Part 1

FRONT FINAL DRIVE ASSEMBLY


Disassembly and Assembly


COMPONENTS (VQ35HR)











COMPONENTS (VK45DE)











ASSEMBLY INSPECTION AND ADJUSTMENT
- Before inspection and adjustment, drain gear oil.

Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.





2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload with preload gauge.

Tool number A: ST3127S000 (J-25765-A)

Total preload torque: 1.56 - 2.65 Nm (0.16 - 0.27 kg-m, 14 - 23 in-lb)

NOTE:
Total preload torque = Pinion bearing preload torque + Side bearing preload torque
- If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.

When the preload torque is large
On pinion bearings: Decrease the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness. Refer to FFD-39, "Inspection and Adjustment".
On side bearings: Increase the side bearing adjusting shim thickness. Refer to FFD-39, "Inspection and Adjustment".
When the preload torque is small
On pinion bearings: Increase the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness. Refer to FFD-39, "Inspection and Adjustment".
On side bearings: Decrease the side bearing adjusting shim thickness. Refer to FFD-39, "Inspection and Adjustment".

Drive Gear Runout
1. Remove carrier cover. Disassembly and Assembly.





2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.

Runout limit: 0.05 mm (0.0020 in)

- If the runout is outside of the repair limit, check drive gear assembly condition; foreign material may be caught between drive gear and differential case, or differential case or drive gear may be deformed, etc.

CAUTION:
Replace drive gear and drive pinion gear as a set.

Tooth Contact
1. Remove carrier cover. Disassembly and Assembly.





2. Apply red lead to drive gear.

CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.





3. Rotate drive gear back and forth several times, check drive pinion gear to drive gear tooth contact.

CAUTION:
Check tooth contact on drive side and reverse side.










4. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).





- If the tooth contact is near the face (face contact), or near the heel
(heel contact), thicken pinion height adjusting washers to move drive pinion closer to drive gear. Inspection and Adjustment.





- If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), thin pinion height adjusting washers to move drive pinion farther from drive gear. Inspection and Adjustment.

Backlash
1. Remove carrier cover. Disassembly and Assembly.





2. Fit a dial indicator to the drive gear face to measure the backlash.

Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)

- If the backlash is outside of the specified value, change the thickness of side bearing adjusting washer.

When the backlash is large:
Decrease side bearing adjusting washer thickness.
Refer to FFD-39, "Inspection and Adjustment".
When the backlash is small:
Increase side bearing adjusting washer thickness. Refer to FFD-39, "Inspection and Adjustment".


Companion Flange Runout





1. Fit a dial indicator onto the companion flange face (inner side of the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.

Runout limit: 0.18 mm (0.0070 in)

3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.

Runout limit: 0.13 mm (0.0051 in)

5. If the runout value is outside the runout limit, follow the procedure below to adjust.
Check for runout while changing the phase between companion flange and drive pinion by 90� step, and a.
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.

DISASSEMBLY

Side Shaft Assembly





1. Hold extension tube retainer with puller, then press out side shaft using a press.





2. Remove side shaft oil seal (1) from extension tube retainer with a flat- blade screwdriver.

CAUTION:
Be careful not to damage extension tube retainer.
3. Remove side shaft bearing from extension tube retainer.
4. Remove O-ring from extension tube retainer.
5. Remove dust sealed from side shaft.

Differential Assembly
1. Drain gear oil, if necessary.
2. Remove carrier cover mounting bolts.





3. Remove carrier cover to insert the seal cutter between gear carrier and carrier cover.

Tool number A: KV10111100 (J-37228)

CAUTION:
- Be careful not to damage the mating surface.
- Never insert flat-bladed screwdriver, this way damage the mating surface.





4. Remove side retainer.
5. Remove side bearing adjusting shim.
6. Remove O-ring from side retainer.





7. Remove differential case assembly from gear carrier.





8. Remove side oil seal (right side) from side retainer.





9. Remove side bearing outer race with puller.

Tool number A: KV381054S0 (J-34286)

10. Remove O-ring from gear carrier.
11. Remove side oil seal (left side) from gear carrier.





12. Remove side bearing outer race with puller.

Tool number A: KV381054S0 (J-34286)





13. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove
( ).

Tool number
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
- To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
- It is not necessary to remove side bearing inner race except it is replaced.





14. For proper reinstallation, paint matching marks on one differential case assembly.

CAUTION:
For matching marks, use paint. Never damage differential case and drive gear.
15. Remove drive gear mounting bolts.
16. Tap drive gear off differential case assembly with a soft hammer.

CAUTION:
Tap evenly all around to keep drive gear from bending.





17. Remove lock pin of pinion mate shaft with a punch from drive gear side.





18. Remove pinion mate shaft.





19. Turn pinion mate gear, then remove pinion mate gears, pinion mate thrust washers, side gears and side gear thrust washers from differential case.

Drive Pinion Assembly
1. Remove differential assembly. Disassembly and Assembly.





2. Remove drive pinion lock nut with a flange wrench.





3. Put matching mark (B) on the end of drive pinion. The matching mark should be in line with the matching mark (A) on companion flange (1).

CAUTION:
For matching mark, use paint. Never damage companion flange and drive pinion.

NOTE:
The matching mark (A) on the final drive companion flange (1) indicates the maximum vertical runout position.
When replacing companion flange, matching mark is not necessary.





4. Remove companion flange using the suitable puller.





5. Press drive pinion assembly out of gear carrier.

CAUTION:
Never drop drive pinion assembly.
6. Remove front oil seal.
7. Remove pinion front bearing inner race.
8. Remove drive pinion bearing adjusting washer and drive pinion adjusting washer.





9. Remove pinion rear bearing inner race and pinion height adjusting washer with replacer (A) (commercial service tool).





10. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.

CAUTION:
Be careful not to damage gear carrier.

INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures below.






ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS (SHIMS)

Differential Side Gear Clearance
- Assemble the differential parts if they are disassembled. Refer to "Differential Assembly".





1. Place differential case straight up so that side gear to be measured comes upward.





2. Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance of the other side as well.

Side gear back clearance specification:
0.2 mm (0.008 in) or less.
(Each gear should rotate smoothly without excessive resistance during differential motion.)

CAUTION:
To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/thinner side gear thrust washer to adjust. Inspection and Adjustment.

When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.

CAUTION:
Select a side gear thrust washer for right and left individually.

Side Bearing Preload
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.





2. Press-fit side bearing outer race into side retainer with tool.

Tool number
A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)

CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flat to side retainer.
- Never reuse side bearing outer race.





3. Press-fit side bearing outer race into gear carrier with tool.

Tool number
A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)

CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
- Never reuse side bearing outer race.





4. Place the differential case assembly into gear carrier.





5. Install side bearing adjusting shim before disassembling or shim which thickness is the same as the one before disassembling.
6. Install side retainer assembly to gear carrier.

CAUTION:
Never install O-ring.





7. Install side retainer mounting bolts to the specified torque. Disassembly and Assembly.





8. Measure the turning torque of the gear carrier at the drive gear mounting bolts with a spring gauge (commercial service tool).

Specification:
34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force at the drive gear bolt





9. If the turning torque is outside the specification, use a thicker/thinner side bearing adjusting shim to adjust. Inspection and Adjustment.

If the turning torque is less than the specified range:
Decrease the side bearing adjusting shim thickness.
If the turning torque is greater than the specification:
Increase the side bearing adjusting shim thickness.

10. Record the total amount of shim thickness required for the correct carrier side bearing preload.

Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.





1. Use the formula below to calculate pinion height adjusting washer thickness.

Washer selection equation:
T = T0 + (t1 - t2)
T: Correct washer thickness
T0: Removed washer thickness
t1: Old drive pinion head letter "H � 0.01" ("H": machined tolerance 1/100 mm � 100)
t2: New drive pinion head letter "H � 0.01" ("H": machined tolerance 1/100 mm � 100)

Example:
T = 3.21 + [(2 � 0.01) - (-1 � 0.01)] = 3.24
T0: 3.21
t1: +2
t2: -1

2. Select the proper pinion height adjusting washer. Inspection and Adjustment.
If impossible find the desired thickness of washer, use washer with thickness closest to the calculated value.

Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm

Pinion Bearing Preload
- Assemble the drive pinion parts if they are disassembled. Refer to "Drive Pinion Assembly".
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.





2. Install companion flange (1).

NOTE:
When reusing drive pinion, align the matching mark (B) of drive pinion with the matching mark (A) of companion flange, and then install companion flange (1).





3. Temporarily tighten removed drive pinion lock nut to drive pinion.

NOTE:
Use removed drive pinion lock nut only for the preload measurement.
4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Tighten to drive pinion lock nut, while adjust pinion bearing preload torque.

Tool number A: ST3127S000 (J-25765-A)

Drive pinion lock nut tightening torque: 127.4 - 245.0 Nm (13.0 - 25.0 kg-m, 94 - 181 ft-lb)

Pinion bearing preload: 0.78 - 1.57 Nm (0.08 - 0.16 kg-m, 7 - 13 in-lb)

CAUTION:
- Adjust to the lower limit of the drive pinion lock nut tightening torque first.
- After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction,
and other malfunctions.
6. If the pinion bearing preload torque is outside the specification, use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust. Inspection and Adjustment.

When the preload torque is large:
Decrease the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness.
When the preload is small:
Increase the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness.

7. Remove companion flange, after adjustment.