SECTION 4D1 - DIFFERENTIAL (FRONT)

Service Precaution

Front Drive Axle

Diagnosis

Pinion Shaft Oil Seal

Pinion Shaft Oil Seal and Associated Parts

Removal

Inspection and Repair

Installation

Front Drive Axle Assembly

and Associated Parts

Removal

Installation

Differential Assembly

Disassembled View

Disassembly

Reassembly

Differential Cage Assembly

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Main Data and Specifications

Special Tools

SERVICE PRECAUTION

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN POSSIBLE

AIR BAG DEPLOYMENT, PERSONAL INJURY, OR

OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fasteners. When you install fasteners, use the

correct tightening sequence and specifications.

Following these instructions can help you avoid

damage to parts and systems.

Techline

FRONT DRIVE AXLE

DIAGNOSIS

Condition Possible cause Correcti on

Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal.

Front axle housing cracked. Repair or replace.

Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.

Oil seal worn or defective. Replace the oil seal.

Pinion flange loose or damaged. Tighten or replace.

Noises In Front Axle Drive Shaft

Joint Broken or worn drive shaft joints and

bellows (BJ and DOJ). Replace the drive shaft joints and

bellows.

“Clank" When Accelerating From

“Coast" Loose drive shaft joint to output

shaft bolts. Tighten.

Damaged inn er drive sha ft joi nt. Replac e.

Shudder or Vibration During

Acceleration Excessive drive shaft joint angle. Repair.

Worn or damaged drive shaft joints. Replace.

Sticking spider assembly (inner

drive shaft joint). Lubricate or replace.

Sticking joint assembly (outer drive

shaft joint). Lubricate or replace.

Vibration At Highway Speeds Out of balance or out of round tires. Balance or replace.

Front end out of alignment. Align.

Noises in Front Axle Insufficient gear oil. Replenish the gear oil.

Wrong or poor grade gear oil. Replace the gear oil.

Drive pinion to ring gear backlash

incorrect. Adjust the backlash.

Worn or chipped ring gear, pinion

gear or side gear. Replace the ring gear , pinion gear or

side gear.

Pinion shaft bearing worn. Replace the pinion shaft bearing.

Wheel bearing worn. Replace the wheel bearing.

Differential bearing loose or worn. Tighten or replace.

Wanders and Pulls Wheel bearing preload too tight. Adjust the wheel bearing preload.

Incorrect front alignment. Adjust the front alignment.

Steering unit loose or worn. Tighten or replace.

Tire worn or improperly inflated. Adjust the inflation or replace.

Front or rear suspension parts loose

or broken. Tighten or replace.

Front Wheel Shimmy Wheel bearing worn or improperly

adjusted. Adjust or replace.

Incorrect front alignment. Adjust the front alignment.

Worn ball joint or bush. Replace the ball joint or bush.

Steering unit loose or worn. Tighten or replace.

Tire worn or improperly inflated. Replace or adjust the inflation.

Shock absorber worn. Replace the shock absorber.

PINION SHAFT OIL SEAL

PINION SHAFT OIL SEAL AND ASSOCIATED PARTS

415R100002

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REMOVAL

1. Raise the vehicle and support it at the frame.

The hoist must remain under the front axle housing.

2. Drain the front axle oil by loosening the drain

plug(1).

412RS001

(1) Flange Nut

(2) Flange

(3) Oil Seal

(4) Outer Bearing

(5) Collapsible Spacer

3. Remove the front propeller shaft. Refer to Front

Propeller Shaft in this section 4C.

4. Remove flange nut by using pinion flange holder

5–8840–0133–0.

415RW040

5. Remove flange.

6. Remove oil seal.

7. Remove outer bearing by using remover

5–8840–2323–0.

415RW048

8. Remove collapsible spacer.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear,

damage, corrosion or any other abnormal condition are

found through inspection.

Check the following parts.

1. Seal surface of the pinion.

2. Cage bore for burns.

INSTALLATION

1. Install collapsible spacer. Discard the used

collapsible spacer and install a new one.

2. Install outer bearing.

NOTE: Do not drive in, but just temporarily set in the

outer bearing by hand, which should be indirectly

pressed in finally by tightening the flange nut.

3. Install oil seal, use oil seal installer 9–8522–1275–0

to install a new oil seal that has grease on seal lip.

415RW021

4. Install flange.

5. Install flange nut, refer to Differential Assembly

Overhaul for flange nut reassembly in this section.

NOTE: Discard the used nut and install a new one.

FRONT DRIVE AXLE ASSEMBLY

FRONT DRIVE AXLE ASSEMBLY AND ASSOCIATED PARTS

412R100001

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(1) Propel le r Sha ft

(2) Mounting Nut

(3) Front Axle Case Assembly and Front Drive

Shaft Assembly

(4) Washer

(5) Mounting Bolt

(6) Tie–rod End; Power Steering Unit

(7) Knuckle and Back Plate

(8) Hub and Disc Assembly

(9) Suspension Crossmember

REMOVAL

1. Jack up the vehicle and support it using jack stand.

2. Remove the tire and wheel.

3. Remove the stone guard.

4. Remove the brake caliper fixing bolt and hang the

caliper. Refer to Disc Brakes in Brake section 5C.

5. Remove the antilock brake system speed sensor.

Refer to Front Wheel Speed Sensor in Brake

section 5B.

6. Remove the hub and disc assembly.

Refer to Front Hub and Disc in this section.

7. Remove the propeller shaft, refer to Front Propeller

Shaft in section 4C.

8. Loosen the height control arm of the torsion bar,

then remove the torsion bar from lower control arm.

refer to Torsion Bar in Suspension section 3.

9. Remove the suspension crossmember.

10. Remove the lower nut (1) of the stabilizer link.

11. Remove the lower bolt and nut (2) of the shock

absorber.

412RW057

12. Remove the tie-rod end from the knuckle. Refer to

Power Steering Unit in Steering Section.

13. Disconnect the hose of the shift on the fly, at the

hose clip portion.

14. Disconnect the shift switch connector.

15. Remove the bolts and nuts of the lower control arm

(Frame side), then disconnect the lower control arm

from frame.

16. Disconnect between the right side upper control arm

and the knuckle, then remove the knuckle with lower

control arm.

CAUTION: When removing the knuckle, be careful

not to damage the oil seal inside of the knuckle.

410RW008

17. Support the differential case by the jack.

18. Remove the front axle mounting bolts and nuts,

lower the jack slowly. Remove the left side drive

shaft end from the knuckle, then lower the axle

assembly from the vehicle.

CAUTION:

• Before commencing this procedure, be sure that

the axle assembly is securely supported.

• Be careful not to damage the bellows of the

power steering unit.

INSTALLATION

1. Support the differential case by the jack.

2. Jack up the front drive axle assembly, install the left

side drive shaft to the knuckle, then install the mount

bolts and nuts.

CAUTION:

• Be careful not to damage the bellows of the

power steering unit.

• When installing the drive shaft to the knuckle,

take care to avoid damage to the oil seal inside

of the knuckle.

3. T ighten the mounting bolts and nuts to the specified

torque.

Torque:168N·m

412RX011

4. Install the right side knuckle with lower control arm

to the upper control arm.

Refer to Knuckle in Suspension section.

CAUTION: When insert the drive shaft to the

knuckle, be careful not to damage the oil seal inside

of the knuckle.

5. Align the bolt hole of the lower control arm, install

the bolts and nuts.

NOTE: Adjust the buffer clearance before tighten the

bolts and nuts of the lower control arm.

6. Install the hose of the shift on the fly (1).

7. Install the shift switch connector (2) of the shift on

the fly.

8. Install the tie-rod end of the power steering unit to

the knuckle, tighten the nut to the specified torque.

Torque:118N·m

9. Install lower bolts and nuts of the shock absorber,

tighten it to the specified torque.

Torque:93N·m

10. Install lower nuts of the stabilizer link, tighten it to

the specified torque.

Torque:50N·m

11. Install the suspension crossmember.

12. Install the torsion bar.

Refer to Torsion Bar in section 3.

13. Install the front propeller shaft.

Refer to Front Propeller Shaft in section 4C.

14. Install the hub and disc assembly and adjust the

bearing preload.

Refer to Front Hub and Disc in this section.

15. Install the wheel speed sensor of the antilock brake

system.

16. Install the brake caliper. Tighten the bolt of the

caliper bracket to the specified torque.

Torque:155N·m

17. Install the stone guard.

18. Install the tire and wheel.

19. Lower the vehicle, adjust the trim height.

Refer to Trim Height Adjustment in Steering section.

20. Tighten the bolts and nuts of the lower control arm

to the specified torque.

Refer to Lower Control Arm in Suspension section.

DIFFERENTIAL ASSEMBLY

DISASSEMBLED VIEW

415R100003

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(1) D ifferent ial Assembly

(2) Flange Nut

(3) Flange

(4) Oil Seal

(5) Outer Bearing

(6) Outer Bearing Outer Race

(7) Differential Carrier

(8) Bearing Cap

(9) Bolt

(10) Co llapsib le Spacer

(11) Inner Bearing Outer Race

(12) Inner Bearing

(13 ) Ad ju st Sh im

(14) P inion Gear

(15) Diff Cage Assembly

(16) Side Bearing Outer Race

(17) Side Bearing

(18 ) Ad ju st Sh im

(19) Bolt

(20) Axle Case

(21) Final Drive Damper (With TOD Only)

(22) Bolt (With TOD Only)

(23) Bracket (With TOD Only)

DISASSEMBLY

1. Remove differential carrier fixing bolt.

2. Remove differential assembly.

3. Using holding fixture 5–8840–0275–0 and holding

fixture base 5–8840–0003–0, fix the differential

assembly to the bench.

425RW046

4. Remo ve bea ring cap bolt.

5. Apply a setting mark to the side bearing cap and the

differential carrier then remove bearing cap.

425RS009

6. Remove differential cage assembly.

7. Remove side bearing outer race, after removal,

keep the right and left hand side bearing assemblies

separate to maintain inner and outer race

combinations.

8. Remove side bearing, using remover

5–8840–2587–0 and adapter 5–8840–2576–0.

• Select insert; 303173 and collet halves; 44801 in

remover kit 5–8840–2587–0.

415RW041

9. Remove adjust shim, note the thickness and

pos ition of the shims removed.

10. Remove the flange nut using holding wrench

5–8840–0133–0.

415RW040

11. Remove flange using an universal puller.

12. Remove the drive pinion assembly using a soft

metal rod and a hammer.

425RS012

13. Remo ve co ll apsible spacer.

14. Remove the inner bearing using remover

5–8840–2587–0.

• Select insert; 303173 and collet halves; 44801 in

remover kit 5–8840–2587–0.

415RW042

15. Remove adjust shim.

16. Remove oil seal.

17. Remove oil seal slinger.

18. Remove outer bearing.

19. Remove the inner bearing outer race (1) and the

outer bearing outer race (2) by using a brass bar

and a hammer.

425RS014

425RS015

REASSEMBLY

1. Using installer 9–8522–1141–0 and grip 5–8840–

0007–0, install outer bearing outer race.

415RW018

2. Using installer 9–8522–1274–0 and grip

5–88 40– 0007 –0, install Inne r bea ring oute r race.

415RW017

3. Install adjust shim and adjust drive pinion mounting

distance:

1. Apply gear oil to the inner and outer drive pinion

bearing.

Clean the pinion setting gauge set.

Then install the gauge set together with the

inner and oute r bearings .

2. Tighten the nut to the specified torque.

Torque:2.3N·m

415RS009

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3. Clean the side bearing bores. Install the dial

indicator with the discs and arbor. Install and

tighten the bearing caps to the specified torque.

Torque:98N·m

415RS010

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(1) Pilot : 5–8840–2085–0

(2) Nut and Bolt: 5–8840–2089–0

(3) Gauge Plate : 5–8840–2087–0

(1) Di al Indic ator : 5–88 40– 0126 –0

(2) Disc (2 pcs.): 5–8840–2088–0

(3) Arbor: 5–8840–0128–0

(4) Gauge Plate: 5–8840–2087–0

4. Set the dial indicator to “0". Place it on the

mounting post of the gauging arbor with the

contac t bu tt on t ouchi ng t h e in di ca to r pad. Fo r ce

the dial indicator downward until the needle has

made a half turn clockwise. Tighten down the

dial indicator in this position.

425RS020

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5. Position the plunger on the gauge plate. Move

the gauging arbor slowly back and forth and

locate the position at which the dial indicator

shows the greatest defection. At this point, once

again set the dial indicator to “0".

Repeat the procedure to verify the “0" setting.

425RS021

6. After the ZERO setting is obtained, rotate the

gauging arbor until the dial indicator rod does

not touch the gauging pl ate.

Record the number the dial indicator needle

points to.

425RS022

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7. Record the pinion depth code on the head of the

drive pin io n.

The number indicates a necessary change in

the pinion mounting distance. A plus number

indicates the need for a greater mounting

distance (which can be achieved by decreasing

the shim thickness). A minus number indicates

the need for a smaller mounting distance (which

can be achieved by increasing the shim

thickness). If examination reveals pinion depth

code “0", the pinion is “nominal".

425RS023

(1) Dial Indicator

(2) Gauging Arbor

(3) Plunger

(4) Gauge Plate

(1) Example=Dial indicator reading of 0.085

8. Select the shim using chart;

NOTE: When ordering shims, find the part number in

Partfinder by using the thickness of shims listed in the

above table.

Pinion

marking +10 +8 +6 +4 +2 0 –2 –4 –6 –8 –10

Dial

indicator

reading

(Inches) mm

(Inches)

0.081 2.18

(0.0858)

0.082 2.18

(0.0858) 2.20

(0.0866)

0.083 2.18

(0.0858) 2.20

(0.0866) 2.23

(0.0882)

0.084 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890)

0.085 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898)

0.086 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914)

0.087 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921)

0.088 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929)

0.089 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937)

0.090 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953)

0.091 2.18

(0.0858) 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961)

0.092 2.20

(0.0866) 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969)

0.093 2.24

(0.0882) 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977)

0.094 2.26

(0.0890) 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992)

0.095 2.28

(0.0898) 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000)

0.096 2.32

(0.0914) 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.097 2.34

(0.0921) 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.098 2.36

(0.0929) 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.099 2.38

(0.0937) 2.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

02.42

(0.0953) 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.001 2.44

(0.0961) 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.002 2.46

(0.0969) 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.003 2.48

(0.0977) 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.004 2.52

(0.0992) 2.54

(0.1000) 2.56

(0.1008)

0.005 2.54

(0.1000) 2.56

(0.1008)

0.006 2.56

(0.1008)

4. Place the shim on the drive pinion. Install the inner

bearing onto the pinion using an installer

9–8522–1165–0 and a press.

NOTE: Do not apply pressure to the roller cage and

apply pressure only to the inner race.

425RW067

5. Discard the used collapsible spacer and install a

new one.

6. Install pinion gear.

7. Install outer bearing.

8. Use oil seal installer 9–8522–1275–0 to install a

new oil seal that has been soaked in front axle

lubricant.

NOTE: Take care to use a front differential oil seal,

NOT the rear differential oil seal.

415RW024

9. Install flange.

10. Install flange nut.

1. Apply lubricant to the pinion threads.

2. Tight e n t h e n ut t o t h e sp ec i f ie d to r que using th e

pinion flange holder 5–8840–0133–0.

Torque:177-275 N·m

NOTE: Discard used flange nut and install new one and

do not over tighten the flange nut.

415RW006

3. Adjust pinion bearing preload.

a Measure the bearing preload by using a

torque meter. Note the scale readin g

required to rotate the flange.

b Continue tightening flange nut until the

specifi ed starting tor que is obtained .

Starting torque:

New bearing:0.7–1.1N·m

Used bearing:0.4–0.5N·m

425RS027

4. Using punch 5–8840–2293–0, stake the flange

nut at two points.

NOTE: When staking, be sure to turn the nut to ensure

that there is no change in bearing preload. Recheck

preload again as instructed in 3)

415RW019

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11. Install adjusting shim.

1. Attach the side bearing to the differential

assembly without shims. Support the opposite

side using a pilot to prevent bearing damage.

425RS029

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2. Insert the differential cage assembly with

bearing outer races into the side bearing bores

of the carrier.

425RS030

(1) 1.3mm or less (1) Driv e hand le :5–8 840 –000 7–0

(2) Installer:9–8522–1164–0

(3) Pilot:9–8521–1743–0

3. Using two sets of feeler gauges, insert a feeler

stock of sufficient thickness between each

bearing outer race and the carrier to remove all

end play. Make certain the feeler stock is

pushed to the bottom of the bearing bores.

Mount the dial indicator 5–8840–0126–0 on the

carrier so that the indicator stem is at right

angles to a tooth on the ring gear.

425RS031

4. Adjust feeler gauge thickness from side to side

until ring gear backlash is in the specified range.

Backlash:0.13–0.18mm

425RS032

With zero end play and correct backlash

established, remove the feeler gauge packs,

determine the thickness of the shims required

and add 0.05 mm to each shim pack to provide

side bearing preload. Always use new shims.

5. Use bearing remover 5–8840–2587–0 and pilot

5–8840–2576–0 to remove side bearing.

• Select insert; 303173 and collet halves;44801

in remover kit 5–8840–2587–0.

415RW041

12. Install the side bearings together with the selected

shims.

425RS029

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(1) Driv e Hand le: 5–88 40– 000 7–0

(2) Installer: 9–8522–1164–0

(3) Pilot: 9–8521–1743–0

13. Install side bearing outer race.

14. Install differential cage assembly.

15. Install bearing cap then align the setting marks(1)

applied at disassembly.

425RS035

16. Tighten the cap bolt to the specified torque.

Torque:98N·m

425RS036

1. Measure the amount of run-out of the ring gear

at its rear face.

Standard: 0.02 mm

Limit: 0.05 mm

425RS037

Gear Tooth Contact Pattern Check and

Adjustment

1. Apply a thin coat of bearing blue or equivalent to

the faces of the 7–8 teeth of the ring gear.

Check the impression of contact on the ring

gear teeth and make necessary adjustment as

described in illustration if the contact is

abnormal.

425RS038

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425RS039

(1) Heel

(2) Toe

(3) Concave Side(Coast)

(4) Convex Side(Drive)

17. Install differential assembly.

1. Clean the faces of the front axle case and

differential carrier.

Apply Three Bond TB1215 or equivalent to the

sealing side of the axle case and the carrier.

2. Attach the differential case and the carrier

assembly to the front axle case and tighten the

nuts and bolts.

Torque:25N·m

415RS014

3. Fill the axle case with hypoid gear lubricant refer

to Section 0B, to just below the filler hole.

Lubricant capacity:1.25L.

DIFFERENTIAL CAGE ASSEMBLY

DISASSEMBLED VIEW

415RS015

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DISASSEMBLY

1. Remo ve bolt.

2. Remo ve ring gea r.

3. Remove lock pin, break staking on the lock pin,

using a 5mm diameter drill.

425RS042

(1) Pinion Gear

(2) Thrust Washer

(3) Side Gear

(4) Cross Pin

(5) Ring Gear

(6) Bolt

(7) Differential Cage

(8) Lock Pin

4. Remove the cross pin, using a soft metal rod and a

hammer.

425RS043

5. Remove pinion gear.

6. Remove side gear.

7. Remove thrust washer.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear ,

damage, corrosion or any other abnormal condition are

found through inspection.

Check the followin g parts.

1. Ring gear, pinion gear

2. Bearing

3. Side gear, pinion gear, cross pin

4. Differential cage, carrier

5. Thrust was her

6. Oil seal

Ring gear replacement:

1. The ring gear should always be replaced with the

drive pinion as a set.

2. Discard used bolts and install new ones.

3. When installing the ring gear , apply LOCTITE 271 or

equivalent to all the threaded area and half of the

unthreaded area of the bolt.

4. Discard used bolts and install new ones..

Torque:108N·m

415RS016

Clearance between the differential pinion

and the cross pin measurement:

Standard: 0.06 - 0.12 mm

Limit: 0.2 mm

425RS045

Clearance between the side gear and the

differential box:

Standard: 0.03 - 0.10 mm

Limit: 0.15 mm

425RS046

Legend

EndOFCallout

Play in splines between the side gear and

the axle shaft:

Standard: 0.08 - 0.36 mm

Limit: 0.5 mm

425RS047

REASSEMBLY

1. Install thrust washer.

2. Install side gear.

3. Install the pinion gear with thrust washer by

engaging it with the side gears while turning both

pinion gears simultaneously in the same direction.

425RS048

4. Install cross pin.

1. Be sure to install the cross pin so that it is in

alignment with the lock pin hole in the differential

cage.

425RS049

(1) Side Gear

(2) Differential Box

2. Adjust the backlash between the side gear and

the pinion gear.

Backlash: 0.03 - 0.08 mm

Thickness of thrust washers available:

1.00mm, 1.05mm, 1.10mm

425RS050

5. Install lock pin. After lock pin installation, stake the

cage to secure the lock pin.

425RS051

Legend

EndOFCallout

6. Clean the ring gear threaded holes to remove the

locking agent. When installing the ring gear, apply

LOCTITE 271 or equivalent to all the threaded area

and half of the unthreaded area of the bolt.

7. Tighten the bolts in diagonal sequence as

illustrated.

Torque:108N·m

NOTE: Discard used bolts and install new ones.

415RS016

(1) Staked Portion

(2) Lock Pin

MAIN DATA AND SPECIFICATIONS

General Specifications

Axle tube Type It consists of the duct, a cast iron housing and the axle

tube.

Gear type Hypoid

Gear ratio (to 1) 4.100 (6VD1 with A/T)

4.300 (6VD1 with M/T)

Differential type Two pinion

Oil capacity 1.25L (Differential)

0.12L (Actuator Housing: Shift on the fly)

Type of lubricant GL–5 (75W–90)

Axle shaft type Constant velocity joint (Birfield Joint (BJ) type and Double

Offset Joint (DOJ)

Hub locking Type Rigid

Torque Specifications

412R100002

415R100004

SPECIAL TOOLS

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–0133–0

(J–8614–01)

Holder; Pinion flange

9–8522–1275–0

(J–24250)

Installer; Oil seal

5–8840–0275–0

(J–37264)

Differential hol din g fixtur e

(Use with 5–8840–0003–

0 base)

5–8840–0003–0

(J–3289–20)

Holding fixture base

5–8840–2587–0

(J–42379)

Remover; Side Pinion/

bearing

9–8521–1743–0

(J–8107–2)

Adapter; Side bearing

plug

9–8522–1141–0

(J–24256)

Installer; Ou ter bearing

outer race

5–8840–0007–0

(J–8092)

Driver handle

9–8522–1274–0

(J–24252)

Installer; Inner bearing

outer race

5–8840–2085–0

(J–21777–42)

Pilot

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2089–0

(J–23597–9)

Nut and bolt

5–8840–2087–0

(J–23597–7)

Gauge plate

5–8840–0126–0

(J–8001)

Dial indicator

5–8840–2088–0

(J–23597–8)

Disc

5–8840–0128–0

(J–23597–1)

Arbor

9–8522–1165–0

(J–6133–01)

Installer; Pinion bearing

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2293–0

(J–39209)

Punch; End nut lock

9–8522–1164–0

(J–24244)

Installer; Side bearing

5–8840–2323–0

(J–39602)

Remover; Outer bearing

ILLUSTRATION TOOL NO.

TOOL NAME