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D DRIVELINE/AXLE

SECTION
FRONT FINAL DRIVE
FFD B

FFD

E
CONTENTS
PRECAUTIONS ......................................................... 2
. FRONT FINAL DRIVE ASSEMBLY ......................... 12 . F
Precautions ............................................................. 2
. Removal and Installation ....................................... 12
.
Precautions for Liquid Gasket ................................. 2 . REMOVAL .......................................................... 12
.
REMOVAL OF LIQUID GASKET SEALING ......... 2 . INSTALLATION .................................................. 13
. G
LIQUID GASKET APPLICATION PROCEDURE 2 ..... Disassembly and Assembly ................................... 14 .
PREPARATION .......................................................... 4
. COMPONENTS .................................................. 14
.
Special Service Tools .............................................. 4
. ASSEMBLY INSPECTION AND ADJUSTMENT 15 ...
H
Commercial Service Tools ....................................... 6 . DISASSEMBLY .................................................. 17
.
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION AFTER DISASSEMBLY ............... 22 .
TROUBLESHOOTING ............................................... 7 . ADJUSTMENT AND SELECTION OF ADJUST-
NVH Troubleshooting Chart .................................... 7 . ING WASHERS .................................................. 23
. I
FRONT OIL SEAL ..................................................... 8. ASSEMBLY ........................................................ 24
.
Removal and Installation ......................................... 8. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 32 .
REMOVAL ............................................................ 8
. General Specifications ........................................... 32
. J
INSTALLATION .................................................... 9
. Inspection and Adjustment .................................... 32.
SIDE OIL SEALS ..................................................... 10
. DIFFERENTIAL SIDE GEAR CLEARANCE ...... 32 .
Removal and Installation ....................................... 10 . PRELOAD TORQUE .......................................... 32 .
K
REMOVAL .......................................................... 10
. BACKLASH ........................................................ 32
.
REAR COVER GASKET ..........................................11 . COMPANION FLANGE RUNOUT ...................... 32 .
Removal and Installation ........................................11 . SELECTIVE PARTS ........................................... 32 .
REMOVAL ...........................................................11
. L
INSTALLATION ...................................................11.

Revision: August 2007 FFD-1 2004 QX56
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions EDS0035E

CAUTION:
G Before starting diagnosis of the vehicle, understand symptoms well. Perform correct and system-
atic operations.
G 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.
G Carry out an overhaul in a clean work place, Using a dust proof room is recommended.
G 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.
G Check appearance of the disassembled parts for damage, deformation, and abnormal wear. If a
malfunction is detected, replace it with a new one.
G Normally replace lock pins, oil seals, and bearings with new ones every times they are removed.
G In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-
side. If tightening sequence is specified, observe it.
G Clean and flush the parts sufficiently and blow them dry.
G Be careful not to damage the sliding surfaces and mating surface.
G 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.
G Always use shop paper for cleaning the inside of components.
G Avoid using cotton gloves or a shop cloth to prevent entering of lint.
G During assembly, observe the specified tightening torque, and new differential gear oil, Vaseline,
or multi-purpose grease, as specified for each vehicle, when necessary.
Precautions for Liquid Gasket EDS0035F

REMOVAL OF LIQUID GASKET SEALING
G After removing nuts and bolts, separate the mating surface and
remove old liquid gasket sealing using Tool.
Tool number : KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mating surfaces.
G Tap seal cutter to insert it, and then slide it by tapping on the
side as shown.
G In areas where Tool is difficult to use, use plastic hammer to
lightly tap the parts, to remove it.
CAUTION: WBIA0566E

If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove old liquid gasket adhering to the gasket
application surface and the mating surface.
G Remove liquid gasket completely from the groove of the gas-
ket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.

PBIC0003E

Revision: August 2007 FFD-2 2004 QX56
PRECAUTIONS

3. Attach liquid gasket tube to Tool.
Tool number : WS39930000 ( -- ) A

Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "Recommended Chemical Products and Sealants" .
B
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
G If there is a groove for liquid gasket application, apply liquid
C
gasket to the groove.

WBIA0567E

FFD
G As for bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of this manual. E
G Within five minutes of liquid gasket application, install the mat-
ing component.
G If liquid gasket protrudes, wipe it off immediately. F
G Do not retighten nuts or bolts after the installation.

G After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant. G
CAUTION: SEM159F
If there are specific instructions in this manual, observe
them. H

Revision: August 2007 FFD-3 2004 QX56
PREPARATION

PREPARATION PFP:00002

Special Service Tools EDS0035G

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
KV10111100 Removing steel oil pan and rear timing chain
(J-37228) case
Seal cutter

S-NT046

WS39930000 Pressing the tube of liquid gasket
( -- )
Tube presser

S-NT052

ST35271000 Installing drive pinion front bearing outer
( -- ) race.
Drift a: 72 mm (2.83 in) dia.
b: 36 mm (1.42 in) dia.

ZZA0702D

KV38100500 Installing front oil seal.
(J-25273) a: 80 mm (3.15 in) dia.
Drift b: 60 mm (2.36 in) dia.

ZZA0811D

G Removing side bearing inner race.
ST30021000 G Removing drive pinion rear bearing inner
( -- ) race.
Puller

ZZA0700D

KV38100300 Installing side bearing inner race.
(J-25523) a: 54 mm (2.13 in) dia.
Drift b: 46 mm (1.81 in) dia.
c: 32mm (1.26 in) dia.

ZZA1046D

ST30901000 Installing drive pinion rear bearing outer race.
( -- ) A: 79mm (3.11 in) dia.
Drift B: 45 mm (1.77 in) dia.
C: 35.2 mm (1.39 in) dia.

SDIA0217J

Revision: August 2007 FFD-4 2004 QX56
PREPARATION

Tool number Description
(Kent-Moore No.) A
Tool name
KV40104810 Installing drive pinion front bearing outer
( -- ) race. B
Drift a: 68 mm (2.68 in) dia.
b: 55 mm (2.17 in) dia.

ZZA1003D

KV38102200 Installing front oil seal. FFD
( -- ) a: 90 mm (3.54 in) dia.
Drift b: 55.3 mm (2.18 in) dia.
c: 31 mm (1.22 in) dia,
E

NT107

ST33081000 Removing and installing side bearing inner F
( -- ) race.
Adapter a: 33.5 mm (1.32 in) dia.
b: 43 mm (1.69 in) dia. G

ZZA0881D H
KV38108300 Removing and installing drive pinion nut.
(J-44195)
Companion flange wrench
I

J
NT771

ST3127S000 Inspecting drive pinion bearing preload and
(J-25765-A) total preload
Preload gauge K
1. GG91030000
(J-25765)
Torque wrench L
2. HT62940000
( -- )
Socket adapter (1/2)
3. HT62900000 NT124 M
( -- )
Socket adapter (3/8)
-- Installing drive pinion rear bearing inner race.
(C-4040)
Installer

SDIA2607E

KV40105230 Installing drive pinion rear bearing outer race.
( -- ) a: 92 mm(3.62 in) dia.
Drift b: 86 mm (3.39 in) dia.

ZZA1141D

Revision: August 2007 FFD-5 2004 QX56
PREPARATION

Tool number Description
(Kent-Moore No.)
Tool name
-- G Removing drive pinion front bearing outer
(C-4171) race
Handle G Removing drive pinion rear bearing outer
race

LDIA0134E

-- Removing drive pinion front bearing outer
(D-103) race
Remover

LDIA0135E

-- Removing drive pinion rear bearing outer
(C-4307) race
Remover

LDIA0135E

Commercial Service Tools EDS0035H

Tool name Description
Slide hammer G Removing front oil seal
G Removing side oil seal

LDIA0133E

Power tool Loosening bolts and nuts

PBIC0190E

Revision: August 2007 FFD-6 2004 QX56
Symptom

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