Position Sensor/Switch: Service and Repair

Removal and Installation

Components:

REMOVAL
Differential Lock Position Switch

CAUTION:
^ Be careful not to damage spline, companion flange and front oil seal when removing propeller shaft.
^ Before removing final drive assembly or rear axle assembly, disconnect ABS sensor harness connector from the assembly and move it away from final drive/rear axle assembly area. Failure to do so may result in sensor wires being damaged and sensor becoming inoperative.

1. Drain rear final drive gear oil.
2. Remove rear propeller shaft.
^ Plug rear end of transfer.

3. Remove both RH and LH axle shafts.
4. Remove carrier cover bolts.

5. Remove carrier cover using Tool.
Tool number: KV10111100 (J-37228)

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

6. Remove differential lock solenoid connector (B) bolt and disconnect differential lock position connector (A).

7. For installation, apply a paint matching mark on one side of side bearing cap.

CAUTION:
^ Side bearing caps are line-board for initial assembly. The matching marks are used to install them in their original positions.
^ For matching mark, use paint. Do not damage side bearing cap.

8. Remove adjuster lock plates.

9. Remove side bearing caps.

10. Loosen the side bearing adjusters using Tool.
Tool number: - (C-4164)

11. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.

12. Remove side bearing adjusters from axle housing.
13. Remove bracket for the differential lock position switch connector and bolts.
14. Remove differential lock position switch.

INSTALLATION
1. Apply sealant to threads of differential lock position switch.
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant adhering to axle housing and differential lock position switch. Also remove any moisture, oil, or foreign material adhering to application and axle housing and differential lock position switch.

2. Install differential lock position switch on axle housing and tighten differential lock position switch bolts with the specified torque. Refer to "COMPONENTS".

3. Install side bearing adjusters into axle housing.

4. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.
5. Apply multi-purpose grease to differential lock position connector.

CAUTION: Do not reuse sensor connector.

6. Connect differential lock solenoid harness (B) and differential lock position switch connector (A). Then install it to axle housing, tighten to the specified torque. Refer to "COMPONENTS".

7. Align paint matching mark on side bearing caps with that on axle housing and install side bearing caps on axle housing without tightening to specification.

CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.

8. Tighten each side bearing adjusters using adjuster tool.
Tool number: - (C-4164)
9. Adjusting backlash of drive gear and drive pinion.
10. Check total preload.
11. Check tooth contact.

12. Apply sealant to mating surface of carrier cover.
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

13. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to "COMPONENTS".
14. Install both RH and LH axle shafts.
15. Install propeller shaft.
16. Refill rear final drive oil.