Part 3

REAR FINAL DRIVE


Disassembly and Assembly

Differential Assembly
1. Apply thread locking sealant to back face of drive gear.





- Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent. Refer to Fluid Type Specifications.

CAUTION:
Make sure the drive gear back and threaded holes are clean.





2. Align the matching mark of differential case assembly with the mark of drive gear, then install drive gear.
3. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts.





- Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent. Refer to Fluid Type Specifications.

CAUTION:
Make sure the drive gear back and threaded holes are clean.





4. Install new drive gear bolts, and then tighten to the specified torque. Refer to "Disassembly and Assembly".

CAUTION:
- Do not reuse the bolts.
- Tighten bolts in a crisscross fashion.





5. Press side bearing inner races to differential case assembly using Tool.

Tool number : ST33081000 ( - )


CAUTION:
Do not reuse side bearing.





6. Install differential lock solenoid and washer.
7. Press side bearing inner races to differential case assembly using Tool.





8. Apply sealant to threads of differential lock position switch.
- Use Genuine Silicone RTV or equivalent. Refer to Fluid Type Specifications.

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





9. Install differential lock position switch on gear carrier and tighten differential lock position switch bolts with the specified torque. Refer to "Disassembly and Assembly".
10. Install side bearing adjusters into gear carrier.





11. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.
12. Apply multi-purpose grease to sensor connector.






CAUTION:
Do not reuse sensor connector.
13. Connect differential lock solenoid harness and sensor connector. Then install it to gear carrier, tighten to the specified torque. Refer to "Disassembly and Assembly".





14. Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier.

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





15. Tighten each side bearing adjusters using adjuster tool.

Tool number : - (C - 4164)






16. Adjusting backlash of drive gear and drive pinion. Refer to "Disassembly and Assembly".
17. Check total preload. Refer to "Disassembly and Assembly".
18. Check tooth contact. Refer to "Disassembly and Assembly".





19. Apply a bead of sealant to the mating surface of the carrier cover as shown.
- Use Genuine Silicone RTV or equivalent. Refer to Fluid Type Specifications.

CAUTION:
Remove any old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
20. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to "Disassembly and Assembly".