Final Drive - RL4F03V

FINAL DRIVE - RL4F03V





DISASSEMBLY




1. Remove final gear.







2. Press out differential side bearings.




3. Remove viscous coupling.




4. Remove speedometer drive gear.




5. Drive out pinion mate shaft retaining pin.




6. Draw out pinion mate shaft from differential case.
7. Remove pinion mate gears and side gears.

INSPECTION

Gear, washer, shaft and case




- Check mating surfaces of differential case, side gears, pinion mate gears and viscous coupling.
- Check washers for wear.

Viscous coupling




- Check case for cracks.
- Check silicone oil for leakage.

Bearings




- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace outer and inner race as a set.

ASSEMBLY




1. Install side gear and thrust washers in differential case.
2. Install pinion mate gears and thrust washers in differential case while rotating them.
- Apply A.T.F. to any parts.




3. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:

Differential case side
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection.

Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 in.)




c. If not within specification adjust clearance by changing thickness of side gear thrust washer.

Side gear thrust washers for differential case side: Refer to Specifications.

Viscous coupling side







a. Place side gear and thrust washer on pinion mate gears installed on differential case.
b. Measure dimension X.
- Measure dimension X in at least two places.







c. Measure dimension Y.
- Measure dimension Y in at least two places.

Clearance between side gear and viscous coupling = X + Y - 2A: 0.1 - 0.2 mm (0.004 - 0.008 in.)
A: Height of gauge

d. It not within specification, adjust clearance by changing thickness of side gear thrust washer.

Side gear thrust washers for viscous coupling side: Refer to Specifications.




4. Install retaining pin.
- Make sure that retaining pin is flush with case.




5. Install side gear (viscous coupling side) on differential case and then install viscous coupling.




6. Install speedometer drive gear on differential case.
- Align the projection of speedometer drive gear with the groove of differential case.




7. Install final gear and tighten fixing bolts in numerical order.




8. Press on differential side bearings.