Part 1

FRONT FINAL DRIVE


Disassembly and Assembly


COMPONENTS











ASSEMBLY INSPECTION AND ADJUSTMENT
- Drain the differential gear oil before inspection and adjustment. Changing Front Differential Gear Oil.
- Remove and install the carrier cover as necessary for inspection and adjustment. Front Final Drive M205.

Total Preload Torque
1. Install the differential side shaft and differential side flange if necessary.

CAUTION:
The differential side shaft and differential side flange must be installed 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 total preload torque using Tool.

Tool number : ST3127S000 (J-25765-A)

Total preload torque : Refer to DLN-234, "Inspection and Adjustment" Inspection and Adjustment

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.

If the total preload torque is greater than specification
On drive pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjuster by the same amount on each side.

If the total preload torque is less than specification
On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Tighten the side bearing adjuster by the same amount on each side.


Drive Gear Runout





1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.

Runout limit: 0.08 mm (0.0031 in) or less

- 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





1. Apply red lead to the drive gear.

NOTE:
Apply red lead to both faces of three to four gears, at four locations 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 drive 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 washer to move drive pinion closer to the drive gear. 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 washer to move the drive pinion farther from the drive gear. Inspection and Adjustment.

Backlash





1. Fit a dial indicator to the drive gear face to measure the backlash.

Backlash : Refer to DLN-234, "Inspection and Adjustment" Inspection and Adjustment





- If the backlash is outside of the specification, adjust each side bearing adjuster.

If the backlash is greater than specification:
Loosen side bearing adjuster A and tighten side bearing adjuster B by the same amount.
If the backlash is less than specification:
Loosen side bearing adjuster B and tighten side bearing adjuster A by the same amount.


CAUTION:
Do not change the side bearing adjusters by different amounts as it will change the side bearing preload torque.

Companion Flange Runout





1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool.

Runout limit
Companion flange face : Refer to DLN-234, "Inspection and Adjustment" Inspection and Adjustment
Companion flange inner side : Refer to DLN-234, "Inspection and Adjustment" Inspection and Adjustment

2. If the runout is outside the runout limit, follow the procedure below to adjust.
Rotate the companion flange on the drive pinion by 90�, 180� and 270� while checking for the position a.
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

Differential Assembly
1. Drain the differential gear oil if necessary.





2. Remove the differential side shaft and differential side flange using suitable tool.





3. Remove the extension tube and O-ring from the gear carrier.





4. Place a small hole in the side oil seal case using suitable tool.





5. Remove the side oil seal using Tool as shown.

Tool number : SP8P






6. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool.

Tool number : KV10111100 (J-37228)


CAUTION:
- Do not damage the mating surface.
- Do not insert flat-bladed screwdriver, this will damage the mating surface.





7. For proper reinstallation, paint matching marks on one side of the side bearing cap and gear carrier.

CAUTION:
- For matching marks, use paint. Do not damage side bearing cap or gear carrier.
- Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





8. Remove the side bearing caps.





9. Remove the side bearing adjuster.





10. Lift the differential case assembly out of the gear carrier.

CAUTION:
Keep side bearing outer races together with side bearing inner races. Do not mix them up.





11. Remove side bearing inner race using Tools as shown.

Tool number
A: ST33081000 ( - )
B: ST30021000 ( - )


CAUTION:
- Do not remove side bearing inner race unless it is being replaced.
- Place copper plates between the vise and the side bearing inner race and drive gear to prevent damage.
- Engage puller jaws in groove to prevent damage to bearing.
- Keep side bearing outer races together with side bearing inner races. Do not mix them up.





12. 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.
13. Remove the drive gear bolts.
14. Tap the drive gear off the differential case using suitable tool.

CAUTION:
Tap evenly all around to keep drive gear from bending.





15. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.





16. Remove the pinion mate shaft.





17. 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.





2. Remove the drive pinion lock nut using suitable 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 drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.

Tool number : ST30021000 ( - )






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 : SP8P

9. Remove the drive pinion front bearing inner race.





10. Remove the drive pinion front bearing outer race using Tool as shown. Locate the driver on the back edge of the drive pinion front bearing outer race, then drive the drive pinion front bearing outer race out.

Tool number
A: C-4171
B: D-103


CAUTION:
Do not damage gear carrier.





11. Remove the drive pinion rear bearing outer race using Tool as shown. Locate the driver on the back edge of the drive pinion rear bearing outer race, then drive the drive pinion rear bearing outer race out.

Tool number
A: C-4171
B: C-4307


CAUTION:
Do not damage gear carrier.