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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 ..................................................................... 18
                                                                                                                                                         .        F
  Precautions ............................................................. 2
                                                                      .            REMOVAL OF DRIVE PINION ASSEMBLY ....... 19                           .
PREPARATION .......................................................... 3
                                                                      .            DISASSEMBLY OF DIFFERENTIAL CASE
  Special Service Tools .............................................. 3
                                                                      .            ASSEMBLY (R200 2-PINION) ............................ 20              .        G
  Commercial Service Tools ....................................... 5  .            DISASSEMBLY OF DIFFERENTIAL CASE
NOISE, VIBRATION AND HARSHNESS (NVH)                                               ASSEMBLY (R200V) .......................................... 22        .
TROUBLESHOOTING ............................................... 6     .            INSPECTION ..................................................... 23   .
                                                                                                                                                                  H
  NVH Troubleshooting Chart .................................... 6    .            ADJUSTMENT OF DIFFERENTIAL CASE (R200
FRONT OIL SEAL ..................................................... 7.            2-PINION) ........................................................... 23
                                                                                                                                                         .
  Removal and Installation ......................................... 7.            ADJUSTMENT OF DIFFERENTIAL CASE
    REMOVAL ............................................................ 7
                                                                      .            (R200V) .............................................................. 24
                                                                                                                                                         .         I
    INSTALLATION .................................................... 8
                                                                      .            SIDE BEARING PRELOAD ................................ 25              .
SIDE OIL SEAL ......................................................... 9
                                                                      .            PINION GEAR HEIGHT ..................................... 26           .
  Removal and Installation ......................................... 9.            TOOTH CONTACT ............................................. 30        .        J
    REMOVAL ............................................................ 9
                                                                      .            ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
    INSTALLATION .................................................... 9
                                                                      .            BLY (R200 2-PINION) ........................................ 31       .
REAR FINAL DRIVE ASSEMBLY ............................11              .            ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
                                                                                                                                                                  K
  Removal and Installation ........................................11 .            BLY (R200V) ....................................................... 31.
    REMOVAL ...........................................................11
                                                                      .            INSTALLATION OF DRIVE PINION ASSEMBLY 32                              ...
    INSTALLATION .................................................. 12.            INSTALLATION OF DIFFERENTIAL CASE
  Components .......................................................... 13
                                                                      .            ASSEMBLY ........................................................ 34  .        L
    R200 2-PINION .................................................. 13
                                                                      .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 37                           .
    R200V VISCOUS ............................................... 15  .          General Specifications ........................................... 37   .
  Pre-Inspection ....................................................... 16
                                                                      .          Drive Gear Runout ................................................. 37  .        M
    TOTAL PRELOAD .............................................. 16   .          Side Gear Adjustment ........................................... 37     .
    DRIVE GEAR TO DRIVE PINION BACKLASH... 16                                      AVAILABLE SIDE GEAR THRUST WASHERS... 38
    DRIVE GEAR RUNOUT ..................................... 16        .          Drive Pinion Height Adjustment ............................. 38         .
    COMPANION FLANGE RUNOUT (2WD) .......... 17                       .            AVAILABLE PINION HEIGHT ADJUSTING
    COMPANION FLANGE RUNOUT (AWD) .......... 17                       .            WASHERS ......................................................... 38  .
    TOOTH CONTACT ............................................. 17    .          Drive Pinion Preload Adjustment ........................... 38          .
  Disassembly and Assembly .................................. 18      .          Side Bearing Preload Adjustment .......................... 39           .
    REMOVAL OF DIFFERENTIAL CASE ASSEM-                                            SIDE BEARING ADJUSTING WASHERS ......... 39                           .
                                                                                 Total Preload Adjustment ....................................... 39     .




                                                                         RFD-1
                                         PRECAUTIONS

PRECAUTIONS                                                                                    PFP:00001

Precautions                                                                                        ADS00104


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.




                                                RFD-2
                                                       PREPARATION

PREPARATION                                                                                                                    PFP:00002
                                                                                                                                               A
Special Service Tools                                                                                                               ADS000D7

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

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

                                                                          ZZA0811D


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


                                                                          ZZA1143D
                                                                                                                                               G
  KV38107900                                                                              Installing side flange
  (J39352)
  Protector
                                                                                                                                               H



                                                                                                                                                I
                                                                          S-NT129


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

                                                                          SDIA0267E


  ST3306S001                                                                              Removing and installing side bearing                 L
  (       --        )
  Differential side bearing puller set
  1.ST33051001
  ( J22888-20 )                                                                                                                                M
  Puller
  2.ST33061000
  (J8107



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