Assembly

Exploded View RFD-15:

Exploded View RFD-85 (Part 1):

Exploded View RFD-85 (Part 2):

ASSEMBLY

Drive Pinion Assembly





1. Press a drive pinion rear bearing outer race into gear carrier using Tool.
Tool number
A: ST01500001 ( - )
B: ST30022000 ( - )

CAUTION: Do not reuse drive pinion rear bearing.





2. Press a drive pinion front bearing outer race into gear carrier using Tool.
Tool number: ST33022000 ( - )

CAUTION: Do not reuse drive pinion front bearing.

3. Select drive pinion height adjusting washer.





4. Press a drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion, using Tool.
Tool number: - (C - 4040)

CAUTION: Do not reuse drive pinion rear bearing.

5. Apply gear oil to drive pinion rear bearing and drive pinion front bearing.
6. Install drive pinion front bearing inner race in gear carrier.
7. Install drive pinion front bearing thrust washer to gear carrier.





8. Apply multi-purpose grease to front oil seal lip. Install front oil seal into gear carrier using Tool.
Tool number: ST15310000 ( - )

CAUTION:
^ Do not reuse front oil seal.
^ Do not incline the new front oil seal when installing.
^ Apply multi-purpose grease to the lips of the new front oil seal.





9. Install collapsible spacer to drive pinion. And then install drive pinion assembly in gear carrier.

CAUTION:
^ Do not reuse collapsible spacer.
^ Do not damage front oil seal.

10. Install the companion flange to the drive pinion while aligning the matching marks.





11. Install the companion flange onto the drive pinion while aligning the matching marks. Then tap the companion flange using suitable tool.

CAUTION: Do not damage companion flange or front oil seal.





12. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut and new drive pinion lock nut washer. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the drive pinion bearing preload torque using Tool B.
Tool number
A: KV40104000 ( - )
B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque: 1.7 - 3.8 Nm (0.18 - 0.38 kg-m, 15 - 33 in-lb)

CAUTION:
^ Do not reuse drive pinion lock nut or drive pinion lock nut washer.
^ Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut.
^ Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to Exploded View RFD-85.
^ If the drive pinion bearing preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

Differential Assembly





1. Align the matching mark of differential case assembly with the mark of drive gear, then install drive gear.





2. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts.
^ Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to GI-47, "Recommended Chemical Products and Sealants". Recommended Chemical Products and Sealants

CAUTION: Make sure the drive gear back and threaded holes are clean.





3. Install new drive gear bolts, and then tighten to the specified torque. Refer to Exploded View RFD-85.

CAUTION:
^ Do not reuse the bolts.
^ Tighten bolts in a crisscross fashion.





4. Press side bearing inner races to differential case assembly using Tool.
Tool number: ST33081000 ( - )

CAUTION: Do not reuse side bearing.





5. Install differential lock solenoid and washer.
6. Press side bearing inner races to differential case assembly using Tool.
Tool number
A: KV38100300 (J-25523)
B: ST33081000 ( - )
7. Apply sealant to threads of differential lock position switch.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-47, "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.





8. Install differential lock position switch on gear carrier and tighten differential lock position switch bolts with the specified torque. Refer to Exploded View RFD-85.





9. Install side bearing adjusters into gear carrier.





10. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.
11. Apply multi-purpose grease to sensor connector.

CAUTION: Do not reuse sensor connector.





12. Connect differential lock solenoid harness and sensor connector. Then install it to gear carrier, tighten to the specified torque. Refer to Exploded View RFD-85.





13. Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier.

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





14. Tighten each side bearing adjusters using adjuster tool.
Tool number: - (C - 4164)
15. Adjusting backlash of drive gear and drive pinion.
16. Check total preload.
17. Check tooth contact.





18. Apply a bead of sealant to the mating surface of the carrier cover as shown.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-47, "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.

19. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to Exploded View RFD-15.