Assemble
TOOLS REQUIRED^ J-41693: Installer
^ J-8092: Grip
^ J-41694: Installer
1. Oil Seal. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer.
- Installer: J-41693.
- Grip: J-8092.
2. Needle Bearing. Force a new needle bearing into inner shaft by using a special tool.
- Installer: J-41694.
- Grip: J-8092.
3. Inner Shaft Bearing:
a. Place a new snap ring in inner shaft.
b. Force a new inner shaft bearing into the inner shaft.
4. Snap Ring.
NOTE: Be careful not to damage the inner shaft.
5. Inner Shaft:
a. Clean the housing contact surface of the front axle case.
b. Insert inner shaft assembly into the front axle case.
NOTE: Be careful not to damage seal.
6. Snap Ring. Install snap ring in the groove of front axle case.
NOTE: Be sure to install the snap ring properly.
7. Clutch Gear. Apply differential gear oil to clutch oil.
8. Sleeve. Apply differential gear oil to sleeve.
9. Housing
a. Clean contact surface with the front axle and actuator mounting surface.
b. Apply liquid gasket to the contact surface on the front axle case and install in the housing.
10. Bolt. Tighten bolts to specified tightening torque.
^ Torque 116 Nm (85 ft. lbs.).
11. Actuator.
a. Clean the actuator contact surface with the housing.
b. Install shift position switch.
c. Tighten shift position switch to specified torque.
^ Torque 39 Nm (29 ft. lbs.).
d. Apply liquid gasket to the contact surface on the actuator side
e. Align shift arm with the groove of sleeve and install the actuator.
12. Bolt. Tighten bolts to specified torque.
^ Torque 13 Nm (113 inch lbs.).
13. Front Axle Drive Shaft (LH side)
14. Bolt
a. Install front axle drive shaft and mounting bracket.
b. Tighten fitting bolts to specified tightening torque.
^ Torque 116 Nm (85 ft. lbs.).
15. Filler Plug:
a. Pour specified amount of differential gear oil.
Differential Cage: 1.5 l (1.6 qts.)
Actuator Housing: 0.12 l (0.13 qts.)
b. Install filler plug through packing and tighten to specified torque.
^ Torque 7.8 Nm (58 inch lbs.).