST: ST3127S000 (J-25765-A)]
Pinion bearing preload : Refer to DLN-185, "Pre-
load Torque".
WDIA0382E
Revision: 2010 May2011 QX56
DLN-184
< UNIT DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: R180A]
DRIVE PINION
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.
5. If the runout value is outside the runout li mit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90 ° step, and
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an
assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for
these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
InspectionINFOID:0000000006222400
INSPECTION AFTER DISASSEMBLY
Drive Gear and Drive Pinion
Clean up the disassembled parts.
If the gear teeth never mesh or line-up correctly, det ermine the cause and adjust or replace as necessary.
If the gears are worn, cracked, damaged, pitted or ch ipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
Clean up the disassembled parts.
If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
Whenever disassembled, replace.
If wear, deterioration of adherence (sealing force lips) , or damage is detected on the lips, replace them.
Companion Flange
Clean up the disassembled parts.
If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace. Companion flange runout : Refer to
DLN-185, "
Com-
panion Flange Runout".
Companion flange runout : Refer to DLN-185, "
Com-
panion Flange Runout".
JSDIA0116ZZ
Revision: 2010 May2011 QX56
DLN-186
< PRECAUTION >[REAR FINAL DRIVE: R230]
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Service Notice or Precautions for Rear Final DriveINFOID:0000000006222406
Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they never interfere with the function of the parts when applied.
Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
Check appearance of the disassembled parts for dam age, deformation, and unusual wear. Replace them
with new ones, if necessary.
Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, observe it.
Clean and flush the parts sufficiently and blow-dry them.
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from t he mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
Always use shop paper for cleaning the inside of components.
Never use cotton gloves or shop rags to prevent entering of lint.
During assembly, observe the specified tightening tor que, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.
Revision: 2010 May2011 QX56