RFD PDF

DRIVELINE/AXLE
SECTION RFD
REAR FINAL DRIVE
B
RFD
E
CONTENTS
STANDARD DIFFERENTIAL SERVICE INFORMATION ........................... 33 F
SERVICE INFORMATION ............................ 2 PRECAUTIONS ................................................. 33

Limited Slip Differential (LSD) Performance Judg- G
PRECAUTIONS ................................................... 2 ment .........................................................................33
Service Notice or Precaution ..................................... 2 Service Notice or Precaution ...................................33
PREPARATION ................................................... 3 PREPARATION ................................................. 34 H
Special Service Tool ................................................. 3 Special Service Tool ................................................34
Commercial Service Tool .......................................... 4 Commercial Service Tool ........................................35
DESCRIPTION .................................................... 6 I
DESCRIPTION .................................................. 37
Cross-Sectional View ................................................ 6 Cross-Sectional View ..............................................37
DIFFERENTIAL GEAR OIL ................................. 7 DIFFERENTIAL GEAR OIL .............................. 38 J
Changing Differential Gear Oil .................................. 7 Changing Differential Gear Oil .................................38
Checking Differential Gear Oil ................................... 7 Checking Differential Gear Oil .................................38
FRONT OIL SEAL ............................................... 8 K
FRONT OIL SEAL ............................................. 39
Removal and Installation ........................................... 8 Removal and Installation .........................................39
CARRIER COVER ..............................................11 CARRIER COVER ............................................. 42 L
Removal and Installation ......................................... 11 Removal and Installation .........................................42
REAR FINAL DRIVE ASSEMBLY .....................12 REAR FINAL DRIVE ASSEMBLY .................... 43
Removal and Installation ......................................... 12 Removal and Installation .........................................43 M
Disassembly and Assembly .................................... 12 Disassembly and Assembly .....................................43
SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS N
(SDS) ..................................................................31 (SDS) ................................................................. 63
General Specification .............................................. 31 General Specification ..............................................63
Inspection and Adjustment ...................................... 31 Inspection and Adjustment ......................................63
O
WITH LIMITED SLIP DIFFERENTIAL
Revision: 2007 September RFD-1 D40

PRECAUTIONS
< SERVICE INFORMATION > [STANDARD DIFFERENTIAL]
SERVICE INFORMATION
PRECAUTIONS
Service Notice or Precaution INFOID:0000000002978624
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they do not interfere with the function of the parts when applied.
• Overhaul should be done in a clean work area, it is preferable to work in dust proof area.
• Before disassembly completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, observe it.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint.
• During assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum jelly,
or multi-purpose grease as specified.

PREPARATION
PREPARATION
A
Special Service Tool INFOID:0000000002978625
B
Tool number
Description
Tool name
ST3127S000 Inspecting pinion bearing preload and to-
C
Preload gauge set tal preload
RFD
ZZA0503D
E
KV40104000 Removing and installing drive pinion lock
Flange wrench nut
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia. F
G
NT659
KV381054S0 Removing front oil seal

Puller H
ZZA0601D
KV10111100 Removing carrier cover J

Seal cutter
S-NT046 L
KV38108800 Removing and installing side bearing ad-
Adjuster tool juster
M
N
WDIA0192E
ST30021000 Removing drive pinion rear bearing inner

Puller race O
ZZA0700D

PREPARATION
Tool number
Description
Tool name
ST23550000 Removing and installing lock pin
Pin punch
a: 4.5 mm (0.177 in) dia.
NT410
ST30022000 Installing drive pinion rear bearing outer

Drift race
a: 46 mm (1.81 in) dia.
b: 110 mm (4.33 in) dia.
NT660
KV38100300 Installing side bearing inner race

Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
ZZA1046D
Commercial Service Tool INFOID:0000000002978626
Tool name Description

Puller • Removing companion flange
• Removing side bearing inner race
NT077
Drift Installing front oil seal

a: 96 mm (3.78 in) dia.
b: 84 mm (3.31 in) dia.
NT115
Adapter Removing and installing side bearing in-

a: 43 mm (1.69 in) dia. ner race
PDIA0893E

PREPARATION
A
Puller Removing side bearing inner race
C
ZZB0823D
Drift Installing drive pinion rear bearing outer

a: 89 mm (3.50 in) dia. race
b: 79 mm (3.11 in) dia. RFD
ZZA0811D
Drift Installing drive pinion front bearing outer F

PDIA0893E
H
Installer Installing drive pinion rear bearing inner
b: 41 mm (1.61 in) dia.
I
J
NT065

DESCRIPTION
DESCRIPTION
Cross-Sectional View INFOID:0000000002978627
SDIA3470E
1. Companion flange 2. Drive pinion 3. Drive gear

4. Differential case 5. Pinion mate gear 6. Axle shaft
7. Side gear 8. Pinion mate shaft

DIFFERENTIAL GEAR OIL
A
Changing Differential Gear Oil INFOID:0000000003258699
DRAINING B
1. Stop engine.
2. Remove drain plug and drain gear oil.
C
3. Apply sealant to drain plug. Install drain plug to final drive
assembly and tighten to the specified torque. Refer to RFD-43,
"Disassembly and Assembly".
RFD
F
PDIA1038E
FILLING
1. Remove filler plug. Fill with new gear oil until oil level reaches G
the specified limit near filler plug hole.
Oil grade and Viscosity: H

Refer to MA-12, "Fluids and Lubricants".
Oil capacity: Approx. 2.01 (3-1/2 pt)
I
2. After refilling oil, check oil level. Apply sealant to filler plug.
Install filler plug to final drive assembly and tighten to the speci-
fied torque. Refer to RFD-43, "Disassembly and Assembly".
PDIA1039E J
Checking Differential Gear Oil INFOID:0000000003258700
K
OIL LEAKAGE AND OIL LEVEL
1. Make sure that gear oil is not leaking from final drive assembly
or around it. L
2. Check oil level from filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
M
3. Apply sealant to filler plug. Install filler plug to final drive assem-
bly and tighten to the specified torque. Refer to RFD-43, "Disas-
sembly and Assembly".
N
PDIA1039E

FRONT OIL SEAL
FRONT OIL SEAL
Removal and Installation INFOID:0000000002978630
REMOVAL
When removing, note the following procedure.
1. Rotate the drive pinion back and forth 2 to 3 times using Tool
and record the rotating torque.
Tool number : ST3127S000
PDIA0309E
2. Remove the drive pinion lock nut and washer using Tool.
Tool number : KV40104000
LDIA0122E
3. Put a matching mark on the thread edge of drive pinion. The

mark should be in line with the mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion
and companion flange.
SDIA2590E
4. Remove the companion flange using suitable tool.
WDIA0249E

FRONT OIL SEAL
5. Remove the front oil seal using Tool.
A
Tool number : KV381054S0
CAUTION:
Do not damage axle housing. B
LDIA0124E
RFD
INSTALLATION
When installing, note the following procedure.
1. Install the front oil seal into the axle housing using a suitable
E
tool.
CAUTION:
• Do not reuse oil seal.
• Do not incline oil seal when installing. F
• Apply multi-purpose grease onto oil seal lip, and gear oil
onto the circumference of oil seal.
G
PDIA1040E
H
2. Align the matching mark of the drive pinion with the mark of the
companion flange, then install the companion flange.
I
K
SDIA2590E
3. Install the washer and drive pinion lock nut. Tighten the nut until L
there is zero bearing end play using Tool.
Tool number : KV40104000 M

CAUTION:
Do not reuse drive pinion lock nut and washer.
N
LDIA0122E O

FRONT OIL SEAL
4. Rotate the drive pinion using Tool. Rotating torque should be
equal to the reading recorded in step 1 above during removal
plus an additional 0.56 N·m (0.06 kg-m, 5 in-lb).

5. If the rotating torque is low, continue to tighten the drive pinion
lock nut in 6.8 N·m (0.69 kg-m, 5 ft-lb) increments without over-
tightening. Refer to RFD-12, "Disassembly and Assembly".
Tighten until proper rotating torque is achieved.
CAUTION:
PDIA0309E
• Do not loosen the drive pinion lock nut to decrease drive
pinion rear bearing rotating torque.
• Do not exceed specified rotating preload torque. If preload torque or rotating torque is exceeded
a new collapsible spacer must be installed.
• Do not exceed maximum tightening torque. If maximum tightening torque is reached prior to
reaching the required rotating torque, the collapsible spacer may have been damaged. Replace
the collapsible spacer.

CARRIER COVER
CARRIER COVER
A
REMOVAL B
• Remove the carrier cover bolts. Then separate carrier cover from
the axle housing using Tool.
C
CAUTION:
• Be careful not to damage the mating surface. RFD
• Do not insert flat-bladed screwdriver, this will damage the
mating surface.
E
PDIA1041E
INSTALLATION
• Apply sealant to mating surface of carrier cover. Refer to RFD-12, F
CAUTION:
Remove old sealant adhering to mounting surfaces. Also G
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
H
I
PDIA1042E

REAR FINAL DRIVE ASSEMBLY
REMOVAL
• Disconnect the following components from the rear final drive.
- ABS sensor wire harness
- Rear cable (LH) and rear cable (RH)
- Brake hoses and brake tube
CAUTION:
Position the wire harness, cable and hoses away from the final drive assembly. Failure to do so may
result in components being damaged during rear axle assembly removal.
• Remove leaf spring U-bolt nuts.
WARNING:
Support the rear final drive assembly using suitable jack before removing leaf spring U-bolt nuts.
Disassembly and Assembly INFOID:0000000002978633
COMPONENTS
PDIA1273E

1. Drive pinion lock nut 2. Washer 3. Companion flange A

4. Front oil seal 5. Front bearing thrust washer 6. Drive pinion front bearing
7. Axle housing 8. Breather 9. Drain plug
10. Side bearing cap 11. Adjuster lock plate 12. Carrier cover B
13. Filler plug 14. Bracket 15. Drive pinion
16. Drive pinion height adjusting washer 17. Drive pinion rear bearing 18. Collapsible spacer
19. Side bearing adjuster 20. Side bearing 21. Pinion mate thrust washer C
22. Pinion mate gear 23. Side gear thrust washer 24. Side gear
25. Pinion mate shaft 26. Lock pin 27. Differential case
28. Drive gear RFD
A : Oil seal lip
B : Screw hole and back face
Refer to GI-7, "Component", and the followings for the symbols in the figure. E
: Apply multi-purpose grease.
: Apply gear oil.

F
: Apply Genuine Liquid Gasket, Three Bond 1215 or equivalent.
: Apply Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent.
G
ASSEMBLY INSPECTION AND ADJUSTMENT
• Before inspection and adjustment, drain gear oil.
Total Preload Torque H
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.
I
3. Turn drive pinion in both directions several times to set bearing
rollers.
4. Measure total preload with preload gauge.
J
K
Total preload: Refer to RFD-31, "Inspection and Adjust-
ment".
NOTE: L
Total preload torque = Pinion bearing preload torque + Side PDIA0309E
bearing preload torque

• If measured value is out of the specification, disassemble it to check and adjust each part. Adjust pinion
bearing preload and side bearing preload. M
Adjust pinion bearing preload first, then adjust side bearing preload.
When the preload torque is greater than specification N

On pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.
O
When the preload torque is less than specification

On pinion bearings: Tighten drive pinion lock nut. P
On side bearings: Tighten side bearing adjuster.
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Remove carrier cover. Refer to RFD-11, "Removal and Installation".

2. Thoroughly clean drive gear and drive pinion teeth.
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
PDIA0321E
4. Hold companion flange steady by hand and rotate drive gear in

both directions.
PDIA0322E
SDIA2591E
5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to "Drive Pinion
Height Adjusting Washer" and "Backlash".
Backlash
1. Remove carrier cover. Refer to "Differential Assembly".
2. Check drive gear to drive pinion backlash using a dial indicator
at several points.
Drive gear to drive pinion backlash: Refer to RFD-31,

"Inspection and Adjustment".
3. If outside the standard, adjust side bearing adjusters.
CAUTION:
Check tooth contact and total preload after adjusting side
bearing adjusters. Refer to "Total Preload Torque", "Tooth
Contact".
SDIA2640E
a. Remove adjuster lock plates.

b. Loosen side bearing cap bolts.
c. Tighten or loosen each side bearing adjusters using Tool. A

B
PDIA1044E
RFD
d. In case of excessive backlash, loosen side bearing adjuster A

and tighten side bearing adjuster B. In case of insufficient back-
E
lash, loosen side bearing adjuster B and tighten side bearing
adjuster A.
PDIA0330E
H
e. After adjusting backlash, tighten side bearing cap bolts to the
specified torque. Refer to "COMPONENTS".
f. Install adjuster lock plates and tighten to the specified torque.
Refer to "COMPONENTS". I
K
PDIA0331E
Companion Flange Runout

1. Fit a dial indicator onto companion flange face (inner side of pro- L
peller shaft bolt holes).
2. Rotate companion flange to check for runout.
M
Runout limit : Refer to RFD-31, "Inspection and Adjust-
ment"
3. Fit a test indicator to the inner side of companion flange (socket N
diameter).
SDIA2078E O
Runout limit : Refer to RFD-31, "Inspection and Adjustment"
5. If the runout value is outside the repair limit, follow the procedure below to adjust.
P
a. Check for runout while changing the phase between companion flange and drive pinion by 90°, 180° and
270° and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, check drive pinion
front bearing, drive pinion rear bearing and drive pinion assembly.
DISASSEMBLY

Differential Assembly
1. Remove carrier cover bolts and bracket.
PDIA1066E
2. Separate carrier cover from axle housing using Tool.

CAUTION:
• Be careful not to damage the mating surface.
mating surface.
PDIA1041E
3. For proper reinstallation, paint matching mark on one side of

side bearing cap and axle housing.
CAUTION:
• Side bearing caps are line-board for initial assembly. The
matching marks are used to reinstall them in their original
positions.
• For matching mark, use paint. Do not damage side bear-
ing cap and axle housing.
4. Remove adjuster lock plates.
PDIA0310E
5. Remove side bearing caps.
PDIA0311E

6. Loosen side bearing adjusters using Tool.
A
PDIA1044E
RFD
7. Keep side bearing outer races together with inner races. Do not
mix them up. Also, keep side bearing adjusters together with
bearing.
E
8. Remove side bearing adjusters from axle housing.
G
SDIA3472E
9. Remove side bearing inner races using suitable tools.

CAUTION: H
Be careful not to damage differential case assembly.
PDIA1072E
K
10. For proper reinstallation, paint matching mark on differential
case assembly and drive gear.
CAUTION: L
For matching mark, use paint. Do not damage differential
11. Remove drive gear bolts. M
12. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from binding.
N
SDIA2238E
13. Pull lock pin out of pinion mate shaft, using pin punch. O
Tool number : ST23550000

P
PDIA0062E

14. Remove pinion mate shaft.
SDIA0031J
15. Turn pinion mate gear, then remove pinion mate gear, pinion
mate thrust washer, side gear and side gear thrust washer from
differential case.
SDIA0032J
Drive Pinion Assembly

1. Remove differential case assembly. Refer to "Differential Assembly".
2. Remove drive pinion lock nut and washer using Tool.
PDIA0314E

mark should be in line with the mark on companion flange.
CAUTION:
SDIA2590E

4. Remove companion flange using suitable tool.
A
PDIA0315E
RFD
5. Remove front oil seal using Tool.
Tool number : KV381054S0 E

CAUTION:
Be careful not to damage axle housing.
6. Remove front bearing thrust washer. F
G
SDIA2586E
7. Press the drive pinion assembly and collapsible spacer from

H
axle housing.
CAUTION:
Do not drop drive pinion assembly.
8. Remove drive pinion front bearing inner race from axle housing. I
PDIA0316E
K
9. Tap drive pinion front bearing outer race uniformly with a brass
bar or equivalent to remove.
CAUTION: L
10. Tap drive pinion rear bearing outer race uniformly with a brass
bar or equivalent for removal. M
CAUTION:
N
SDIA2641E
11. Remove drive pinion rear bearing inner race and drive pinion O
height adjusting washer using Tool.
Tool number : ST30021000 P

12. Remove the breather.
SDIA2236E

INSPECTION AFTER DISASSEMBLY
Drive Gear and Drive Pinion
• If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as nec-
essary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.
• Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and
drive gear are etched for verification. If a new gear set is being used, verify the numbers of each drive pinion
and drive gear before proceeding with assembly.
Bearing
• If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing,
replace with new bearing assembly (as a new set).
• Bearing must be replaced with a new one whenever disassembled.
Side Gear, Pinion Mate and Pinion Mate Shaft
• Replace with a new one if found any cracks or damage on the surface of the tooth.
• Replace with a new one if found any worn or chipped mark on the contact sides of thrust washer.
• Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.
Side Gear Thrust Washer and Pinion Mate Thrust Washer
• Replace with a new one if found that it is chipped (by friction), damaged, or unusual worn.
Differential Case Assembly
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new differen-
tial case assembly.
SELECTION ADJUSTING WASHERS
Side Gear Thrust Washer
1. Place differential case straight up so that side gear to be mea-
sured comes upward.
PDIA0460E

2. Using a thickness gauge, measure the clearance between side
gear back and differential case at 3 different points, while rotat- A
ing side gear. Average the 3 readings, and then measure the
clearance. (Measure the clearance of the other side as well.)
B
Side gear back clearance standard:
0.305 mm (0.0120 in) or less.
(Each gear should rotate smoothly without excessive
C
resistance during differential motion.)
CAUTION:
To prevent side gear from tilting, insert thickness gauges RFD
with the same thickness from both sides.
3. If the back clearance is outside the standard, use a thicker/thin-
ner side gear thrust washer to adjust. E
When the back clearance is greater than specification:
Use a thicker thrust washer.
F
When the back clearance is less than specification:
Use a thinner thrust washer.
CAUTION: G
SDIA0583E
Select a side gear thrust washer for right and left individu-
ally.
Drive Pinion Height Adjusting Washer H
• Drive gear and drive pinion are supplied in matched sets only.
Matching numbers on both drive pinion and drive gear are etched
for verification. If a new hypoid gear set is being used, verify the I
numbers of each drive pinion and drive gear before proceeding
with assembly.
J
K
SDIA2241E
L
• The mounting distance from the center line of drive gear to the back face of drive pinion for the M226 final
drive is 109.5 mm (4.311 in).
On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular hypoid gear set. This dimension is controlled by M
a selective drive pinion height adjusting washer between drive pinion rear bearing inner race and drive pin-
ion.
For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height
N
adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjusting washer
thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched
m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would
be required if drive pinion were etched “0”. By adding 0.08 mm (0.003 in), the mounting distance of drive pin- O
ion was decreased to 109.4 mm (4.307 in) which is just what a m-8 (-3) etching indicated.
• To change drive pinion adjustment, use different drive pinion height adjusting washer which come in different
thickness. P
• Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to
add or subtract from the old drive pinion height adjusting washer.

Unit: mm (in)
OLD DRIVE NEW DRIVE PINION MARKING

PINION -10 -8 -5 -3 +3 +5 +8 +10
MARKING 0
(-4) (-3) (-2) (-1) (+1) (+2) (+3) (+4)
+10 +0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0
(+4) (+0.008) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0)
+8 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02
(+3) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001)
+5 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05
(+2) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002)
+3 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08
(+1) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003)
+0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10
0
(+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004)
-3 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13
(-1) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005)
-5 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15
(-2) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006)
-8 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18
(-3) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007)
-10 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
(-4) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007) (-0.008)
ASSEMBLY
1. Install the breather and then tighten to the specified torque. Refer to "COMPONENTS".
2. Press a drive pinion rear bearing outer race into axle housing
using suitable tool and Tool.

CAUTION:
Do not reuse drive pinion rear bearing.
PDIA1051E
3. Press drive pinion front bearing outer race into axle housing
using suitable tool.
CAUTION:
Do not reuse drive pinion front bearing.
PDIA1052E

4. Temporarily install drive pinion height adjusting washer.
A
When hypoid gear set has been replaced
• Select drive pinion height adjusting washer. Refer to "Drive
Pinion Height Adjusting Washer".
B
When hypoid gear set has been reused
• Temporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
C
SDIA1666E
RFD
5. Install selected drive pinion height adjusting washer to drive pin-
ion, and press-fit drive pinion rear bearing inner race in it, using
a press and suitable tool.
E
CAUTION:
6. Apply gear oil to drive pinion rear bearing and drive pinion front
bearing. F
7. Install drive pinion front bearing inner race in axle housing.
CAUTION:
Do not reuse drive pinion front bearing. G
8. Install front bearing thrust washer to axle housing. PDIA1053E
9. Perform checking and adjusting the tooth contact and backlash of the hypoid gear following the procedure
below. H
a. Assemble the drive pinion assembly to the axle housing.
CAUTION:
Do not assemble a collapsible spacer. I
b. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
CAUTION: J
Do not assemble a front oil seal.
L
PDIA0328E
c. Temporarily tighten removed drive pinion lock nut and washer to M

drive pinion.

N
NOTE:
Use removed drive pinion lock nut and washer only for the pre-
load measurement.
O
d. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
PDIA0313E P

e. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
Drive pinion lock nut tightening torque:

298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tightening torque first.
• Drive pinion lock nut is tightened with no collapsible spacer. Be careful not to overtighten it.
While measuring the preload, tighten it by 5° to 10°.
• After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction and other malfunctions.
f. Install side bearing adjusters into axle housing.
PDIA0381E
g. Apply gear oil to side bearings. Install differential case assembly

with side bearing outer races into axle housing.
SDIA3472E
h. Align paint matching mark on side bearing cap with that on axle
housing and install side bearing caps on axle housing.
• Do not tighten at this point. This allows further tightening of
side bearing adjusters.
i. Check and adjust the backlash and tooth contact. Refer to
"Backlash" and "Tooth Contact".
j. Remove side bearing caps.
k. Remove differential case assembly.
l. Remove companion flange.
SDIA3446E

m. Press the drive pinion assembly from axle housing.
CAUTION: A
PDIA0316E
RFD
10. Install front oil seal into axle housing using suitable tool.
CAUTION:
E
• Do not incline oil seal when installing.
F
G
PDIA1054E
11. Install collapsible spacer to drive pinion. And then install drive
H
pinion assembly in axle housing.
CAUTION:
• Do not reuse collapsible spacer.
• Be careful not to damage front oil seal. I
SDIA2595E
K
L
N
SDIA2590E
13. Insert companion flange onto drive pinion. Tap the companion O
CAUTION:
Be careful not to damage companion flange and front oil P
seal.
PDIA0328E

14. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut and
washer to drive pinion.

CAUTION:
15. Rotate drive pinion at least 20 times to check for smooth opera-
PDIA0313E
16. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.

298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E
CAUTION:
• Adjust the lower limit of the drive pinion lock nut tightening torque first.
• If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again
to adjust. Never loosen drive pinion lock nut to adjust the preload torque.
tion malfunction, and other malfunctions.
17. Install differential case assembly. Refer to "Differential Assembly".
CAUTION:
Do not install carrier cover yet.
18. Check and adjust backlash, tooth contact and companion flange runout. Refer to "Backlash", "Tooth Con-
tact" and "Companion Flange Runout". Recheck above items. Readjust the above description, if neces-
sary.
19. Check total preload torque. Refer to "Total Preload Torque".
20. Apply sealant to mating surface of carrier cover. Refer to "COM-
PONENTS".
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
PDIA1042E
21. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer to "COMPO-
NENTS".
PDIA1066E

1. Assemble side gear thrust washers with the same thickness as A
the ones installed prior to disassembly or reinstall the old ones
on side gears.
2. Assemble side gear and side gear thrust washer into differential B
case.
SDIA0193J
RFD
3. Align 2 pinion mate gears in diagonally opposite positions, then

rotate and assemble them into differential case after assembling E
pinion mate thrust washer to pinion mate gear.
SDIA0036J
H
4. Align lock pin holes on differential case and shaft, and assemble
pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate I
side gear thrust washers. Refer to "Side Gear Thrust Washer".
K
SDIA0037J
6. Drive a lock pin into pinion mate shaft, using pin punch.
L
CAUTION: M
Do not reuse lock pin.
PDIA0062E
O

7. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
SPD322
8. Apply sealant to back face of drive gear. Refer to "COMPO-

NENTS".
CAUTION:
PDIA1059E
9. Align the matching mark of differential case assembly with the

mark of drive gear, then install drive gear.
SDIA2593E
10. Apply thread locking sealant into the thread hole of drive gear.
Refer to "COMPONENTS".
CAUTION:
Make sure threaded holes are clean.
SDIA2594E
11. Install the drive gear bolts, and then tighten to the specified
torque. Refer to "COMPONENTS".
CAUTION:
• Do not reuse the bolts.
• Tighten bolts in a crisscross fashion.
SDIA0247J

12. Press side bearing inner races to differential case assembly
using suitable tool and Tool. A

CAUTION: B
Do not reuse side bearings.
PDIA1060E
RFD
13. Install side bearing adjusters into axle housing.
G
PDIA0381E
14. Apply gear oil to side bearings. Install differential case assembly H
SDIA3472E K
15. Align paint matching mark on side bearing cap with that on axle
CAUTION: L
Do not tighten at this point. This allows further tightening of
M
SDIA3446E
16. Tighten each side bearing adjusters using Tool. O

P
17. Adjust backlash of drive gear and drive pinion. Refer to "Back-
lash".
18. Check tooth contact. Refer to "Tooth Contact".
19. Check total preload. Refer to "Total Preload Torque".
PDIA1044E

PONENTS".
CAUTION:
PDIA1042E
NENTS".
PDIA1066E

SERVICE DATA AND SPECIFICATIONS (SDS)
A
General Specification INFOID:0000000002978634
2WD models B
YD25
Applied model
5AT 5MT 6MT
Double cab C
Body type Double cab
Double cab wide
Rear Final drive model M226
Gear ratio 3.357 3.916* 4.363 4.636* 3.538 4.083* RFD
Number of teeth (Drive gear / drive pinion) 47/14 47/12 48/11 51/11 46/13 49/12
Number of pinion gears 2
E
Oil capacity (Approx.) (lmp pt) 2.01 (3 - 1/2)
Drive pinion adjustment spacer type Collapsible
*: Option F
QR25
Applied model G
5AT 6MT
Grade Luxury Standard Middle Luxury
Rear final drive model M226 H
Gear ratio 3.916 4.083 4.363*1 4.636*2 4.363*3 4.083*1 4.363
Number of teeth (Drive gear / drive pinion) 47/12 49/12 48/11 51/11 48/11 49/12 48/11
I

Drive pinion adjustment spacer type Collapsible J
*1: Option
*2: Except for the Middle East
*3: For the Middle East K
4WD models
YD25
Applied model L
5AT 6MT
Body type Double cab wide Double cab
Rear Final drive model M226 M
Gear ratio 3.538 4.363* 3.692 4.363* 3.538
Number of teeth (Drive gear / drive pinion) 46/13 48/11 48/13 48/11 46/13
Number of pinion gears 2 N
O
*: Option
Inspection and Adjustment INFOID:0000000002978635

P
PRELOAD TORQUE

Unit: N·m (kg-m, in-lb)
Item Specification
Gear ratio 3.357 3.538 3.692 3.916 4.083 4.363 4.636
2.27 - 4.01 2.24 - 3.96 2.22 - 3.93 2.19 - 3.88 2.17 - 3.85 2.14 - 3.80 2.11 - 3.76
Total preload (0.24 - 0.40, (0.23 - 0.40, (0.23 - 0.40, (0.23 - 0.39, (0.23 - 0.39, (0.22 - 0.38, (0.22 - 0.38,
20 - 35) 20 - 35) 20 - 34) 20 - 34) 20 - 34) 19 - 33) 19 - 33)
Pinion bearing pre-
1.7 - 3.1 (0.18 - 0.31, 15 - 27)
load
BACKLASH
Unit: mm (in)
Item Standard
Drive gear to drive pinion gear 0.15 - 0.23 (0.0059 - 0.0091)
COMPANION FLANGE RUNOUT

Unit: mm (in)
Item Runout limit
Companion flange face 0.10 (0.0039) or less
Inner side of companion flange 0.13 (0.0051) or less

PRECAUTIONS
< SERVICE INFORMATION > [WITH LIMITED SLIP DIFFERENTIAL]
SERVICE INFORMATION A
PRECAUTIONS
Limited Slip Differential (LSD) Performance Judgment INFOID:0000000002978636
B
• Inspection is required when detecting any noise or malfunction while driving or turning. Improper condition of
oil or differential case assembly is suspected. Refer to "METHOD FOR TROUBLESHOOTING ".
C
METHOD FOR TROUBLESHOOTING
1. Check differential gear oil level and differential gear oil leakage. Refer to RFD-38, "Checking Differential
Gear Oil". RFD
2. Changing differential gear oil. Refer to RFD-38, "Changing Differential Gear Oil".
3. Start engine. Drive for 10 min.
4. Again changing differential gear oil. Refer to RFD-38, "Changing Differential Gear Oil". E
5. Start engine. Drive for 10 min. Check if any noise or improper oil condition is detected.
• If OK, check differential gear oil level and differential gear oil leakage. Refer to RFD-38, "Checking Dif-
ferential Gear Oil". F
• If NG, replace differential case assembly after checking each part of final drive. Refer to RFD-43, "Disas-
Service Notice or Precaution INFOID:0000000002978637 G
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they do not interfere with the function of the parts when applied. H
• Overhaul should be done in a clean work area, it is preferable to work in dust proof area.
• Before disassembly completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them I
with new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight- J
ening sequence is specified, observe it.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil, K
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint. L
• During assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum jelly,
or multi-purpose grease as specified.
M

PREPARATION
PREPARATION
Special Service Tool INFOID:0000000002978638
Tool number
Description
Tool name
ST3127S000 Inspecting pinion bearing preload and to-
Preload gauge set tal preload
1. GG91030000
Torque wrench
2. HT62940000(1/2″)
Socket adapter
3. HT62900000(3/8″)
Socket adapter
NT124
KV40104000 Removing and installing drive pinion lock

Flange wrench nut
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.
NT659
KV381054S0 Removing front oil seal

Puller
ZZA0601D
KV10111100 Removing carrier cover

Seal cutter
S-NT046
KV38108800 Removing and installing side bearing ad-

Adjuster tool juster
WDIA0192E
KV11105210 Measure differential torque

Attachment
ZZA0009D

PREPARATION
Tool number
Description
Tool name A
ST30021000 Removing drive pinion rear bearing inner
Puller race
B
C
ZZA0700D
ST33061000 Removing and installing pinion mate

Drift gear RFD
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
E
NT660
F
ST30022000 Installing drive pinion rear bearing outer
Drift race
a: 46 mm (1.81 in) dia.
b: 110 mm (4.33 in) dia. G
H
NT660
KV38100300 Installing side bearing inner race

Drift
a: 54 mm (2.13 in) dia. I
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
J
ZZA1046D
K
Commercial Service Tool INFOID:0000000002978639
Tool name Description L

Puller • Removing companion flange
• Removing side bearing inner race
M
N
NT077
Drift Installing front oil seal

a: 96 mm (3.78 in) dia. O
b: 84 mm (3.31 in) dia.
NT115

PREPARATION
Adapter Removing and installing side bearing in-
a: 43 mm (1.69 in) dia. ner race
PDIA0893E
Puller Removing side bearing inner race
ZZB0823D
Puller Removing and installing pinion mate

gear
ZZC1575D
Drift Installing drive pinion rear bearing outer

b: 79 mm (3.11 in) dia.
ZZA0811D
Drift Installing drive pinion front bearing outer

PDIA0893E
Installer Installing drive pinion rear bearing inner

b: 41 mm (1.61 in) dia.
NT065

DESCRIPTION
DESCRIPTION
A
Cross-Sectional View INFOID:0000000002978640
RFD
J
PDIA1037E
1. Companion flange 2. Drive pinion 3. Drive gear K

4. Differential case 5. Pinion mate gear 6. Axle shaft
7. Side gear 8. Pinion mate shaft
L

Changing Differential Gear Oil INFOID:0000000002978641
DRAINING
1. Stop engine.
2. Remove drain plug and drain gear oil.
3. Apply sealant to drain plug. Install drain plug to final drive
assembly and tighten to the specified torque. Refer to RFD-43,
PDIA1038E
FILLING
1. Remove filler plug. Fill with new gear oil until oil level reaches
the specified limit near filler plug hole.
Oil grade and Viscosity:

Refer to MA-12, "Fluids and Lubricants".
Oil capacity: Approx. 2.01 (3-1/2 pt)
2. After refilling oil, check oil level. Apply sealant to filler plug.
Install filler plug to final drive assembly and tighten to the speci-
fied torque. Refer to RFD-43, "Disassembly and Assembly".
PDIA1039E
Checking Differential Gear Oil INFOID:0000000002978642
OIL LEAKAGE AND OIL LEVEL

1. Make sure that gear oil is not leaking from final drive assembly
or around it.
2. Check oil level from filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
3. Apply sealant to filler plug. Install filler plug to final drive assem-
bly and tighten to the specified torque. Refer to RFD-43, "Disas-
PDIA1039E

FRONT OIL SEAL
FRONT OIL SEAL
A
REMOVAL B
When removing, note the following procedure.
1. Rotate the drive pinion back and forth 2 to 3 times using Tool
and record the rotating torque. C

RFD
PDIA0309E
F
2. Remove the drive pinion lock nut and washer using Tool.

G
I
LDIA0122E

mark should be in line with the mark on companion flange. J
CAUTION:
and companion flange. K
SDIA2590E
M
4. Remove the companion flange using suitable tool.
P
WDIA0249E

FRONT OIL SEAL
5. Remove the front oil seal using Tool.

CAUTION:
Do not damage axle housing.
LDIA0124E
INSTALLATION
When installing, note the following procedure.
1. Install the front oil seal into the axle housing using a suitable
tool.
CAUTION:
PDIA1040E
SDIA2590E
3. Install the washer and drive pinion lock nut. Tighten the nut until
there is zero bearing end play using Tool.

CAUTION:
LDIA0122E

FRONT OIL SEAL
4. Rotate the drive pinion using Tool. Rotating torque should be
equal to the reading recorded in step 1 above during removal A
plus an additional 0.56 N·m (0.06 kg-m, 5 in-lb).
Tool number : ST3127S000 B

5. If the rotating torque is low, continue to tighten the drive pinion
lock nut in 6.8 N·m (0.69 kg-m, 5 ft-lb) increments without over-
tightening. Refer to RFD-12, "Disassembly and Assembly". C
Tighten until proper rotating torque is achieved.
CAUTION:
PDIA0309E
• Do not loosen the drive pinion lock nut to decrease drive
RFD
pinion rear bearing rotating torque.
• Do not exceed specified rotating preload torque. If preload torque or rotating torque is exceeded
a new collapsible spacer must be installed.
• Do not exceed maximum tightening torque. If maximum tightening torque is reached prior to E
reaching the required rotating torque, the collapsible spacer may have been damaged. Replace
the collapsible spacer.
F

CARRIER COVER
CARRIER COVER
REMOVAL
• Remove the carrier cover bolts. Then separate carrier cover from
the axle housing using Tool.

CAUTION:
mating surface.
PDIA1041E
INSTALLATION
• Apply sealant to mating surface of carrier cover. Refer to RFD-12,
CAUTION:
PDIA1042E

A
REMOVAL B
• Disconnect the following components from the rear final drive.
- ABS sensor wire harness
- Rear cable (LH) and rear cable (RH) C
- Brake hoses and brake tube
CAUTION:
Position the wire harness, cable and hoses away from the final drive assembly. Failure to do so may
result in components being damaged during rear axle assembly removal. RFD
• Remove leaf spring U-bolt nuts.
WARNING:
Support the rear final drive assembly using suitable jack before removing leaf spring U-bolt nuts. E
Disassembly and Assembly INFOID:0000000002978646
F
COMPONENTS
JPDID0151GB

1. Drive pinion lock nut 2. Washer 3. Companion flange

4. Front oil seal 5. Front bearing thrust washer 6. Drive pinion front bearing
7. Axle housing 8. Breather 9. Drain plug
10. Collapsible spacer 11. Drive pinion rear bearing 12. Drive pinion height adjusting washer
13. Drive pinion 14. Side bearing cap 15. Adjuster lock plate
16. Carrier cover 17. Filler plug 18. Bracket
19. Retainer 20. Friction plate 21. Friction disc
22. Spring plate 23. Side gear 24. Pinion mate thrust washer
25. Pinion mate gear 26. Pinion mate shaft 27. Lock pin
28. Side bearing adjuster 29. Side bearing 30. Differential case
31. Drive gear
A: Oil seal lip B: Screw hole C: Back face
Refer to GI-7, "Component", and the followings for the symbols in the figure.
: Apply multi-purpose grease
: Apply gear oil
: Apply Genuine Liquid Gasket, Three Bond 1215 or equivalent.
: Apply Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent.
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. Turn drive pinion in both directions several times to set bearing rollers.
4. Measure total preload with preload gauge.
Total preload
Gear ratio 3.538 Type:
2.34 – 4.34 N·m (0.24 – 0.44 kg-m, 21 – 38 in-lb)
Gear ratio 3.692 Type:
2.32 – 4.34 N·m (0.24 – 0.44 kg-m, 21 – 38 in-lb)
PDIA0309E
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 pinion
bearing preload and side bearing preload.
Adjust pinion bearing preload first, then adjust side bearing preload.
When the preload torque is greater than specification

On pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.
When the preload torque is less than specification

On pinion bearings: Tighten drive pinion lock nut.
On side bearings: Tighten side bearing adjuster.
Tooth Contact

Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check A
gear tooth contact pattern to obtain the best contact for low noise and long life.
2. Thoroughly clean drive gear and drive pinion teeth. B
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca- C
tions evenly spaced on drive gear.
RFD
PDIA0321E E
4. Hold companion flange steady by hand and rotate drive gear in

both directions.
F
PDIA0322E
N
SDIA2591E
5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to "Drive Pinion
Height Adjusting Washer" and "Backlash". O
Backlash
1. Remove carrier cover. Refer to "Differential Assembly". P

2. Check drive gear to drive pinion backlash using a dial indicator
at several points.
Drive gear to drive pinion backlash: Refer to RFD-63,

"Inspection and Adjustment"
3. If outside the standard, adjust side bearing adjusters.
CAUTION:
Check tooth contact and total preload after adjusting side
bearing adjusters. Refer to "Total Preload Torque", "Tooth
Contact".
SDIA2640E
a. Remove adjuster lock plates.
b. Loosen side bearing cap bolts.
c. Tighten or loosen each side bearing adjusters using Tool.
PDIA1044E
d. In case of excessive backlash, loosen side bearing adjuster A

and tighten side bearing adjuster B. In case of insufficient back-
lash, loosen side bearing adjuster B and tighten side bearing
adjuster A.
PDIA0330E
e. After adjusting backlash, tighten side bearing cap bolts to the

specified torque. Refer to "COMPONENTS".
f. Install adjuster lock plates and tighten to the specified torque.
PDIA0331E
Companion Flange Runout

1. Fit a dial indicator onto companion flange face (inner side of pro-
peller shaft bolt holes). A
Runout limit : RFD-63, "Inspection and Adjustment" B

3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout. C
Runout limit : RFD-63, "Inspection and Adjustment" SDIA2078E
RFD
5. If the runout value is outside the repair limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90°, 180° and
270° and search for the point where the runout is the minimum. E
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, check drive pinion
front bearing, drive pinion rear bearing and drive pinion assembly. F
Differential Torque
2. Remove rear drum brake of left. Refer to BR-20, "Component". G
3. Fix right rear drum brake with a suitable tool, and install the tool
to axle shaft.
H
4. Turn side gear several times, then measure the differential I
torque after side gear begins to rotate in order to determine
whether it is within the specified range (note).
Differential torque : 50 – 70 N·m (5.1 – 7.1 Kg·m, 37 – 51 J

in-lb) PDIA1048E
NOTE:
K
The differential torque is for reference value only.
a. If the value is outside the standard, replace spring plates, friction discs and friction plates after checking
side gear and differential case. Refer to “INSPECTION AFTER DISASSEMBLY” and “Differential Assem-
bly” L
DISASSEMBLY
Differential Assembly M
1. Remove carrier cover bolts and bracket.
P
PDIA1066E

2. Separate carrier cover from axle housing using Tool.

CAUTION:
mating surface.
PDIA1041E
3. For proper reinstallation, paint matching mark on one side of

side bearing cap and axle housing.
CAUTION:
• Side bearing caps are line-board for initial assembly. The
matching marks are used to reinstall them in their original
positions.
• For matching mark, use paint. Do not damage side bear-
ing cap and axle housing.
4. Remove adjuster lock plates.
PDIA0310E
5. Remove side bearing caps.
PDIA0311E
6. Loosen side bearing adjusters using Tool.
PDIA1044E
7. Keep side bearing outer races together with inner races. Do not
mix them up. Also, keep side bearing adjusters together with
bearing.
8. Remove side bearing adjusters from axle housing.
PDIA0312E

9. Remove side bearing inner races using suitable tools.
CAUTION: A
Be careful not to damage differential case assembly.
PDIA1072E
RFD
10. For proper reinstallation, paint matching mark on differential
CAUTION:
E
For matching mark, use paint. Do not damage differential
11. Remove drive gear bolts.
F
12. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from binding.
G
SDIA2238E
13. Remove lock pin of the pinion mate shaft from the drive gear
H
side, using pin punch.
PDIA0809J
K
14. Remove pinion mate shaft.
N
SDIA0031J
15. Widen the gap between side gears by using puller and drift. O
A : Puller (Commercial service tool)

B : Drift (SST: ST33061000) P
CAUTION:
• Be careful not to damage differential case (flange face).
• Be careful not to damage side gears.
• Do not space excessively between side gears.
SDIA3598E

16. Install axle shaft (1) removed the vehicle on the left side of differ-
ential case, then rotate slowly axle shaft.
CAUTION:
• Be careful not to damage axle shaft.
SDIA3599E
17. Remove pinion mate thrust washers (1) and pinion mate gears
(2) from differential case (3).
CAUTION:
Be careful not to damage differential case (flange face).
SDIA3601E
18. Remove puller, drift and axle shaft then remove side gears,
spring plates, friction discs, friction plates and retainer from dif-
ferential case.
CAUTION:
Make sure the arrangement order of spring plates, friction
discs and friction plates, as well as the placement of each
part.
PDIA1047E

1. Remove differential case assembly. Refer to "Differential Assembly".
2. Remove drive pinion lock nut and washer using Tool.
PDIA0314E

mark should be in line with the mark on companion flange. A
CAUTION:
B
SDIA2590E
RFD
4. Remove companion flange using suitable tool.
G
PDIA0315E
5. Remove front oil seal using Tool.

H
CAUTION: I
6. Remove front bearing thrust washer.
J
SDIA2586E
K
7. Press the drive pinion assembly and collapsible spacer from
axle housing.
CAUTION: L
8. Remove drive pinion front bearing inner race from axle housing.
M
N
PDIA0316E
9. Tap drive pinion front bearing outer race uniformly with a brass O
bar or equivalent to remove.
CAUTION:
Be careful not to damage axle housing. P
10. Tap drive pinion rear bearing outer race uniformly with a brass
bar or equivalent for removal.
CAUTION:
SDIA2641E

11. Remove drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.

12. Remove the breather.
SDIA2236E
INSPECTION AFTER DISASSEMBLY

Drive Gear and Drive Pinion
• If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as nec-
essary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.
• Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and
drive gear are etched for verification. If a new gear set is being used, verify the numbers of each drive pinion
and drive gear before proceeding with assembly.
Bearing
• If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing,
replace with new bearing assembly (as a new set).
• Bearing must be replaced with a new one whenever disassembled.
Side Gear, Pinion Mate Gear and Pinion Mate Shaft
• If any cracks or damage are found on the surface of the tooth, replace with new one.
• If any worn or chipped marks are found on the contact sides of thrust washer, replace with new one.
• Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.
Pinion Mate Thrust Washer
If any chips (by friction), damage, or unusual wear are found, replace with new one.
Differential Case
If any wear or cracks are found on the contact sides of differential case, replace with new one.
Spring plate, Friction Disc and Friction Plate
Confirm that there is not any wear, rip, scratch or dent on each part. If any damage is found on any part,
replace all of the spring plates, friction discs and friction plates to new parts.
SELECTION ADJUSTING WASHERS
Drive Pinion Height Adjusting Washer
• Drive gear and drive pinion are supplied in matched sets only.
Matching numbers on both drive pinion and drive gear are etched
for verification. If a new hypoid gear set is being used, verify the
numbers of each drive pinion and drive gear before proceeding
with assembly.
SDIA2241E
• The mounting distance from the center line of drive gear to the back face of drive pinion for the M226 final
drive is 109.5 mm (4.311 in).
On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular hypoid gear set. This dimension is controlled by
a selective drive pinion height adjusting washer between drive pinion rear bearing inner race and drive pin-
ion.

For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height
adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjusting washer A
thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched
m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would
be required if drive pinion were etched “0”. By adding 0.08 mm (0.003 in), the mounting distance of drive pin-
B
ion was decreased to 109.4 mm (4.307 in) which is just what a m-8 (-3) etching indicated.
• To change drive pinion adjustment, use different drive pinion height adjusting washer which come in different
thickness.
• Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to C
add or subtract from the old drive pinion height adjusting washer.
Unit: mm (in)
OLD DRIVE NEW DRIVE PINION MARKING RFD

PINION -10 -8 -5 -3 +3 +5 +8 +10
MARKING 0
(-4) (-3) (-2) (-1) (+1) (+2) (+3) (+4)
+10 +0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 E
(+4) (+0.008) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0)
+8 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02
(+3) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) F
+5 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05
(+2) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002)
+3 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 G
(+1) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003)
+0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10
0
(+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) H
-3 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13
(-1) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005)
-5 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 I
(-2) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006)
-8 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18
(-3) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007) J
-10 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
(-4) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007) (-0.008)
ASSEMBLY K
1. Install the breather and then tighten to the specified torque. Refer to "COMPONENTS". L
2. Press a drive pinion rear bearing outer race into axle housing
using suitable tool and Tool.
M
CAUTION:
Do not reuse drive pinion rear bearing. N
O
PDIA1051E

3. Press drive pinion front bearing outer race into axle housing
using suitable tool.
CAUTION:
PDIA1052E
4. Temporarily install drive pinion height adjusting washer.

When hypoid gear set has been replaced.
• Select drive pinion height adjusting washer. Refer to "Drive
Pinion Height Adjusting Washer".
When hypoid gear set has been reused.
• Temporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
SDIA1666E
5. Install selected drive pinion height adjusting washer to drive pin-

ion, and press-fit drive pinion rear bearing inner race in it, using
a press and suitable tool.
CAUTION:
6. Apply gear oil to drive pinion rear bearing and drive pinion front
bearing.
7. Install drive pinion front bearing inner race in axle housing.
CAUTION:
8. Install front bearing thrust washer to axle housing. PDIA1053E
9. Perform checking and adjusting the tooth contact and backlash of the hypoid gear following the procedure
below.
a. Assemble the drive pinion assembly to the axle housing.
CAUTION:
Do not assemble a collapsible spacer.
b. Insert companion flange onto drive pinion. Tap the companion
CAUTION:
Do not assemble a front oil seal.
PDIA0328E

c. Temporarily tighten removed drive pinion lock nut and washer to
drive pinion. A

NOTE: B
Use removed drive pinion lock nut and washer only for the pre-
load measurement.
d. Rotate drive pinion at least 20 times to check for smooth opera- C
PDIA0313E
RFD
e. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
E
Drive pinion lock nut tightening torque: F

298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb) G
PDIA0309E
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tightening torque first.
• Drive pinion lock nut is tightened with no collapsible spacer. Be careful not to overtighten it. H
While measuring the preload, tighten it by 5° to 10°.
tion malfunction and other malfunctions. I
f. Install side bearing adjusters into axle housing.
L
PDIA0381E
g. Apply gear oil to side bearings. Install differential case assembly M

PDIA0312E
P

h. Align paint matching mark on side bearing cap with that on axle
• Do not tighten at this point. This allows further tightening of
i. Check and adjust the backlash and tooth contact. Refer to
"Backlash" and "Tooth Contact".
j. Remove side bearing caps.
k. Remove differential case assembly.
l. Remove companion flange.
SDIA3446E
m. Press the drive pinion assembly from axle housing.

CAUTION:
PDIA0316E
10. Install front oil seal into axle housing using suitable tool.
CAUTION:
PDIA1054E
11. Install collapsible spacer to drive pinion. And then install drive
pinion assembly in axle housing.
CAUTION:
• Do not reuse collapsible spacer.
• Be careful not to damage front oil seal.
SDIA2595E
SDIA2590E

13. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated. A
CAUTION:
Be careful not to damage companion flange and front oil
seal. B
PDIA0328E
RFD
14. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut and
washer to drive pinion. E

CAUTION: F
15. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing. G
PDIA0313E
16. Tighten to drive pinion lock nut, while adjust pinion bearing pre- H
load torque.

I

298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb) J
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E K
CAUTION:
• Adjust the lower limit of the drive pinion lock nut tightening torque first.
• If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again
to adjust. Never loosen drive pinion lock nut to adjust the preload torque. L
tion malfunction, and other malfunctions.
17. Install differential case assembly. Refer to "Differential Assembly". M
CAUTION:
Do not install carrier cover yet.
18. Check and adjust backlash, tooth contact and companion flange runout. Refer to "Backlash", "Tooth Con- N
tact" and "Companion Flange Runout". Recheck above items. Readjust the above description, if neces-
sary.
19. Check total preload torque. Refer to "Total Preload Torque".
O
PONENTS".
CAUTION:
Remove old sealant adhering to mounting surfaces. Also P
PDIA1042E

NENTS".
PDIA1066E
1. As an aid to installation, apply sufficient amounts of recom-
mended limited slip differential gear oil (refer to MA-12, "Fluids
and Lubricants") to the faces of spring plates, friction discs, fric-
tion plates and side gears to be assembled together.
PDIA1055E
2. Assemble spring plates (1), friction discs (2), friction plates (3)
and retainers (4) to side gears (5).
CAUTION:
• When install the parts, place the parts exactly on the place
of removal.
• Confirm that the installation of spring plate is performed
as shown ( ) in the figure.
SDIA3600E
3. Assemble side gear assembly into differential case.

CAUTION:
When install the parts, place the parts exactly on the place
of removal.
SDIA3603E

4. Widen the gap between side gears by using puller and drift.
A
A : Puller (Commercial service tool)
B : Drift (SST: ST33061000)
CAUTION: B
• Be careful not to damage side gears.
• Do not space excessively between side gears. C
SDIA3598E
RFD
5. Install the pinion mate thrust washers (1) and pinion mate gears
(2) to differential case (3).
CAUTION:
E
of removal.
F
G
SDIA3601E
6. Install axle shaft (1) removed from the vehicle on the left side of
H
differential case, then rotate slowly axle shaft until the bore of
pinion mate shaft fits to that of pinion mate gears.
CAUTION:
• Be careful not to damage differential case (flange face). I
• Be careful not to damage axle shaft.
of removal. J
7. Remove puller, drift and axle shaft.
SDIA3599E
K
8. Align lock pin holes on differential case and pinion mate shaft,
and assemble pinion mate shaft.
L
N
SDIA0037J
9. Drive a new lock pin into pinion mate shaft, using pin punch. O
CAUTION:
Do not reuse lock pin.
P
PDIA0809J

10. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
SPD322
11. Apply sealant to back face of drive gear. Refer to "COMPO-

NENTS".
CAUTION:
PDIA1059E
12. Align the matching mark of differential case assembly with the
mark of drive gear, then install drive gear.
SDIA2593E
13. Apply thread locking sealant into the thread hole of drive gear.
CAUTION:
Make sure threaded holes are clean.
SDIA2594E
14. Install the drive gear bolts, and then tighten to the specified
torque. Refer to "COMPONENTS".
CAUTION:
• Do not reuse the bolts.
• Tighten bolts in a crisscross fashion.
SDIA0247J

15. Press side bearing inner races to differential case assembly
using suitable tool and Tool. A

CAUTION: B
Do not reuse side bearings.
PDIA1060E
RFD
16. Install side bearing adjusters into axle housing.
G
PDIA0381E
17. Apply gear oil to side bearings. Install differential case assembly H
PDIA0312E K
18. Align paint matching mark on side bearing cap with that on axle
CAUTION: L
Do not tighten at this point. This allows further tightening of
M
SDIA3446E
19. Tighten each side bearing adjusters using Tool. O

P
20. Adjust backlash of drive gear and drive pinion. Refer to "Back-
lash".
21. Check tooth contact. Refer to "Tooth Contact".
22. Check total preload. Refer to "Total Preload Torque".
PDIA1044E

PONENTS".
CAUTION:
PDIA1042E
NENTS".
PDIA1066E

A
General Specification INFOID:0000000002978647
B
4WD
Applied model
5AT 6MT
Body type Double cab wide Double cab C
Final drive model M226
Gear ratio 3.538 3.692 3.538
RFD
Number of teeth (Drive gear / drive pinion) 46/13 48/13 46/13
Oil capacity (Approx.) (lmp pt) 2.01 (3-1/2) E
Inspection and Adjustment INFOID:0000000002978648

F
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
G
Item Specification
Gear ratio 3.538 3.692
2.24 - 3.96 2.22 - 3.93
H
Total preload
(0.23 - 0.40, 20 - 35) (0.23 - 0.40, 20 - 34)
Pinion bearing preload 1.7 - 3.1 (0.18 - 0.31, 15 - 27)
I
BACKLASH
Unit: mm (in)
Item Standard J
Drive gear to drive pinion gear 0.15 - 0.23 (0.0059 - 0.0091)
COMPANION FLANGE RUNOUT

K
Unit: mm (in)
Item Runout limit

Companion flange face 0.10 (0.0039) or less L
Inner side of companion flange 0.13 (0.0051) or less

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DRIVELINE/AXLE

SERVICE INFORMATION ............................ 2 PRECAUTIONS ................................................. 33

Revision: 2007 September RFD-1 D40

Revision: 2007 September RFD-2 D40

KV381054S0 Removing front oil seal

KV10111100 Removing carrier cover J

ST30021000 Removing drive pinion rear bearing inner

Revision: 2007 September RFD-3 D40

ST30022000 Installing drive pinion rear bearing outer

KV38100300 Installing side bearing inner race

Commercial Service Tool INFOID:0000000002978626

Tool name Description

Drift Installing front oil seal

Adapter Removing and installing side bearing in-

Revision: 2007 September RFD-4 D40

Drift Installing drive pinion rear bearing outer

Drift Installing drive pinion front bearing outer F

Revision: 2007 September RFD-5 D40

1. Companion flange 2. Drive pinion 3. Drive gear

Revision: 2007 September RFD-6 D40

Oil grade and Viscosity: H

Checking Differential Gear Oil INFOID:0000000003258700

Revision: 2007 September RFD-7 D40

Tool number : ST3127S000

Tool number : KV40104000

3. Put a matching mark on the thread edge of drive pinion. The

4. Remove the companion flange using suitable tool.

Revision: 2007 September RFD-8 D40

Tool number : KV40104000 M

Revision: 2007 September RFD-9 D40

Tool number : ST3127S000

Revision: 2007 September RFD-10 D40

Revision: 2007 September RFD-11 D40

Revision: 2007 September RFD-12 D40

1. Drive pinion lock nut 2. Washer 3. Companion flange A

: Apply gear oil.

bearing preload torque

When the preload torque is greater than specification N

When the preload torque is less than specification

Revision: 2007 September RFD-13 D40

4. Hold companion flange steady by hand and rotate drive gear in

Drive gear to drive pinion backlash: Refer to RFD-31,

Revision: 2007 September RFD-14 D40

Tool number : KV38108800

d. In case of excessive backlash, loosen side bearing adjuster A

Companion Flange Runout

Revision: 2007 September RFD-15 D40

2. Separate carrier cover from axle housing using Tool.

Tool number : KV10111100

3. For proper reinstallation, paint matching mark on one side of

5. Remove side bearing caps.

Revision: 2007 September RFD-16 D40

9. Remove side bearing inner races using suitable tools.

Tool number : ST23550000

Revision: 2007 September RFD-17 D40

Drive Pinion Assembly

Tool number : KV40104000

3. Put a matching mark on the thread edge of drive pinion. The

Revision: 2007 September RFD-18 D40