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rfd


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REAR FINAL DRIVE


D DRIVELINE/AXLE

                                                                                                                                                                  A




                                                                                  SECTION                    RFD
                                                                                                 REAR FINAL DRIVE
                                                                                                                                                                  B



                                                                                                                                                                  C


                                                                                                                                                                  RFD


                                                                                                                                                                  E
                                                                CONTENTS
PRECAUTIONS ......................................................... 2
                                                                      .            BLY ..................................................................... 14
                                                                                                                                                         .        F
  Precautions ............................................................. 2
                                                                      .            REMOVAL OF DRIVE PINION ASSEMBLY ....... 15                           .
PREPARATION .......................................................... 3
                                                                      .            DISASSEMBLY OF DIFFERENTIAL CASE
  Special Service Tools .............................................. 3
                                                                      .            ASSEMBLY ........................................................ 17  .        G
  Commercial Service Tools ....................................... 5  .            INSPECTION ..................................................... 18   .
NOISE, VIBRATION AND HARSHNESS (NVH)                                               ADJUSTMENT OF DIFFERENTIAL CASE ........ 19                           .
TROUBLESHOOTING ............................................... 6     .            SIDE BEARING PRELOAD ................................ 20              .
                                                                                                                                                                  H
  NVH Troubleshooting Chart .................................... 6    .            PINION GEAR HEIGHT ..................................... 21           .
FRONT OIL SEAL ..................................................... 7.            TOOTH CONTACT ............................................. 25        .
  Removal and Installation ......................................... 7.            ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
    REMOVAL ............................................................ 7
                                                                      .            BLY ..................................................................... 26
                                                                                                                                                         .         I
    INSTALLATION .................................................... 7
                                                                      .            INSTALLATION OF DRIVE PINION ASSEMBLY 27                              ...
SIDE OIL SEAL ......................................................... 9
                                                                      .            INSTALLATION OF DIFFERENTIAL CASE
  Removal and Installation ......................................... 9.            ASSEMBLY ........................................................ 28  .        J
    REMOVAL ............................................................ 9
                                                                      .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 31                           .
    INSTALLATION .................................................. 10.          General Specifications ........................................... 31   .
REAR FINAL DRIVE ASSEMBLY ............................11              .          Drive Gear Runout ................................................. 31  .
                                                                                                                                                                  K
  Removal and Installation ........................................11 .          Side Gear Adjustment ........................................... 31     .
    REMOVAL ...........................................................11
                                                                      .            AVAILABLE SIDE GEAR THRUST WASHERS... 31
    INSTALLATION ...................................................11.          Drive Pinion Height Adjustment ............................. 31         .
  Components .......................................................... 12
                                                                      .            AVAILABLE PINION HEIGHT ADJUSTING                                              L
    R200 2-PINION .................................................. 12
                                                                      .            WASHERS ......................................................... 31  .
  Pre-Inspection ....................................................... 13
                                                                      .          Drive Pinion Preload Adjustment ........................... 31          .
    TOTAL PRELOAD .............................................. 13   .          Side Bearing Preload Adjustment .......................... 31           .        M
    DRIVE GEAR TO DRIVE PINION BACKLASH... 13                                      SIDE BEARING ADJUSTING WASHERS ......... 32                           .
    DRIVE GEAR RUNOUT ..................................... 13        .          Total Preload Adjustment ....................................... 32     .
    COMPANION FLANGE RUNOUT ..................... 14                  .          Companion Flange ................................................ 32    .
    TOOTH CONTACT ............................................. 14    .
  Disassembly and Assembly .................................. 14      .
    REMOVAL OF DIFFERENTIAL CASE ASSEM-




Revision; 2004 April                                                     RFD-1                                                                     2003 FX
                                         PRECAUTIONS

PRECAUTIONS                                                                                    PFP:00001

Precautions                                                                                        ADS000K2


CAUTION:
q  Before starting diagnosis of the vehicle, understand symptoms well. Perform correct and system-
   atic operations.
q  Check for the correct installation status prior removal or disassembly. When matching marks are
   required, be sure they do not interfere with the function of the parts they are applied to.
q  Carry out an overhaul in a clean work place, Using a dust proof room is recommended.
q  Before disassembly, using steam or white gasoline, completely remove sand and mud from the
   exterior the unit, preventing them from entering into the unit during disassembly or assembly.
q  Check appearance of the disassembled parts for damage, deformation, and abnormal wear. If a
   malfunction is detected, replace it with a new one.
q  Normally replace lock pins, oil seals, and bearings with new ones every times they are removed.
q  In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-
   side. If tightening sequence is specified, observe it.
q  Clean and flush the parts sufficiently and blow them dry.
q  Be careful not to damage the sliding surfaces and mating surface.
q  When applying sealant, remove the old sealant from the mounting surface; then remove any mois-
   ture, oil, and foreign materials from the application and mounting surfaces.
q  Always use shop paper for cleaning the inside of components.
q  Avoid using cotton gloves or a shop cloth to prevent entering of lint.
q  During assembly, observe the specified tightening torque, and new differential gear oil, Vaseline,
   or multi-purpose grease, as specified for each vehicle, when necessary.




Revision; 2004 April                            RFD-2                                           2003 FX
                                            PREPARATION

PREPARATION                                                                                                   PFP:00002
                                                                                                                              A
Special Service Tools                                                                                              ADS000JM


The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
   Tool number (Kent-Moore No.)
                                                                                                                              B
                                                                        Description
   Tool name

                                                                                                                              C
   ST30720000 (J25405)
   a: 77 mm (3.03 in) dia.
                                                                        Installing front oil seal
   b: 55 mm (2.17 in) dia.
                                                                                                                              RFD
   Drift

                                                            ZZA0811D

                                                                                                                              E

   KV38100200 (J26233)
   a: 65 mm (2.56 in) dia.
                                                                        Installing side oil seal                              F
   b: 49 mm (1.93 in) dia.
   Drift

                                                            ZZA1143D
                                                                                                                              G



   KV38107900 (J39352)                                                                                                        H
                                                                        Installing side flange
   Protector


                                                            S-NT129
                                                                                                                               I



   KV38100800 (J25604-01)                                                                                                     J
   a: 541 mm (21.30 in)
                                                                         Fixing unit assembly
   b: 200 mm (7.87 in)
   Attachment
                                                                                                                              K
                                                            SDIA0267E



                                                                                                                              L
   ST3306S001 ( 



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