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FFD


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D DRIVELINE/AXLE

                                                                                                                                                                  A


                                                                                                                                                                  B
                                                                                    SECTION
                                                                                            FRONT FINAL DRIVE                                                     C


                                                                                                                                                                  FFD


                                                                                                                                                                  E
                                                                CONTENTS
PREPARATION .......................................................... 2
                                                                       .           BLY ..................................................................... 13
                                                                                                                                                         .        F
 Special Service Tools .............................................. 2.           REMOVAL OF DRIVE PINION ASSEMBLY ....... 15                           .
NOISE, VIBRATION, AND HARSHNESS (NVH)                                              DISASSEMBLY OF DIFFERENTIAL CASE
TROUBLESHOOTING ............................................... 5      .           ASSEMBLY ........................................................ 16  .        G
 (NVH) Troubleshooting Chart .................................. 5      .           DISASSEMBLY OF DIFFERENTIAL SIDE
FRONT OIL SEAL ..................................................... 6 .           SHAFT ................................................................ 17
                                                                                                                                                         .
 Removal and Installation ......................................... 6  .           INSPECTION ..................................................... 18   .
                                                                                                                                                                  H
   REMOVAL ............................................................ 6
                                                                       .           ADJUSTMENT OF DIFFERENTIAL CASE
   INSTALLATION .................................................... 6 .           ASSEMBLY ........................................................ 19  .
REAR COVER GASKET ........................................... 8        .           SIDE BEARING PRELOAD ................................ 19              .
 Removal and Installation ......................................... 8  .           DRIVE PINION GEAR HEIGHT AND PINION                                             I
   REMOVAL ............................................................ 8
                                                                       .           BEARING PRELOAD ......................................... 21          .
   INSTALLATION .................................................... 8 .           TOOTH CONTACT ............................................. 25        .
FRONT FINAL DRIVE ASSEMBLY ........................... 9               .           INSTALLATION OF DRIVE PINION ASSEMBLY 26                              ...       J
 Removal and Installation ......................................... 9  .           ASSEMBLY OF DIFFERENTIAL SIDE SHAFT... 28
   REMOVAL ............................................................ 9
                                                                       .           ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
   INSTALLATION .................................................... 9 .           LBY ..................................................................... 28
                                                                                                                                                         .
                                                                                                                                                                  K
 Components ...........................................................11
                                                                       .           INSTALLATION OF DIFFERENTIAL CASE
 Pre-Inspection ....................................................... 12
                                                                       .           ASSEMBLY ........................................................ 30  .
   TOTAL PRELOAD .............................................. 12     .        SERVICE DATA AND SPECIFICATIONS (SDS) ..... 33                           .
   RING GEAR TO DRIVE PINION BACKLASH ... 12                                     General Specifications ........................................... 33   .         L
   RING GEAR RUNOUT ....................................... 13         .         Ring Gear Runout .................................................. 33  .
   TOOTH CONTACT ............................................. 13      .         Side Gear Adjustment ........................................... 33     .
   SIDE GEAR TO DRIVE PINION GEAR BACK-                                          Side Bearing Adjustment ....................................... 33      .        M
   LASH .................................................................. 13
                                                                       .         Total Preload Adjustment ....................................... 33     .
 Disassembly and Assembly .................................. 13        .         Drive Pinion Height Adjustment ............................. 34         .
   REMOVAL OF DIFFERENTIAL CASE ASSEM-                                           Drive Pinion Preload Adjustment ........................... 34          .




                                                                         FFD-1
                                                       PREPARATION

PREPARATION                                                                                                                   PFP:00002

Special Service Tools                                                                                                              EDS000T2

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number
  (Kent-Moore No.)                                                                        Description
  Tool name
  ST3127S000                                                                             Measuring pinion bearing preload and total
  (See J25765-A)                                                                         preload
  Preload gauge
  1 GG91030000
  (J25765)
  Torque wrench
  2 HT62940000
  (      --      )
  Socket adapter
  3 HT62900000                                                           NT124

  (      --      )
  Socket adapter
  KV38100800                                                                             Mounting final drive housing
  (J34310, J25604-01)                                                                    (To use, make a new hole.)
  Differential attachment                                                                a: 152 mm (5.98 in)




                                                                         NT119


  KV38108300                                                                             Removing and installing propeller shaft lock
  (J-44195)                                                                              nut, and drive pinion nut
  Companion flange wrench




                                                                         NT771


  ST3090S000                                                                             Removing and installing drive pinion rear in-
  (       --       )                                                                     ner cone
  Drive pinion rear inner race puller set                                                a: 79 mm (3.11 in) dia.
  1 ST30031000                                                                           b: 45 mm (1.77 in) dia.
  (J22912-01)                                                                            c: 35 mm (1.38 in) dia.
  Puller
  2 ST30901000
  (J26010-01)
                                                                         NT527
  Base
  ST3306S001                                                                             Removing and installing differential side bear-
  Differential side bearing puller set                                                   ing inner cone
  1 ST33051001                                                                           a: 28.5 mm (1.122 in) dia.
  (J22888-20)                                                                            b: 38 mm (1.50 in) dia.
  Body
  2 ST33061000
  (J8107-2)
  Adapter                                                                NT072


  KV38100300                                                                             Installing side bearing inner cone
  (J25523)                                                                               a: 54 mm (2.13 in) dia.
  Differential side bearing drift                                                        b: 46 mm (1.81 in) dia.
                                                                                         c: 32 mm (1.26 in) dia.



                                                                         NT085




                                                               FFD-2
                                    PREPARATION

Tool number
(Kent-Moore No.)                                   Description                                          A
Tool name
KV38100600                                         Installing side bearing spacer
(J25267)                                           a: 8 mm (0.31 in)                                    B
Side bearing spacer drift                          b: R42.5 mm (1.673 in)


                                                                                                        C

                                           NT528


ST30611000                                         Installing drive pinion rear bearing outer race      FFD
(J25742-1)                                         and drive pinion front bearing outer race
Drift                                              (Use with ST30621000 or ST30613000)

                                                                                                        E

                                           NT090


ST30621000                                         Installing drive pinion rear bearing outer race
                                                                                                        F
(J25742-5)                                         (Use with ST30611000)
Drift                                              a: 79 mm (3.11 in) dia.
                                                   b: 59 mm (2.32 in) dia.                              G


                                           NT073                                                        H
ST30613000                                         Installing drive pinion front bearing outer race
(J25742-3)                                         (Use with ST30611000)
Drift                                              a: 72 mm (2.83 in) dia.
                                                                                                         I
                                                   b: 48 mm (1.89 in) dia.



                                                                                                         J
                                           NT073


KV38100500                                         Installing front oil seal and side flange oil seal
(J25273)                                           a: 85 mm (3.35 in) dia.
Gear carrier front oil seal drift                  b: 60 mm (2.36 in) dia.                              K


                                                                                                         L
                                           NT115


KV38100200                                         Installing side oil seal
(J26233)                                                                                                M
Gear carrier side oil seal drift




                                           NT120


(J34309)                                           Adjusting bearing pre-load and gear height
Differential shim selector




                                           NT134




                                       FFD-3
                     PREPARATION

Tool number
(Kent-Moore No.)                    Description
Tool name
(J25269-4)                          Selecting drive pinion height adjusting washer
Side bearing discs
(2 Req'd)




                            NT136


(J8129)                             Measuring differential case assembly turning
Spring gauge                        resistance




                            NT127




                        FFD-4
          NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING                                                                                                                                                                                                                               PFP:00003
                                                                                                                                                                                                                                                                                                            A
(NVH) Troubleshooting Chart                                                                                                                                                                                                                                                                   EDS000T3


Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
                                                                                                                                                                                                                                                                                                            B




                                                                                                                                                                                                                    FAX-4,RAX-5 , FSU-4 , RSU-4
                                                                                                                                                                                                                                                                                                            C




                                                     FFD-19

                                                                        FFD-25

                                                                                                FFD-19

                                                                                                                     FFD-12



                                                                                                                                                                              MA-39




                                                                                                                                                                                                                                                                       FAX-4
                                                                                                                                                                                                                                                  WT-3

                                                                                                                                                                                                                                                          WT-3
                                                                                                                                                                                                  PR-3




                                                                                                                                                                                                                                                                                     BR-5

                                                                                                                                                                                                                                                                                                 PS-5
                                                                                                                                          --
 Reference page

                                                                                                                                                                                                                                                                                                            FFD


                                                                                                                                                                                                                                                                                                            E




                                                                                                                                          Companion flange excessive runout
                                                                                                                                                                                                                                                                                                            F




                                                                                                                                                                                                                    AXLE AND SUSPENSION
                                                                        Improper gear contact




                                                                                                                                                                                                  PROPELLER SHAFT
                                                                                                Tooth surface worn
 Possible cause and SUSPECTED PARTS




                                                                                                                     Incorrect backlash
                                                     Rough gear tooth




                                                                                                                                                                              Improper gear oil
                                                                                                                                                                                                                                                                                                            G




                                                                                                                                                                                                                                                          ROAD WHEEL

                                                                                                                                                                                                                                                                       DRIVESHAFT



                                                                                                                                                                                                                                                                                                 STEERING
                                                                                                                                                                                                                                                                                     BRAKES
                                                                                                                                                                                                                                                  TIRES
                                                                                                                                                                                                                                                                                                            H


 Symptom          DIFFERENTIAL   Noise                     



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