REAR FINAL DRIVE

D DRIVELINE/AXLE

SECTION RFD
REAR FINAL DRIVE
B

RFD

E
CONTENTS
PRECAUTIONS .......................................................... 2 Rear Final Drive Breather Hose ............................. 13 F
Caution ..................................................................... 2 Components ........................................................... 14
Precautions for Brake System .................................. 2 Inspection Before Disassembly .............................. 15
PREPARATION ........................................................... 3 OVERALL PRELOAD TORQUE ......................... 15 G
Special Service Tools ............................................... 3 HYPOID GEAR BACKLASH ............................... 15
OIL .............................................................................. 6 DRIVE GEAR BACK RUNOUT ........................... 16
Inspection ................................................................. 6 COMPANION FLANGE RUNOUT ....................... 17
H
FLUID LEAKAGE AND OIL LEVEL ...................... 6 TOOTH CONTACT .............................................. 17
REAR FINAL DRIVE SYSTEM ................................... 7 Disassembly and Assembly .................................... 20
Sectional View .......................................................... 7 DISASSEMBLY ................................................... 20
FRONT OIL SEAL ...................................................... 8 ASSEMBLY ......................................................... 22 I
Removal and Installation .......................................... 8 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 29
REMOVAL ............................................................. 8 General Specification ............................................. 29
INSTALLATION ..................................................... 8 Ring Gear Vibration ................................................ 29 J
SIDE OIL SEAL .......................................................... 9 Side Gear Clearance Adjustment ........................... 29
Removal and Installation .......................................... 9 THRUST WASHER FOR ADJUSTMENT OF
REMOVAL ............................................................. 9 SIDE GEAR BACK CLEARANCE ....................... 29
K
INSTALLATION ..................................................... 9 Drive Pinion Gear Preload Adjustment ................... 29
REAR COVER GASKET .......................................... 10 DRIVE PINION GEAR PRELOAD ADJUSTING
Replacement .......................................................... 10 SHIM ................................................................... 29
REAR FINAL DRIVE ASSEMBLY .............................11 Side Bearing Preload Adjustment ........................... 29 L
Removal and Installation .........................................11 ADJUSTING SHIM FOR SIDE BEARING PRE-
REMOVAL ............................................................11 LOAD ................................................................... 30
INSTALLATION ....................................................11 Overall Preload ....................................................... 30 M
Electronically Controlled Coupling Breather Hose... 12

RFD-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

Caution EDS000ME

● Before starting diagnosis of the vehicle, understand symptoms well. Perform correct and systematic oper-
ations.
● Check for the correct installation status prior to removal or disassembly. When mating marks are required,
be sure they do not interfere with the function of the parts they are applied to.
● Carry out an overhaul in a clean work place. Using a dust proof room is recommended.
● Before disassembly, using steam or white gasoline, 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 abnormal wear. If a malfunc-
tion is detected, replace it with a new one.
● Normally replace lock pins, oil seals, and bearings with new ones every time they are removed.
● In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
● Clean and flush the parts sufficiently and blow them dry.
● Be careful not to damage the 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 a shop cloth to prevent entering of lint.
● During assembly, observe the specified tightening torque, and apply new differential oil, Vaseline, or Nis-
san MP Special Grease No. 2, as specified for each vehicle, when necessary.
● Do not reuse drained oil. Discard waste oil after oil changes or part treatment in accordance with local
laws and regulations.
Precautions for Brake System EDS000MF

● When installing rubber parts, final tightening must be carried out under unladen condition* with tires on
ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
● After installing removed suspension parts, check wheel alignment and adjust if necessary.
● Use flare nut wrench when removing or installing brake tubes.
● Always torque brake lines when installing.

SBR820BA

RFD-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools EDS000MG

Tool name
Description
Tool number B

Drift C
ST27861000
Installing final drive front oil seal
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.
RFD
ZZA0832D

E
Drift
KV38100200 ● Installing final drive front oil seal
a: 65 mm (2.56 in) dia. ● Installing final drive side oil seal
b: 49 mm (1.93 in) dia. F

ZZA1143D

Preload gauge
Measuring preload torque
ST3127S000 H

ZZA0503D

Drift
ST33052000 J
● Removing side bearing inner
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.

ZZA1023D K

● Removing and installing carrier

Drift case and rear cover (2 pieces are L
KV40100610 used)
a: 63 mm (2.48 in) dia.
b: 54.3 mm (2.138 in) dia. ● Installing pinion front bearing inner
race
M
ZZA0810D

Pin punch
ST23550000 Removing and installing lock pin
Tip diameter: 4.5 mm (0.177 in) dia.

ZZA0815D

Drift
ST17130000 Installing pinion rear bearing outer
a: 31.8 mm (1.252 in) dia. race
b: 58 mm (2.28 in) dia.

ZZA0836D

RFD-3
 PREPARATION

Tool name
Description
Tool number

Drift
ST33230000
Installing pinion front bearing outer
a: 51 mm (2.01 in) dia.
race
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.
ZZA1046D

Drift ● Installing pinion rear bearing inner

ST23860000 race
a: 38 mm (1.50 in) dia. ● Installing pinion front bearing inner
b: 33 mm (1.30 in) dia. race

ZZA0534D

Press stand
ST38220000
Installing pinion front bearing inner
a: 63 mm (2.48 in) dia.
race
b: 65 mm (2.56 in)

ZZA1058D

Drift
KV40105020
a: 39.7 mm (1.563 in) dia. Installing side bearing inner race
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
ZZA1133D

Drift
ST22350000
Installing coupling front bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.

ZZA0534D

Drift
ST33400001
Installing coupling cover oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.

ZZA0814D

● Checking backlash
Dummy cover set
● Checking drive gear back runout
KV381086S1
● Checking tooth contact

ZZA1204D

RFD-4
 PREPARATION

Tool name
Description A
Tool number

B
drive pinion gear socket ● Measuring preload torque
KV38108500 ● Removing and installing pinion nut
C
ZZA1205D

RFD

Pinion nut wrench

Removing and installing pinion nut E
KV38108400

ZZA1206D
F

Oil seal drift

G
ST15310000
Center oil seal installation
a: 96 mm (3.78 in) dia.
b: 84 mm (3.31 in) dia.
H
ZZA0908D

I
Support ring
KV40104710
Center oil seal installation
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia. J

ZZA0832D

Flare nut torque wrench

GG94310000 Removing and installing brake piping L
a: 10 mm (0.39 in)

NT406
M

RFD-5
 OIL

OIL PFP:00024

Inspection EDS000MI

FLUID LEAKAGE AND OIL LEVEL

1. Check for fluid leakage and for proper oil level.
2. Install the filler plug to the final drive, and tighten to the specified
torque.
CAUTION:
Do not reuse gasket.
: 30 - 39 N·m (3.0 - 4.0 kg-m,22 - 28 ft-lb)

SDIA1151E

RFD-6
 REAR FINAL DRIVE SYSTEM

REAR FINAL DRIVE SYSTEM PFP:38300

A
Sectional View EDS000MJ

RFD

SDIA0141E

RFD-7
 FRONT OIL SEAL

FRONT OIL SEAL PFP:38189

Removal and Installation EDS000MK

REMOVAL
1. Remove propeller shaft. Refer to PR-3, "REMOVAL" .
2. Paint mating marks on the final drive companion flange and the thread edge of the electronically con-
trolled coupling.
CAUTION:
Use paint to avoid scratching the surface.
3. Using a differential flange tool, remove companion flange nut to remove companion flange.
4. Using a screwdriver or similar tool, remove oil seal.
INSTALLATION
1. Apply multi-purpose grease to oil seal lips. Using a drift as
shown, install oil seal. It should become flush with case end sur-
face.
CAUTION:
● When installing, do not incline the oil seal.

● Oil seals are not reusable. Never reuse them.

SDIA0142J

2. Align the mating marks on the companion flange and on the electronically controlled coupling, and install
the companion flange.
3. Install a companion flange nut. Using a differential flange tool, tighten the nut to the specified torque.
: 100 - 122 N·m (11 - 12 kg-m,74 - 89 ft-lb)

CAUTION:
Do not reuse the companion flange nut.
4. Connect propeller shaft. Refer toPR-3, "Removal and Installation" .

RFD-8
 SIDE OIL SEAL

SIDE OIL SEAL PFP:38343

A
Removal and Installation EDS000ML

REMOVAL
1. Remove drive shaft. Refer to RAX-13, "REMOVAL" .
B
2. Using flat tip screwdriver as shown in the figure, remove oil seal.

RFD

E
PDIA0003E

INSTALLATION
1. Apply multi-purpose grease.to oil seal lips. Using a drift as F
shown, install oil seal. It should become flush with case end sur-
face.
CAUTION: G
● When installing, do not incline the oil seal.

● Oil seals are not reusable. Never reuse them.

2. Install drive shaft. Refer to RAX-13, "INSTALLATION" . H

PDG0172D
I

RFD-9
 REAR COVER GASKET

REAR COVER GASKET PFP:38320

Replacement EDS000MM

● Apply a continuous bead of sealant (Three bond 1217 or equiva-

lent) around the gear carrier mating surface on the coupling
cover as shown in the figure. Overlap both ends of the bead for
at least 3 mm.
CAUTION:
Remove old sealant on the mounting surface, then remove any
moisture, oil, and foreign material from the application and
mounting surfaces.
● Apply sealant (Three bond 1217 or the equivalent) around the
carrier case of rear cover as shown.
CAUTION:
Remove old sealant on the mounting surface, then remove any
moisture, oil, and foreign material from the application and
mounting surfaces.

SDIA0143E

RFD-10
 REAR FINAL DRIVE ASSEMBLY

REAR FINAL DRIVE ASSEMBLY PFP:38300

A
Removal and Installation EDS000MN

RFD

PDIA0001E
G

1. Propeller shaft 2. Final drive assembly 3. Drive shaft

4. Final drive mounting bracket 5. Suspension member H

REMOVAL
1. Remove exhaust center tube.Refer to EX-2, "EXHAUST SYSTEM" . I
2. Remove propeller shaft. Refer to PR-3, "Removal and Installation" .
3. Remove drive shaft. Refer to RAX-13, "REAR DRIVE SHAFT" .
4. Remove rear suspension member. Refer to RSU-13, "Removal and Installation" . J
5. Remove air breather hose (for electronically controlled coupling and for rear final drive). Refer to RFD-12,
"Electronically Controlled Coupling Breather Hose" ,RFD-13, "Rear Final Drive Breather Hose" .
6. Remove the mounting bolt and nuts connecting to the suspension member, and remove the rear final K
drive
INSTALLATION
L
Install in the reverse order of the removal.
CAUTION:
● Keep the air breather hose to exhaust tube clearance for at least 40 mm (1.57 in).
M

RFD-11
 REAR FINAL DRIVE ASSEMBLY

Electronically Controlled Coupling Breather Hose EDS000MO

SDIA0144E

CAUTION:
● Refer to the figure for removal and installation procedure of the electronically controlled coupling
breather hose.
● When installing the electronically controlled coupling breather hose, be careful not to damage or
sharply bend the hose. Otherwise, the hose may be pinched or restricted.

RFD-12
 REAR FINAL DRIVE ASSEMBLY

Rear Final Drive Breather Hose EDS000MP

RFD

SDIA0109E

CAUTION: G
● Refer to the figure for removal and installation of rear final drive breather hose.
● When installing the air breather hose, be careful not to damage or sharply bend the hose. Other-
wise, the hose may be pinched or restricted. H

RFD-13
 REAR FINAL DRIVE ASSEMBLY

Components EDS000MQ

PDIA0002E

RFD-14
 REAR FINAL DRIVE ASSEMBLY

Inspection Before Disassembly EDS000MR

OVERALL PRELOAD TORQUE A

1. Drain the oil.
2. Remove electronically controlled coupling assembly.
Refer to “Electronically Controlled Coupling Assembly”. B
3. Rotate the drive pinion gear back and forth in 2 - 3 times to check for abnormal noise and rotation mal-
function.
4. Rotate the drive pinion gear at least 20 times to check for C
smooth operation of the bearing.
5. Fit the drive pinion gear socket onto the drive pinion gear spline.
Using a preload gauge, measure the overall preload torque. RFD
Overall preload torque:
:1.33 - 2.15 N·m (0.14 - 0.21 kg-m,12 - 19 in-lb) E
● If outside the standard, disassemble, check, and adjust each
part. Adjust the pinion bearing and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bear- F
ing preload. PDG0207D

When the preload torque is large

On pinion bearings : Replace the collapsible spacer. G
On side bearings : Use thinner side bearing adjusting shims.

When the preload is small H

On pinion bearings : Tighten the pinion nut.
On side bearings : Use thicker side bearing adjusting shims.
I
Side bearing adjusting shims
Thickness Part No. Thickness Part No. Thickness Part No.
1.85 mm (0.0728 in) 38453 4N200 2.05 mm (0.807 in) 38453 4N204 2.25 mm (0.0866 in) 38453 4N208
J
1.90 mm (0.0748 in) 38453 4N201 2.10 mm (0.0827 in) 38453 4N205 2.30 mm (0.0906 in) 38453 4N209
1.95 mm (0.0768 in) 38453 4N202 2.15 mm (0.0854 in) 38453 4N206 2.35 mm(0.0925 in) 38453 4N210
2.00 mm (0.0787 in) 38453 4N203 2.20 mm (0.0866 in) 38453 4N207
K
HYPOID GEAR BACKLASH
1. Drain the oil.
2. Remove the rear cover. Refer to RFD-20, "Removal of Differen- L
tial Assembly" .
3. Following the procedure below, install a dummy cover set to the
gear carrier. M
a. Fit dummy cover shims to the right and left side bearing adjust-
ing shims.

SDIA0562E

RFD-15
 REAR FINAL DRIVE ASSEMBLY

b. Temporarily tighten a dummy cover to the carrier case.

c. Position a dummy cover spacer to the dummy cover.
d. Tighten rear cover mounting bolts to the specified torque.
: 31 - 36 N·m (3.2 - 3.6 kg-m, 23 - 26 ft-lb)

e. Tighten dummy cover spacer mounting bolts evenly to the spec-

ified torque.
: 5.9 N·m (0.6 kg-m, 52 in-lb)

4. Fit a dial gauge to the drive gear face to measure the backlash. PDG0209D

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

● If outside the standard, change the thickness of the side bearing adjusting shims.
When the backlash is large:
Make the drive gear back adjusting shims thicker, and the drive gear front adjusting
shims thinner.
When the backlash is small:
Make the drive gear back adjusting shims thinner, and the drive gear front adjusting
shims thicker.
Side bearing adjusting shims
Thickness Part No. Thickness Part No. Thickness Part No.
1.85 mm (0.0728 in) 38453 4N200 2.05 mm (0.0807 in) 38453 4N204 2.25 mm (0.0886 in) 38453 4N208
1.90 mm (0.0748 in) 38453 4N201 2.10 mm (0.0827 in) 38453 4N205 2.30 mm (0.0906 in) 38453 4N209
1.95 mm (0.0768 in) 38453 4N202 2.15 mm (0.0854 in) 38453 4N206 2.35 mm (0.0925 in) 38453 4N210
2.00 mm (0.0787 in) 38453 4N203 2.20 mm (0.0866 in) 38453 4N207

DRIVE GEAR BACK RUNOUT

1. Drain the oil.
2. Remove the rear cover.Refer to RFD-20, "Removal of Differen-
tial Assembly" .
3. Attach dummy cover set. Refer to RFD-15, "HYPOID GEAR
BACKLASH" .
4. Fit a dial gauge to the drive gear back face.
5. Rotate the drive gear to measure runout.
Runout limit : 0.05 mm (0.0020 in)
● If outside the repair limit, check drive gear assembly condition; PDG0210D
foreign material may be caught between drive gear and differen-
tial case, or differential case or drive gear may be deformed, etc.
CAUTION:
Replace the drive gear and drive pinion gear as a set.

RFD-16
 REAR FINAL DRIVE ASSEMBLY

COMPANION FLANGE RUNOUT

1. Fit a dial gauge onto the companion flange face (inner side of A
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
B
Runout limit : 0.13 mm (0.0051 in)
3. Fit a test indicator to the inner side of the companion flange
(socket diameter). C
4. Rotate the companion flange to check for runout.
Runout limit : 0.19 mm (0.0075 in)
SDIA0569E
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 gear by 90° step, E
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 the companion
flange.
F
c. If the runout value is still outside of the limit after the companion flange has been replaced, possible cause
will be an assembly malfunction of the drive pinion gear and the electronically controlled coupling, mal-
functioning coupling bearing, or malfunctioning electronically controlled coupling.
G
TOOTH CONTACT
1. Drain the oil.
2. Remove the rear cover. Refer to RFD-20, "Removal of Differen- H
tial Assembly"
3. Attach dummy cover set. Refer to RFD-15, "HYPOID GEAR
BACKLASH" .
I
4. Apply red lead to drive gear face.
CAUTION:
Apply red lead to the both faces of 3 to 4 gears at 4 loca- J
tions evenly spaced on the drive gear.
PDG0211D

K
5. Rotate the drive gear back and forth in several times, check
drive pinion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side (acceleration) and L
reverse side (deceleration).

SDIA0570E

RFD-17
 REAR FINAL DRIVE ASSEMBLY

SDIA0563E

6. If the tooth contact is improperly adjusted, follow the procedure

below to adjust the pinion height (dimension X in the figure).

PDH0085D

RFD-18
 REAR FINAL DRIVE ASSEMBLY

Drive pinion gear adjusting shim

Thickness Part No. Thickness Part No.
A

1.70 mm (0.0669 in) 381544N200 2.00 mm (0.0787 in) 381544N210

1.73 mm (0.0681 in) 381544N201 2.03 mm (0.0799 in) 381544N211
1.76 mm (0.0693 in) 381544N202 2.06 mm (0.0811 in) 381544N212 B
1.79 mm (0.0705 in) 381544N203 2.09 mm (0.0823 in) 381544N213
1.82 mm (0.0717 in) 381544N204 2.12 mm (0.0835 in) 381544N214
1.85 mm (0.0728 in) 381544N205 2.15 mm (0.0846 in) 381544N215
1.88 mm (0.0740 in) 381544N206 2.18 mm (0.0858 in) 381544N216 C
1.91 mm (0.0752 in) 381544N207 2.21 mm (0.0870 in) 381544N217
1.94 mm (0.0764 in) 381544N208 2.24 mm (0.0882 in) 381544N218
1.97 mm (0.0776 in) 381544N209
RFD
● In case of face contact or heel contact, thicken the drive pinion
gear adjusting shims to move the drive pinion gear closer to the
drive gear. E

SDIA0571E
K
● In case of flank contact or toe contact, thin the drive pinion gear
adjusting shims to move the drive pinion gear farther from the
drive gear. L

SDIA0572E

RFD-19
 REAR FINAL DRIVE ASSEMBLY

Disassembly and Assembly EDS000MS

DISASSEMBLY
Removal of Electronically Controlled Coupling Assembly
1. Using a flange wrench, remove companion flange nut.
2. Remove companion flange.
3. Remove coupling cover.
4. Using flat tip screwdriver, remove oil seal from the coupling
cover.
CAUTION:
Be careful not to damage the coupling cover.

PDG0213D

5. Remove electronically controlled coupling assembly from the

drive pinion gear.

SDIA0573E

6. Using a puller, remove coupling front bearing from the electroni-

cally controlled coupling.
CAUTION:
When the bearing is replaced with new one, reassemble the
shim between bearing and the coupling.

SDIA0574E

Removal of Differential Assembly

1. Using flat tip screwdriver, remove side oil seal from the carrier
case assembly.
CAUTION:
Be careful not to damage the carrier case and rear cover.
2. Remove rear cover mounting bolts.

PDG0216D

RFD-20
 REAR FINAL DRIVE ASSEMBLY

3. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case assembly and side bearing A
to remove carrier case assembly and rear cover.
CAUTION:
The pressure shall be as low as possible to remove carrier B
case assembly and rear cover. The maximum pressure shall
be 10kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
C
The differential case assembly, side bearings, and adjusting
shims are compressed and integrated in the carrier case and
rear cover. SDIA0575E

4. Remove side bearing adjusting shims and side bearing outer RFD
race.
CAUTION:
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be E
identified later.
5. Remove drive gear mounting bolts, and remove drive gear from the differential case.
6. Using a puller and a drift, remove side bearing inner race. F

SDIA0620E
I

7. Using a pin punch, pull the lock pin out of the pinion mate shaft.
8. Remove pinion mate shaft, pinion mate gears, pinion mate J
thrust washers, side gears, side gear thrust washers from the
differential case.
K

PDG0219D

M
Removing Drive Pinion Assembly
1. Remove electronically controlled coupling assembly. Refer to
RFD-20, "Removal of Electronically Controlled Coupling Assem-
bly" .
2. Remove differential case assembly. Refer to RFD-20, "Removal
of Differential Assembly" .
3. Fit a drive pinion socket onto the drive pinion spline. Using a
pinion nut wrench, remove pinion nut.
4. Remove center oil seal.

PDG0220D

RFD-21
 REAR FINAL DRIVE ASSEMBLY

5. Press the drive pinion gear assembly out of the carrier case.
6. Remove pinion front bearing inner race.
7. Remove collapsible spacer.

SDIA0576E

8. Using a puller, remove pinion rear bearing inner race from the
drive pinion.

SDIA0577E

9. Using a brass rod, tap the pinion front bearing outer race evenly
from the 2 cutouts on the carrier case, and remove pinion front
bearing outer race.
CAUTION:
Be careful not to damage the carrier case.
10. Using a brass rod, tap the drive pinion adjusting shim evenly
from the 2 cutouts on the carrier case, and remove drive pinion
adjusting shims and pinion rear bearing outer race.
CAUTION:
Be careful not to damage the carrier case.
SDIA0564E

ASSEMBLY
Assembly of Drive Pinion Assembly
1. Assemble with a drive pinion adjusting shim of the same thick-
ness as was installed prior to disassembly. Using a drift, press a
pinion rear bearing outer race into the carrier case.
CAUTION:
● At first, using a hammer, tap the bearing outer race until it
becomes square to the carrier case.
● Do not reuse the pinion rear bearing outer race.

SDIA0578E

RFD-22
 REAR FINAL DRIVE ASSEMBLY

2. Using a drift, press a pinion front bearing outer race into the car-
rier case. A
CAUTION:
● At first, using a hammer, tap the bearing outer race until it
becomes square to the carrier case. B
● Do not reuse the pinion front bearing outer race.

SDIA0579E

RFD
3. Using a drift, press a pinion rear bearing inner race into the drive
pinion.
CAUTION: E
Do not reuse the pinion rear bearing inner race.

G
SDIA0580E

4. After checking and adjusting the tooth contact and backlash of H

the hypoid gear following the procedure below, assemble a col-
lapsible spacer to the drive pinion.
CAUTION:
● Be careful of the mounting orientation of the collapsible I
spacer.
● Do not reuse the collapsible spacer.

a. Apply differential oil to the pinion bearing, and assemble the J

drive pinion to the carrier case.
CAUTION: SDIA0581E
Do not assemble a collapsible spacer. K
b. Assemble a pinion front bearing inner race to the drive pinion.
Using a drift and press stand, press the pinion nut as far as it
can be tightened. L
c. Temporarily tighten the removed pinion nut to the drive pinion.
NOTE:
Use the removed pinion nut only for the preload torque mea- M
surement.

SDIA0582E

RFD-23
 REAR FINAL DRIVE ASSEMBLY

d. Fit the drive pinion socket onto the drive pinion spline. Using a
pinion nut wrench, tighten the pinion nut to the specified preload
torque.
CAUTION:
The pinion nut is tightened with no collapsible spacer. Be
careful not to overtighten it. While measuring the preload,
tighten it by 5° to 10°.
e. Apply differential oil to the side bearings, and install new side
bearing adjusting shims with the same thickness or re-install the
old ones to the same mounting position they were in prior to dis-
assembly. Install the differential case assembly to the carrier
case. Refer to RFD-25, "Installation of Differential Assembly" .
f. Install a dummy cover set to check and adjust the tooth contact.
Refer to RFD-17, "TOOTH CONTACT" .
g. Check and adjust the backlash. Refer to RFD-15, "HYPOID
GEAR BACKLASH" .

PDG0229D

h. Remove dummy cover set, and remove differential case assembly.

i. Remove pinion nut, pinion front bearing inner race, and remove
drive pinion gear.
5. Install the drive pinion gear with a collapsible spacer to the car-
rier case.

SDIA0576E

6. Using a drift and press stand, press the pinion front bearing
inner race to the drive pinion as far as a pinion nut can be tight-
ened.
7. Apply anti-corrosive oil to the thread and seat of the pinion nut,
and temporarily tighten the pinion nut and washer to the drive
pinion.
CAUTION:
Do not reuse the pinion nut.

SDIA0582E

RFD-24
 REAR FINAL DRIVE ASSEMBLY

8. Fit a drive pinion socket onto the drive pinion gear spline. Using
a pinion nut wrench, adjust the pinion nut tightening torque and A
pinion bearing preload torque.
Pinion nut tightening torque:
99 - 431 N·m (10 - 43 kg-m, 73 - 317 ft-lb) B

Pinion bearing preload torque:

0.69 - 1.17 N·m (0.07 - 0.11 kg-m, 7 - 10 in-lb) C
CAUTION:
● Do not reuse the pinion nut.
● Adjust the lower limit of the pinion nut tightening torque RFD
first.
● If the preload torque exceeds the specified value, replace
the collapsible spacer and tighten it again to adjust. Never E
loosen the pinion nut to adjust the preload torque.
● After adjustment, rotate the drive pinion gear back and forth
2 - 3 times to check for abnormal noise, rotation malfunc- F
tion, and other malfunctions.

G
PDG0229D

9. Install center oil seal.

H
10. Install the differential case assembly. Refer to RFD-25, "Installa-
tion of Differential Assembly" .
CAUTION:
Do not install the rear cover. I
11. Install a dummy cover set, and check backlash, drive gear back
runout, and tooth contact. Refer to RFD-17, "TOOTH CON-
TACT" . J
12. Remove dummy cover, then install the rear cover, and drive in
the oil seal.RFD-25, "Installation of Differential Assembly" Refer SDIA0146E
to K
13. Check overall preload torque. Refer to RFD-15, "OVERALL PRELOAD TORQUE" .
14. Connect electronically controlled coupling assembly. Refer to RFD-28, "Installation of Electronically Con-
trolled Coupling Assembly" . L
15. Check companion flange runout. Refer to RFD-17, "COMPANION FLANGE RUNOUT" .

Installation of Differential Assembly M

1. Assemble new side gear thrust washers with the same thickness as the ones installed prior to disassem-
bly or reinstall the old ones on the side gears.
2. Assemble the side gears, side gear thrust washers, pinion mate gears, and pinion mate thrust washers to
the differential case, and temporarily assemble the pinion mate shaft.

RFD-25
 REAR FINAL DRIVE ASSEMBLY

3. Measure the side gear endplay following the procedure below,

and select the appropriate side gear thrust washers.
● Using a thickness gauge, measure the clearance between
side gear back and the differential case at 3 different points,
while rotating the side gear. Average the 3 readings, and
select the appropriate side gear thrust washer so that the
mean value is within specifications below. (Measure the clear-
ance of the other side as well.)
Side gear endplay standard:
0.2 mm (0.008 in) or less. Every gear shall rotate
smoothly with no abnormal feeling of drag.

Thickness Part No. Thickness Part No.

0.74 mm (0.0291 in) 38424 4N200 0.83 mm (0.0327 in) 38424 4N203
0.77 mm (0.0303 in) 38424 4N201 0.86 mm (0.0339 in) 38424 4N204
0.80 mm (0.0315 in) 38424 4N202

CAUTION:
● Before measurement, place differential case straight up
so that side gear to be measured comes upward. To pre-
vent the side gear from tilting, insert thickness gauges
with the same thickness from both sides. SDIA0583E

● Select a side gear thrust washer for right and left individ-
ually.
4. Assemble the selected side gear thrust washer to the differential case.
5. Using a pin punch, drive a lock pin into the pinion mating shaft.
CAUTION:
Do not reuse the lock pin.

PDG0219D

6. Using a drift, press a side bearing inner race into the differential
case.

SDIA0584E

7. Apply locking sealant (Thread lock super 1303 or equivalent) onto the thread of the drive gear.
CAUTION:
The drive gear back, threaded holes, and drive gear bolts shall be cleaned and decreased suffi-
ciently.
8. Assemble the drive gear to the differential case, and tighten it with drive gear bolt.
: 94 - 112 N·m (9.6 - 11 kg-m, 70 - 82 ft-lb)

RFD-26
 REAR FINAL DRIVE ASSEMBLY

9. Apply differential oil to the side bearings, and assemble new side bearing adjusting shims (2 pieces for
one side) with the same thickness as the ones installed prior to disassembly or re-install the old ones, with A
a side bearing outer race to the differential case.
If the side bearing adjusting shims have been already selected, use them.
10. Fit a drift to the right and left side bearing adjusting shims indi- B
vidually. Compress differential case assembly and side bearing
to install the carrier case assembly to differential case assembly.
CAUTION:
C
● A drift shall be placed on the center of the adjusting
shims.
● The pressure shall be as low as possible to install the
carrier case assembly into the differential assembly. The RFD
maximum pressure shall be 1 ton.
● If the adjusting shims are installed by tapping, the carrier
case may be damaged. Avoid tapping. SDIA0585E E
11. Install a dummy cover set, check and adjust the backlash, drive gear back runout, tooth contact, and over-
all preload torque. Refer to RFD-15, "Inspection Before Disassembly" .
12. Remove dummy cover set. F
13. Apply sealant (Three bond 1217 or the equivalent) around the carrier case mounting surface on the rear
cover.Refer to
CAUTION: G
Remove old sealant on the mounting surface, then remove any moisture, oil, and foreign material
on the application and mounting surfaces.
14. Fit a drift to the right and left side bearing adjusting shims indi- H
vidually. Compress differential case assembly and side bearing
to install the rear cover.
CAUTION: I
● A drift shall be placed on the center of the adjusting
shims.
● The pressure shall be as low as possible to install the J
rear cover. The maximum pressure shall be 10kN (1 ton,
1.1US ton, 1.0 Imp ton)
● If the rear cover is forced in by tapping, the rear cover
K
may be damaged by the adjusting shims. Avoid tapping. SDIA0575E

15. Tighten rear cover mounting bolts to the specified torque.

L
Tightening torque
M8-bolt : 14 - 17 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb)
M10-bolt : 31 - 36 N·m (3.2 - 3.6kg·m, 23 - 26 ft-lb) M

16. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
● Oil seals are not reusable. Never reuse them.
PDG0234D
● Apply multi-purpose grease onto the oil seal lips, and dif-
ferential oil onto the circumference of the oil seal.
17. Check overall preload torque. Refer to RFD-15, "OVERALL PRELOAD TORQUE" .

RFD-27
 REAR FINAL DRIVE ASSEMBLY

Installation of Electronically Controlled Coupling Assembly

1. Using a drift, install the coupling front bearing to the electroni-
cally controlled coupling.
CAUTION:
At disassembly, be sure to install shim between electroni-
cally-controlled coupling and bearing. Chamfering side of
shim should be coupled to install.

SDIA0586E

2. Assemble the electronically controlled coupling assembly to the drive pinion gear.

3. Using a drift, drive an oil seal until it becomes flush with the case
end.
CAUTION:
● Oil seals are not reusable. Never reuse them.

● Apply multi-purpose grease onto the oil seal lips, and dif-
ferential oil onto the circumference of the oil seal.

PDG0237D

4. Apply sealant (Three bond 1217 or the equivalent) around the

carrier case mounting surface on the coupling cover.Refer to
RFD-10, "REAR COVER GASKET" .
CAUTION:
Remove old sealant on the mounting surface, then remove
any moisture, oil, and foreign material from the application
and mounting surfaces.
5. Assemble the coupling cover to the carrier case assembly with
the arrow facing upward, temporarily tighten reamer bolts to the
positions shown in the figure.
6. Tighten the reamer bolts and coupling cover mounting bolts to SDIA0587E

the specified torque.

7. Assemble the companion flange.
8. Using a flange wrench, tighten the companion flange nut to the specified torque.
CAUTION:
Do not reuse the companion flange nut.
9. Check companion flange runout. Refer to RFD-17, "COMPANION FLANGE RUNOUT" .

RFD-28
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specification EDS000MT

Applide model QR20DE, QR25DE, YD22DDTi

Final drive model R145 B
Ring gear pitch diameter 145
Gear ratio 2.466
C
Number of teeth (Ring gear/Drive pinion) 37/15
Oil capacity (approx.) 0.55 (1 lamp pt.)
Number of pinion gears 2 RFD
Drive pinion adjustment spacer type Collapsible

Ring Gear Vibration EDS000MU E

Type R145
Vibration limit at drive gear back 0.05 mm (0.0020 in) or less
F
Side Gear Clearance Adjustment EDS000MV

Type R145 G
Side gear back clearance 0.2 mm (0.008 in) or less. Every gear shall rotate smoothly with no abnormal feeling of drag.

THRUST WASHER FOR ADJUSTMENT OF SIDE GEAR BACK CLEARANCE H

Thickness Part No. Thickness Part No.

Thrust washer 0.74 mm (0.0291 in) 38424 4N200 0.83 mm (0.0327 in) 38424 4N203
0.77 mm (0.0303 in) 38424 4N201 0.86 mm (0.0339 in) 38424 4N204 I
0.80 mm (0.0315 in) 38424 4N202

Drive Pinion Gear Preload Adjustment EDS000MW

J
Adjustment of drive pinion gear Collapsible spacer
Drive pinion gear preload 0.69 - 1.17 N·m (0.07 - 0.11 kg-m,7 - 10 in-lb)
K
DRIVE PINION GEAR PRELOAD ADJUSTING SHIM
Thickness Part No. Thickness Part No.
L
1.70 mm (0.0669 in) 38154 4N200 2.00 mm (0.0787 in) 38154 4N210
1.73 mm (0.0681 in) 38154 4N201 2.03 mm (0.0799 in) 38154 4N211
1.76 mm (0.0693 in) 38154 4N202 2.06 mm (0.0811 in) 38154 4N212
1.79 mm (0.0705 in) 38154 4N203 2.09 mm (0.0823 in) 38154 4N213 M
Adjusting shim 1.82 mm (0.0717 in) 38154 4N204 2.12 mm (0.0835 in) 38154 4N214
1.85 mm (0.0728 in) 38154 4N205 2.15 mm (0.0846 in) 38154 4N215
1.88 mm (0.0740 in) 38154 4N206 2.18 mm (0.0858 in) 38154 4N216
1.91 mm (0.0752 in) 38154 4N207 2.21 mm (0.0870 in) 38154 4N217
1.94 mm (0.0764 in) 38154 4N208 2.24 mm (0.0882 in) 38154 4N218
1.97 mm (0.0776 in) 38154 4N209

Side Bearing Preload Adjustment EDS000MX

Adjustment of side bearing Adjusting shim

Side bearing preload 0.64 - 0.98 N·m (0.07 - 0.09 kg-m,6 - 8 in-lb)

RFD-29
 SERVICE DATA AND SPECIFICATIONS (SDS)

ADJUSTING SHIM FOR SIDE BEARING PRELOAD

Thickness Part No. Thickness Part No.
1.85 mm (0.0728 in) 38154 4N200 2.15 mm (0.0854 in) 38154 4N206
1.90 mm (0.0748 in) 38154 4N201 2.20 mm (0.0866 in) 38154 4N207
Adjusting shim 1.95 mm (0.0768 in) 38154 4N202 2.25 mm (0.0886 in) 38154 4N208
2.00 mm (0.0787 in) 38154 4N203 2.30 mm (0.0906 in) 38154 4N209
2.05 mm (0.0807 in) 38154 4N204 2.35 mm (0.0925 in) 38154 4N210
2.10 mm (0.0827 in) 38154 4N205

Overall Preload EDS000MY

Overall preload with oil seal installed 1.33 - 2.15 N·m (0.14 - 0.21 kg-m,12 - 19 in-lb)
Ring gear backlash 0.10 - 0.15 mm (0.0039 - 0.0059 in)

RFD-30