Switch: Service and Repair

DIFFERENTIAL LOCK POSITION SWITCH


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. Rear Final Drive M226 (ELD).
2. Remove rear propeller shaft. Removal And Installation.
- Plug rear end of transfer.
3. Remove both RH and LH axle shafts. Rear Final Drive M226.
4. Remove the rear stabilizer bar. Stabilizer Bar.
5. Disconnect the following components from the rear final drive.
- Arrow indicates: Vehicle front
- Parking brake cable (1). Component.
- Brake hoses and tubes (2). Rear Brake Piping And Brake Hose
- 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. Rear Final Drive M226 (ELD).
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

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.
6. Install the differential lock solenoid (3) to axle housing and tighten bolt with specified torque. Rear Final Drive M226 (ELD).





7. Connect the differential lock position switch connector (4).
- Arrow indicates: Front
- 1: Parking brake cables
- 2: Brake hose and tubes





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. Rear Final Drive M226 (ELD).
11. Check total preload. Rear Final Drive M226 (ELD).
12. Check tooth contact. Rear Final Drive M226 (ELD).





13. Apply sealant to mating surface of carrier cover.
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

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. Rear Final Drive M226 (ELD).
15. Connect the brake tube (2) and parking brake cable (4) to the carrier cover and tighten to the specified torque. Rear Final Drive M226 (ELD).





- Arrow indicates: Front
16. Install the rear stabilizer bar. Stabilizer Bar.
17. Install both RH and LH axle shafts. Rear Final Drive M226.
18. Install propeller shaft. Removal And Installation .
19. Refill rear final drive oil. Rear Final Drive M226 (ELD).