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FRONT FINAL DRIVE

D DRIVELINE/AXLE

SECTION
FRONT FINAL DRIVE
FFD B

FFD

E
CONTENTS
PRECAUTIONS ......................................................... 2 . Differential Case Assembly ................................... 20 . F
Precautions ............................................................. 2
. Installation Drive Pinion Assembly ........................ 23 .
PREPARATION .......................................................... 3. DIFFERENTIAL CASE INSTALLATION ............. 24 .
Special Service Tools .............................................. 3. TOOTH CONTACT INSPECTION ...................... 25 . G
Commercial Service Tools ....................................... 5 . TOOTH CONTACT PATTERN AND HEIGHT
NOISE, VIBRATION AND HARSHNESS (NVH) ADJUSTING WASHER SELECTION ................. 26 .
TROUBLESHOOTING ............................................... 6 . TOOTH CONTACT ADJUSTMENT .................... 26 .
H
NVH Troubleshooting Chart .................................... 6 . TOTAL PRELOAD INSPECTION ....................... 28 .
FRONT OIL SEAL ..................................................... 7 . DRIVE PINION PRELOAD ADJUSTMENT ........ 28 .
Removal and Installation ......................................... 7 . PRELOAD ADJUSTMENT ................................. 28 .
REMOVAL ............................................................ 7
. After Inspection ...................................................... 30
. I
INSTALLATION .................................................... 8 . Carrier Cover Installation ....................................... 31 .
SIDE OIL SEAL ......................................................... 9
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 33 .
Removal and Installation ......................................... 9 . General Specifications ........................................... 33 . J
REMOVAL ............................................................ 9
. Drive Gear Runout ................................................. 33 .
INSTALLATION .................................................... 9 . Side Gear Adjustment ........................................... 33 .
FRONT FINAL DRIVE ASSEMBLY ......................... 10 . SIDE GEAR THRUST WASHERS ..................... 33 .
K
Removal and Installation ....................................... 10 . Side Bearing Adjusting Shims ............................... 33 .
REMOVAL .......................................................... 10
. SIDE RETAINER SIDE: ...................................... 33 .
INSTALLATION .................................................. 10 . DIFFERENTIAL CASE TO SIDE BEARING: ...... 33 .
Front Final Drive Breather Hose ............................11 . Drive Pinion Height Adjustment ............................. 34 . L
REMOVAL AND INSTALLATION ........................11 . DRIVE PINION HEIGHT ADJUSTING WASH-
Components .......................................................... 12
. ERS .................................................................... 34
.
Side Shaft .............................................................. 14
. Drive Pinion Preload Adjustment ........................... 34 . M
BEARING AND OIL SEAL REPLACEMENT ..... 14 . AVAILABLE PINION PRELOAD ADJUSTING
EXTENSION TUBE REPLACEMENT ................ 15 . WASHERS ......................................................... 34 .
PRE-DIASSEMBLY INSPECTION ..................... 15 . Drive Pinion Backlash ............................................ 34 .
DISASSEMBLY AND ASSEMBLY ..................... 17 . Total Preload .......................................................... 34
.

FFD-1
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions ADS000YZ

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 mating 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 oil, Vaseline, or
multi-purpose grease, as specified for each vehicle, when necessary.

FFD-2
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ADS000Z0

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

ST33400001 q Installing front oil seal
C
(J26082) q Installing right side oil seal
Drift
a: 60 mm (2.36 in) dia. q Installing oil seal
b: 47 mm (1.85 in) dia. FFD

ZZA0702D

ST33290001 q Removing side bearing outer race
E
(J34286) q Removing side oil seal
Outer race puller
q Removing front oil seal
F

ZZA0601D
G
ST3306S001 Removing and installing side bearing
( -- )
Differential side bearing puller set
H
1.ST33051001
(J22888-20)
Puller
2.ST33061000 I
(J8107

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