Position Sensor/Switch: Service and Repair
DIFFERENTIAL LOCK POSITION SWITCHExploded View RFD-119:
Removal and Installation
REMOVAL
Differential Lock Position Switch
CAUTION:
^ Do not 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 the rear stabilizer bar.
5. Disconnect the following components from the rear final drive.
^ <=: Vehicle front
^ Parking brake cable (1)
^ Brake hoses and tubes (2)
^ Differential lock position switch connector (4)
6. Remove the bolt from the differential lock solenoid (3) and remove the solenoid from the axle housing.
7. Remove the carrier cover bolts. Then separate the carrier cover from the axle housing 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.
8. 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.
9. Remove adjuster lock plates.
10. Remove side bearing caps.
11. Loosen the side bearing adjusters using Tool.
Tool number: - (C-4164)
12. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
13. Remove side bearing adjusters from axle housing.
14. Remove the differential lock position switch harness from the bracket.
15. Remove differential lock position switch.
INSTALLATION
1. Apply sealant to threads of differential lock position switch and install it to the axle housing with the specified torque. Refer to Exploded View RFD-119.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-47, "Recommended Chemical Products and Sealants". Testing and Inspection
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 harness to the bracket on axle housing.
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.
^ <=: Front
6. Install the differential lock solenoid (3) to axle housing and tighten bolt with specified torque. Refer to Exploded View RFD-119.
7. Connect the differential lock position switch connector (4).
8. 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.
9. Tighten each side bearing adjusters using adjuster tool.
Tool number: - (C-4164)
10. Adjusting backlash of drive gear and drive pinion.
11. Check total preload.
12. Check tooth contact.
13. Apply sealant to mating surface of carrier cover.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-47, "Recommended Chemical Products and Sealants". Testing and Inspection
CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
14. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to Exploded View RFD-119.
^ <=: Front
15. Connect the brake tube (2) and parking brake cable (4) to the carrier cover and tighten to the specified torque. Refer to Exploded View RFD-119.
16. Install the rear stabilizer bar.
17. Install both RH and LH axle shafts.
18. Install propeller shaft.
19. Refill rear final drive oil.