Front Axle

Removal
1. Bolt
2. Differential assembly
3. Axle case
4. Bolt
5. Bearing cup

- Apply a setting mark to the side bearing cup and the differential carrier
6. Diff. cage assembly
7. Side bearing outer race
- After removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations.
8. Side bearing

- Using special tools, remove the side bearing.
Remover: J-22888
Adapter: J-8107-2
9. Adjust shims

- Note the thickness and position of the shims removed.

10. Flange nut

- Remove the flange nut using special tool
Holding wrench: J-8614-O1

- Before removal of flange nut, apply setting marks to pinion gear and flange nut with chalk. Note the number of threads of pinion gear that protrude from the flange nut. This will help to obtain proper pinion bearing preload after reinstallation and to avoid over tightening.
11. Flange
12. Dust cover
13. Pinion gear.

- Remove the drive pinion assembly using a soft metal rod and a hammer.
14. Inner bearing.

- Remove the inner bearing using a separator and a press.
Separator: J-22912-O1
15. Adjust shim
16. Collapsible spacer
17. Inner bearing outer race
18. Oil seal
19. Outer bearing
20. Outer bearing outer race

- Remove the inner bearing outer race and the outer bearing outer race by using a brass bar and a hammer.
21. Diff. carrier

INSTALLATION
21. Diff. carrier

20. Outer bearing outer race.
Installer: J-24256
Grip: J8092

17. Inner bearing outer race
Installer: J-24252
Grip: J-8092
15. Adjust shim
- Adjustment of drive pinion mounting distance:

(a) Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings
(1) Pilot: J-21777-42
(2) Nut and bolt: J-23597-9
(3) Gauge plate: J-23597-7
- Tighten the stud nut to the specified torque.
Torque N.m (lb.in.) 2.3 (20)
(b) Clean the side bearing bores. Install the dial indicator with the discs and arbor. Install and tighten the bearing cups to the specified torque.
Torque N.m (lb.ft.) 98.1(72.3)

(1) Dial indicator: J-8001
(2) Disc (2 pcs.): J-23597-8
(3) Arbor: J-23597-1
(4) Gauge plate: J-23597-7

(c) Set the dial indicator to "0". Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.

(d) Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest deflection. At this point, once again set the dial indicator to "0" Repeat the procedure to verify the "0" setting.

(e) After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.

(f) Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code "0", the pinion is "nominal".

NOTE: When ordering shims, find the part number in the parts catalog by using the thickness of shims listed in the above table.
14. Inner bearing
- Place the shim on the drive pinion, with the chamfered side turned towards the pinion head then install the inner bearing onto the pinion using an installer and a press.
Installer: J-6133-O1

NOTE: Do not apply pressure to the roller cage. Apply pressure only to the inner race.
16. Collapsible spacer
- Discard the used collapsible spacer and install a new one.
13. Pinion gear
19. Outer bearing
18. Oil seal
- Use oil seal installer to install a new oil seal that has been soaked in rear axle lubricant
Installer: J-24250

NOTE: Take care to use a front differential oil seal, NOT the rear differential oil seal.

12. Dust cover
11. Flange
10. Flange nut
(a) Apply lubricant to the pinion threads.
(b) Tighten the nut to the specified torque using the pinion flange holder.
Pinion flange holder: J-8614-O1
Torque N.m (lb.ft.) 177-274 (130-200)

NOTE: Discard used flange nut and install new one. Do not overtighten the flange nut.

(c) Pinion bearing preload
(1) Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange.

(2) Continue tightening until the specified starting torque is obtained.

Using special tool, caulk the flange nut at two points. Punch: J-39209

NOTE: When caulking, be sure to turn the nut to insure that there is no change in bearing preload. Make sure of preload again as instructed in step (c) above.
9. Adjust shim

(a) Attach the side bearing to the differential assembly without shims. Support the opposite side using a pilot to prevent bearing damage
Installer: J-24244
Drive handle: J-8092
Pilot: J-8107-2

(b) Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier

(c) Using two sets of feeler gauges insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator on the carrier so that the indicator stem is at right angles to a tooth on the ring gear. Dial indicator: J-8001

(d) Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range. Backlash 0.155 (0.006) mm (in.)
With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 in.) to each shim pack to provide side bearing preload. Always use new shims.

(e) Remove side bearing.
Remover: J-22888
Pilot: J-8107-2
8. Side bearing

- Install the side bearings together with the selected shims.
(1) Installer: J-24244
(2) Drive handle: J-8092
(3) Pilot: J-8107-2
7. Side bearing outer race
6. Diff. cage assembly
5. Bearing cup

- Align the setting marks applied at disassembly.

4. Bolt
- Tighten the bolt to the specified torque.
Torque N.m (lb. ft.) 98.1(72.3)

- Measure the amount of run out of the ring gear at its rear face.
Standard: 0.02(0.001) mm (in)
Limit: 0.05(0.002) mm (in)
Gear Tooth Contact Pattern Check and Adjustment

- Apply a thin coat of prussian blue or equivalent to the faces of the 7 - 8 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment. if the contact is abnormal.
3. Axle case
2. Differential assembly
(a) Clean the faces of the front axle case and differential carrier. Apply the recommended liquid gasket or its equivalent to the sealing side of the axle case and the carrier.

(b) Attach the differential case and the carrier assembly to the front axle case and tighten the nuts and bolts. The axle case bolt is used for drainage
Torque N.m (lb.ft.) 25.5 (18.8)
(c) Install the axle shaft assemblies as instructed earlier in this section under "AXLE SHAFT REPLACEMENT". Drive Axles, Bearings and Joints
(d) Fill the axle case with hypoid gear lubricant, to just below the filler hole.
Lubricant capacity liter (US gal) 1.5 (0.4)

REMOVAL, MINOR COMPONENTS
1. Bolt
2. Ring gear
3. Lockpin

- Break staking on the lock pin, using a 5 mm (0.20 in.) diameter drill.
4. Cross pin

- Remove the cross pin, using a soft metal rod and a hammer.
5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage.

INSPECTION (VISUAL CHECK)
Inspect the following parts for wear, damage, or other abnormal conditions.
- Ring gear, pinion gear
- Bearing
- Side gear, pinion gear, cross pin
- Differential cage, carrier
- Thrust washer
- Oil seal
Ring gear replacement
(a) The ring gear should always be replaced with the drive pinion as a set.
(b) When installing the ring gear, apply LOCTITE 271 or equivalent to the threaded hole and bolt.

(c) Tighten the fixing bolts in a diagonal sequence, in the numeric order shown.
(d) Discard used bolts and install new ones.
Torque N.m (lb.ft.) 107.9 (79.6)

Clearance between the differential pinion and earance the cross pin measurement
Standard: 06-0.12 mm (in).
Limit: (0.002 - 0.005) mm (in).

Clearance between the side gear and the differential box.
Standard : 0.03-0.10 mm (in).
Limit: (0.001-0.004) mm (in).

Play in splines between the side gear and the axle shaft.
Standard: 0.08-0.36 (0.0032 - 0.0141 mm (in).

INSTALLATION
8. Differential cage
7. Thrust washer
6. Side gear
5. Pinion gear

- Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction
4. Cross pin

(a) Be sure to install the cross pin so that it is in alignment with the lock pin hole in the differential cage

(b) Adjust the backlash between the side gear and the pinion gear.
Backlash: 0.03- 0.08 (0.001 - 0.003) mm (in)
Thickness of thrust washers available 1.00, 1.05, 1.10 (0.039, 0.041, 0.043) mm (in)
3. Lockpin

- After lock pin installation, stake the cage to secure the lock pin.
2. Ring gear
- When installing the ring gear, apply LOCTITE 271 or equivalent to the threaded hole and bolt.
1. Bolt

- Tighten the bolts in diagonal sequence as illustrated.
Torque N.m (lb.ft.) 107.9 (79.6)

NOTE: Discard used bolts and install new ones.