Position Sensor/Switch: Service and Repair

Differential Lock Position Switch: Removal and Installation

Removal

Differential Lock Position Switch

CAUTION:

- Be careful not to damage spline, companion flange and front oil seal when removing propeller shaft.
- Before removing rear final drive assembly or rear axle assembly, disconnect ABS sensor harness connector from the assembly and move it away from rear final drive assembly/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. Refer to [Changing Differential Gear Oil] Rear Differential (M226 ELD Type).
2) Remove rear propeller shaft. Refer to [Propeller Shaft: Removal and Installation] 2S1330 Type.
3) Remove both RH and LH axle shafts. Refer to [Axle Shaft: Removal and Installation] Rear Axle (M226 Type).
4) Remove the carrier cover. Refer to [Carrier Cover: Removal and Installation] Rear Differential (M226 ELD Type).
5) Remove differential lock solenoid connector (B) bolt and disconnect differential lock position connector (A).





- : Front
6) 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.

7) Remove adjuster lock plates.
8) Remove side bearing caps.





9) Loosen the side bearing adjusters using Tool.











10) Remove the differential case assembly, keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.





11) Remove side bearing adjusters from gear carrier.





12) Remove bracket for the differential lock position switch connector and bolts.
13) Remove differential lock position switch.

Installation

1) Apply sealant to threads of differential lock position switch.
- Use Genuine Silicone RTV or equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

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.

2) Install differential lock position switch on gear carrier and tighten differential lock position switch bolts with the specified torque. Refer to [Rear Final Drive: Disassembly and Assembly] Rear Differential (M226 ELD Type).





3) Install side bearing adjusters into gear carrier.





4) Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.





5) Apply multi-purpose grease to differential lock position connector.

CAUTION:
Do not reuse sensor connector.

6) Connect differential lock solenoid harness (B) and differential lock position switch connector (A). Then install it to gear carrier, tighten to the specified torque. Refer to [Rear Final Drive: Disassembly and Assembly] Rear Differential (M226 ELD Type).





- : Front
7) Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier without tightening to specification.






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

8) Tighten each side bearing adjusters using adjuster tool.











9) Adjusting backlash of drive gear and drive pinion. Refer to [Rear Final Drive: Disassembly and Assembly] Rear Differential (M226 ELD Type).
10) Check total preload torque. Refer to [Rear Final Drive: Disassembly and Assembly] Rear Differential (M226 ELD Type).
11) Check tooth contact. Refer to [Rear Final Drive: Disassembly and Assembly] Rear Differential (M226 ELD Type).
12) Apply a bead of sealant to the mating surface of the carrier cover as shown.





- Use Genuine Silicone RTV or equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

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.

13) Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to [Carrier Cover: Removal and Installation] Rear Differential (M226 ELD Type).
14) Installation of the remaining components is in the reverse order of removal.

CAUTION:
Fill the front final drive assembly with recommended differential gear oil. Refer to [Changing Differential Gear Oil] Rear Differential (M226 ELD Type).