Removal And Installation

ELECTRIC CONTROLLED COUPLING


Removal and Installation


REMOVAL
1. Remove rear propeller shaft. Exploded View.
2. Disconnect AWD solenoid harness connector.
3. Remove connector bracket.





4. Put matching mark on the thread edge of electric controlled coupling. The matching mark should be in line with the matching mark on the companion flange.

CAUTION:
For matching mark, use paint. Never damage electric controlled coupling.

NOTE:
When replacing electric controlled coupling, matching mark is not necessary.





5. Remove companion flange lock nut, using a flange wrench
(commercial service tool).
6. Remove companion flange.
7. Remove electric controlled coupling breather hose from coupling cover.





8. Remove coupling cover with electric controlled coupling from final drive assembly.
9. Remove electric controlled coupling from coupling cover.
10. Remove AWD solenoid harness.





11. Remove front oil seal from coupling cover, using a suitable tool.

CAUTION:
Be careful not to damage coupling cover.
12. Remove center oil seal from final drive assembly.

INSTALLATION





1. Using the drift (A) [SST: ST35271000 (J-26091)], install center oil seal (1) as shown in the figure.

D : 0.8 - 1.2 mm (0.031 - 0.047 in)


CAUTION:
- Never reuse oil seal.
- When installing, never incline oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.

2. Connect AWD solenoid harness to electric controlled coupling.





3. Install electric controlled coupling to spline of drive pinion inside gear carrier.

CAUTION:
- Align the pin on electric controlled coupling with the groove of gear carrier.
- Be careful not to damage center oil seal.
4. Set AWD solenoid harness guide to gear carrier.









5. Using the drifts, drive front oil seal until it becomes flush with the coupling cover end.


CAUTION:
- Never reuse oil seal.
- When installing, never incline oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.





6. Apply liquid gasket to mating surface of coupling cover. Overlap both ends of the bead for at least 3 mm (0.12 in).
Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

CAUTION:
Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to the mounting surfaces.





7. Install coupling cover to final drive assembly with arrow facing upward, temporarily tighten reamer bolts to the positions shown in the figure.
8. Tighten reamer bolts and coupling cover mounting bolts to the specified torque.
9. Install electric controlled coupling breather hose to coupling cover.
10. Install connector bracket, and tighten bolts to the specified torque.
11. Connect AWD solenoid harness connector.





12. Install companion flange.

NOTE:
When reusing electric controlled coupling, align the matching mark of electric controlled coupling with the matching mark of companion flange, then install companion flange.
13. Install companion flange lock nut with flange wrench (commercial service tool), tighten to the specified torque.

CAUTION:
Never reuse companion flange lock nut.
14. Check companion flange runout. Adjustment.
15. Install rear propeller shaft. Exploded View.
16. When oil leaks while removing, check oil level after the installation. Inspection.