Front Final Drive, Bearing Housing & Driveshafts Page 4B3–1

Page 4B3-1

Section 4B3

Front Final Drive, Bearing Housing & Driveshafts

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Description ...............................................................................................................................3

1.1 Final Drive Assembly Identification ..................................................................................................................... 4

1.2 Final Drive Maintenance........................................................................................................................................ 5

Maintenance........................................................................................................................................................... 5

Driveshaft Bearings and Constant Velocity Joints.............................................................................................. 5

Differential Carrier Assembly.............................................................................................................................. 5

Final Drive Assembly Breather........................................................................................................................... 5

Lubrication ............................................................................................................................................................. 6

2 Minor Service Operations......................................................................................................................7

2.1 Checking Final Drive Lubricant Level.................................................................................................................. 7

2.2 Changing/Flushing Final Drive Lubricant............................................................................................................ 8

2.3 Pinion Oil Seal........................................................................................................................................................ 9

Replace................................................................................................................................................................... 9

2.4 Driveshaft Assembly ........................................................................................................................................... 10

Remove................................................................................................................................................................. 10

Reinstall................................................................................................................................................................ 12

2.5 Driveshaft Outer Constant Velocity Joint.......................................................................................................... 15

Remove................................................................................................................................................................. 15

Reinstall................................................................................................................................................................ 17

2.6 Driveshaft Inner Tripot Joint............................................................................................................................... 18

Disassemble......................................................................................................................................................... 18

Inspect .................................................................................................................................................................. 20

Reassemble.......................................................................................................................................................... 20

2.7 Bearing Housing/Final Drive Carrier Outer Oil Seal.......................................................................................... 22

Replace................................................................................................................................................................. 22

2.8 Pinion Oil Seal...................................................................................................................................................... 24

Replace................................................................................................................................................................. 24

2.9 Pinion Flange ....................................................................................................................................................... 25

Replace................................................................................................................................................................. 25

3 Major Service Operations....................................................................................................................26

3.1 Bearing Housing Assembly ................................................................................................................................ 26

Remove................................................................................................................................................................. 26

GEN III V8 Engine............................................................................................................................................ 26

All AWD............................................................................................................................................................ 27

Disassemble......................................................................................................................................................... 27

Inspect .................................................................................................................................................................. 29

Reassemble.......................................................................................................................................................... 30

Reinstall................................................................................................................................................................ 32

Techline

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–2

Page 4B3-2

3.2 Front Final Drive Assembly................................................................................................................................. 33

Remove................................................................................................................................................................. 33

GEN III V8 Engine............................................................................................................................................ 33

All AWD............................................................................................................................................................ 33

Reinstall................................................................................................................................................................ 36

3.3 Removed Final Drive Assembly.......................................................................................................................... 38

Disassemble......................................................................................................................................................... 39

Final Drive Cover.............................................................................................................................................. 39

Examining Gear Tooth Contact........................................................................................................................ 40

Drive Pinion...................................................................................................................................................... 40

Differential Assembly........................................................................................................................................ 44

Inspect .................................................................................................................................................................. 46

General Items................................................................................................................................................... 46

Gears ............................................................................................................................................................... 46

Bearing Cups ................................................................................................................................................... 46

Bearing Cone and Roller Assemblies............................................................................................................... 47

Pinion Flange ................................................................................................................................................... 47

Carrier and Cover Housings............................................................................................................................. 47

Differential Case............................................................................................................................................... 47

Reassemble.......................................................................................................................................................... 47

Differential........................................................................................................................................................ 47

Drive Pinion – Shim Selection.......................................................................................................................... 49

Differential Assembly – Bearing Preload and Backlash.................................................................................... 52

Final Drive Unit Assembly................................................................................................................................ 56

4 Diagnosis ..............................................................................................................................................59

5 Specifications.......................................................................................................................................60

6 Torque Wrench Specifications............................................................................................................61

7 Special Tools ........................................................................................................................................62

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–3

Page 4B3-3

1 General Description

The front final drive assembly (1) is attached to the left side of the engine oil pan and a driveshaft support bearing

assembly (3) is located on the right side of the engine oil pan. An interconnecting shaft (2) passes through an integrally

cast tube in the engine oil pan, from the front drive assembly to the support bearing housing assembly. Refer to

Figure 4B3-1. The interconnecting shaft is retained in the right side differential axle gear by a snap ring.

The final drive assembly is a “Clam Shell” design, that is split vertically along its length and consists of two housings (1

and 2) made from ductile iron. The major housing (1) is the carrier that houses the hypoid pinion and supports the left

hand crown wheel carrier bearing. The minor half of the unit is called the cover (2), that supports the right hand crown

wheel carrier bearing. This cover is locate d on the carrier with a large diameter spigot and a hollow dowel to control

bearing to bearing alignment and is secured by ten bolts (5).

The hypoid drive pinion is supporte d in the carrier on two opposed, preloaded taper roll er bearings. A pinion positioning

shim is located under the pinion head bearing cup while the bearing preload is achieved with a collapsible spacer at the

outer (small) pinion bearing. The bearings and the companion flange are retained with the pinion nut.

The differential assembly and ring gear are supported on two opposed and preloaded taper roller bearings; one in the

carrier and the second in the cover. The backlash and the bearing pre lo ad are controlled with shims under the final drive

carrier bearing cups in the carrier an d the cover.

The final drive assembl y is indexed to the engine oil pa n by the cover seal housing, engagin g with a machined recess in

the engine oil pan, while a dowel (6) near the rear mounting bolt controls the pinion nos e angle. Four bolts are used to

attach the final drive assembly to the engine pan. The left front driveshaft is retained in the left differential axle gear b y a

snap ring on the inboard spline of the inner tripot joint.

The final drive ratio is 3.46:1 and the conventional differential assembly has two pinions, with a single, pin ned pinion

shaft and two axle side gears.

Figure 4B3-1

Legend

1 Final Drive Assembly, Major Housing

2 Final Drive Assembly, Cover

3 Interconnecting Shaft

4 Driveshaft Support Bearing Assembly

5 Carrier to Cover Attaching Bolts (10 places)

6 Pinion Nose Angle Locating Dowel

7 Interconnecting Shaft Snap Ring

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–4

Page 4B3-4

The bearing housin g assembly is a one piece aluminium casting attached to the right side of the engine oil pan with three

bolts. The bearing housing assembly is fitted with a needle roller bearing (2) and a ball bearing (6) to support and locate

the connecting sleeve (5). The sleeve supports one end of the interconnecting shaft and retains the rig ht side front

driveshaft, again by a retaining ring on the inner tripot joint spline. Both bearings are lubricated for life and require no

periodic maintenance. An oil seal (1 and 9) at each end of the bearing housing assembly, retain the lubricant.

Figure 4B3-2

Legend

1 Oil Seal – Inner

2 Needle Roller Bearing

3 Bearing Housing

4 O-Ring Seal

5 Connecting Sleeve

6 Single Row Ball Bearing

7 Circlip – Small

8 Circlip – Large

9 Oil Seal – Outer

1.1 Final Drive Assembly Identification

There is only one front final drive assembly available for fitment to all MY 2005 All Wheel Drive models, which has a final

drive ratio of 3.46:1 with a two pinion type, standard differential.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–5

Page 4B3-5

1.2 Final Drive Maintenance

Maintenance

Driveshaft Bearings and Constant Velocity Joints

The driveshaft outer constant velocity joint and the inner tripot joint are lubricated for life and therefore require no periodic

maintenance.

The constant velocity joint boots are to be inspected at every maintenance service. If there is any evidence of damage to

boots, remove driveshaft and inspect constant velocity joints, refer to 2.4 Driveshaft Assembly in this Section.

Differential Carrier Assembly

Check for lubricant leaks at every maintena nce service. If there is evidence of leakage, correct the leak and add l ubricant

as necessary. (Refer to 2 Minor Service Operations in this Section).

Final Drive Assembly Breathe r

The breather hose and pipe assembly (1) should be checked regu larly to ensure that it is correctly routed, the hose

condition is sound, the end is not blocke d and the pipe bracket fastener (2) is secure.

NOTE

View ‘A’ shows the GEN III V8 routing of the

breather tube, while view ‘B’ shows the V6

arrangement.

Figure 4B3 – 3

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–6

Page 4B3-6

Lubrication

Never use any other than the stated and

recommended lubricant.

The lubricant level should be checked and topped up (if requir ed), at the time or distance intervals outlined in the

appropriate Owner's Handbook, with the differential carrier COLD and the vehicle on level ground; refer to

2.1 Checking Final Drive Lubricant Level in this Section. At this temperature, the lubricant should be within 5 mm of the

bottom of the filler plug hole. Operation 2.1 also d etails the recommended lubricant for this final drive.

NOTE

• The lubricant used in this final drive, is a

synthetic product and the oil s eals fitted, have

been specially formulated to tolerate this

lubricant. It must also be noted that, using a

mineral type lubricant in this final drive, may

cause gear set and/or bearing damage under

high load driving conditio ns.

• If the incorrect lubricant is accide ntall y used i n

the front final drive of any AWD vehicle, then

the front final drive must be drained, flushed

(with the recommended lubricant) and then

refilled with the correct lubricant. Refer to

2.2 Changing/Flushing Final Drive Lubricant,

in this Section.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–7

Page 4B3-7

2 Minor Service Operations

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. W h ere specified in this section, fasteners MUST be rep laced with parts of the

same part number or an approved equivalent. Do not use fasten ers of an inferior quality or substitute desig n.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be replaced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanic al thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

2.1 Checking Final Drive Lubricant Level

1 Ensure vehicle is on level ground.

2 Clean area around filler plug (1).

3 Remove the hexagon headed filler plug (1) from the

carrier housing, using suitable socket equipment.

4 The lubricant l evel is to be maintained within 5 mm of

the bottom edge of the filler plug hole, when COLD

and the vehicle is on level ground. Use only the

recommended lubricant, detail ed as follows:

Front Final Drive Lubricant Specification

Synthetic Hypoid Gear Oil, SAE 80W-140

such as;

Castrol SAF-XA or Mobilube SHC ID

5 Inspect filler plug (1) for damage. If OK, reinstall to the

carrier housing. If damaged, repl ace plug.

Figure 4B3 – 4

6. Tighten filler plug (1) to the correct torque specificati on.

Final drive filler plug

torque specification..............................................28 N.m

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–8

Page 4B3-8

2.2 Changing/Flushing Final Drive Lubricant

1 To drain lubric ant from differential carrier assembly,

remove the hexagon headed filler plug (refer

Figure 4B3-4), then the 8 mm Allen key headed drain

plug (1), allowing (preferably warm) lubricant to drain

into a suitable container of at least 1 litre capacity.

2 If flushing is required, use an undiluted quantit y of the

recommended lubricant for the operation.

3 When the draining and flushing (if required), operation

is completed, clean the final drive drai n plug (1)

threads. If required, Teflon tape may be applied to the

threads. Reinstall and tighten drain plug (1) to the

correct torque specification.

Final drive drain plug

torque specification..............................................45 N.m

Figure 4B3 – 5

4 Fill the final drive assembly with 0.8 litres of the recommended lubricant. Reinstall the filler plug ('1', in Figure 4B 3-

4) and tighten the filler plug to the correct torque spec ification.

Final drive filler plug

torque specification..............................................28 N.m

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–9

Page 4B3-9

2.3 Pinion Oil Seal

Replace

Apart from the fact that it is the front propeller shaft that needs to be removed (rather than the rear), the procedure for the

front final drive pinion oil seal replacement is the same as that described for the rear final drive assembly.

Refer to Section 4C2 Front Propeller Shaft & Universal Joi nts and Section 4B1 Rear Final Drive & Driveshafts.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–10

Page 4B3-10

2.4 Driveshaft Assembly

LT Section No. – 05-290

Remove

1 Raise the vehicle and secure in a safe manner. Refer to Section 0A General Information for the location of jacking

and support points.

2 Remove the centre wheel nut cap, then mark the relationship of the road wheel to one of the wheel studs.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern.

Refer to Section 10 Wheels and T yres for de tailed information. Remove the road wheel.

NOTE

Steps 2 and 3 are necessary to maintain

component relationships and to avoid brake rotor

distortion and the creation of brake shudder, after

the vehicle is placed back in service.

4 Attach holding tool KM-468 to the wheel hub with two

inverted wheel nuts. Support the tool outer end on a

safety stand.

5 Using suitable socket equipment, loosen then remove

the 36 mm driveshaft retaining nut and flat washer.

Discard the removed nut.

Figure 4B3 – 6

6 Remove the dust cover (1) from the upper strut

support, in the engine compartment.

7 While holding the strut rod shaft (2) with a 10 mm

socket, loosen the self-locking nut (3), using a 24 mm

ring spanner. Do not fully remove the nut.

NOTE

This step is necessary to allow the strut to be

moved outward, enabling driveshaft removal.

Figure 4B3 – 7

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–11

Page 4B3-11

Under no circumstances is the end of the

driveshaft to be struck with a hammer to

dislodge the splines. To do so, will not only

damage the front hub bearing but the

driveshaft to outer constant velocity joint

snap ring can be also be dislodged.

8 Install Tool No. 7208 to the fro nt hub studs a nd secure

with three of the wheel nuts (1).

9 Tighten the forcing screw to separate the front hub

and outer driveshaft splines. Remove Tool No. 7208.

Figure 4B3 – 8

10 Disconnect the front control arm ball joint stud from the front control arm.

Refer to Section 3B Front Suspension – AW D.

11 Install adaptor(1) from slide hammer J 2619-O1 to the

remover/installer, Tool No. DT-47570, then install DT-

47570 to the groove in the tripot joint housing,

tightening the thumb screw to secure.

12 Screw slide hammer J 2619-O1 into the adaptor unti l

secure.

13 Using the action of the slide hammer weight aga inst

the handle, dislodge the tripot joint snap ring from the

bearing housing (right side) or the front final drive side

gear (left side).

NOTE

While the right side view is sho wn, the procedur e

is the same for the either side.

14 Remove the driveshaft from the vehicle by first

pushing inward to free the outer shaft from the front

hub, then withdraw the driveshaft by pulling on the

tripot housing.

NOTE

If the driveshaft is removed from the final drive

(left) side, lubricant will flow from the oil seal.

Either plug the recess immediately with a

suitable plug or rag, or drain the lubricant into a

suitable, clean container. Refer to

2.2 Changing/Flushing Final Drive Lubricant, in

this Section.

Figure 4B3 – 9

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–12

Page 4B3-12

• When removing the driveshaft do not

allow the tripot splines to drag on th e final

drive (or bearing housing) oil seal.

• The removed driveshaft must be handled

with care. Do not rest th e shaft or bellows

for any longer than necessary.

• The shaft is not to be allowed to hang free

on one end. Driveshaft joint deflection

should be kept to a minimum by

supporting the driveshaft with wooden

blocks, as shown.

NOTE

If both driveshafts are removed, the left side is

shorter than the right.

Figure 4B3 – 10

Reinstall

1 Install adaptor from slide hammer J 2619-O1 to the driveshaft remover installer, Tool No. DT-47570.

2 Install remover / installer Tool No. DT-47570 to the machined groove in the tripot housing and tighten the thumb

screw to secure.

3 Coat the tripot splines with the recommended final

drive lubricant, then reinstall the shorter driv eshaft

tripot joint into the front final drive (left side) or the

longer driveshaft tripot joint into the support bearing

(right side).

• When reinstalling the driveshaft, do not

allow the tripot splines to rub on the oil

seal, as the seal lip will be damaged.

• Under no circumstances is the driveshaft

to be used as a ram to install the tripot

joint. If this occurs, damage to the needle

rollers in the joint will most likely result.

4 Fully install the tripot joint by using the slide hammer

J 2619-O1, working against its adaptor.

5 Remove the slide hammer J-2619-O1, adaptor and the

remover/installer DT-47570.

6 Check that the retaining ring on the shaft is engaged,

by attempting to pull outwards on the tripot joint

housing. Disengagement should not be possible.

Figure 4B3 – 11

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–13

Page 4B3-13

7 Lightly lubricate the outer driveshaft splines (1) with

the recommended final drive l ubricant, then pull

outward (arrow) by hand, on the wheel speed sensor

pulse ring (2) to allow the splined outer shaft to

engage with the front wheel hub. T ake care not to

damage the wheel speed sens or ring in the process.

NOTE

As the splined shaft is designed to be an

interference fit to the hub, use the old retaining

nut and washer to fully install the shaft through

the front wheel hub.

Figure 4B3 – 12

8 Support the front control arm with a floor jack fitted

with a block of wood (1) on the lifting pad. Raise the

jack until the front control arm is fully supported.

9 Reinstall the front control arm ball joint stud into the

front control arm, fit a new nut, then use a torque

wrench (2) to tighten to the correct torque

specification.

(  ) Front control arm ball joint

stud nut torque specification ................................55 N.m

Figure 4B3 – 13

10 Raise the floor jack under the front control arm until

the strut is fully raised into the strut tower.

11 Hold the strut rod with a 10 mm socket and suitable

equipment, then fully remove the strut rod retaini ng nut

and discard.

12 Install a new strut rod retaining nut (3), then use a 10

mm socket to hold the strut rod (2) from turning.

13 Tighten the upper strut rod retaining n ut (3) to the

correct torque specification, using a 24 mm ring

spanner with a torque wrench attached.

(  ) Upper strut locating plate

retaining nut torque specification .........................55 N.m

14 Reinstall the dust cover (1).

Figure 4B3 – 14

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–14

Page 4B3-14

15 Install holding tool KM-468 to two of the wheel studs

and secure with two reversed wheel nuts. Support the

outer end of the holding tool on a safety stand (1).

16 Remove the old hub nut and washer. Reinstall the

washer with a new nut and tighten to the correct

torque specification.

(  ) Front driveshaft outer

retaining nut torque

specification................ Stage 1 .........................130 N.m

Stage 2 ... Loos en nut until loose

Stage 3 .........................200 N.m

17 If it was the left driveshaft that was removed, check

the final drive lubricant level, topp ing up as required.

Refer to 2.1 Checking Final Drive Lubrica nt L evel, in

this Section.

18 Reinstall the road wheel, aligning the marks made

prior to removal and secure with attaching nuts. Figure 4B3 – 15

19 Remove the safety stands and lower vehicle.

20 Tighten road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern,

refer to Section 10 Wheels and T yres.

Road wheel attaching

nut torque specification............................110 – 140 N.m

21 Install the centre wheel nut cap.

22 Bounce the vehicle up and down several times to settle the suspension.

23 Check the wheel alignment, refer to 2.2 Wheel Alignment Checking and Adjustment in Section 3B Front

Suspension – AWD.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–15

Page 4B3-15

2.5 Driveshaft Outer Constant Velocity Joint

LT Section No. – 06-200

NOTE

Disassembly of the outer constant velocity joi nt is

not recommended. With normal handling, the

constant velocity joint balls will not be dislodged

but, should the joint become disassembled while

handling, then the assembl y must be repl aced.

NOTE

There are two service kits available for this outer

constant velocity joint:

• A Boot Kit comprising the boot, two boot

clamps and a retaining ring.

• A constant velocity Joint Kit, that includes the

Boot Kit, plus a new constant velocity joint

and lubricant of the correct type and quantity.

• For lubricant quantities, refer to

5 Specifications, in this Section.

Remove

1 Remove the driveshaft. Refer to 2.4 Driveshaft Assembly, in this Section.

2 Clean the outside of the assembly with suitable cleaning solvent before removing.

To reduce the possibility of boot damage

during the clamp removal process, it is

recommended that rag be placed over the

boot before using a screwdriver to release

clamp tension.

3 Using a small s c rewdriver or similar, lever the boot

clamp tang at the constant velocity joint (larger clamp)

sufficient to release the clamp tension. Disca rd the

removed clamp.

Figure 4B3 – 16

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–16

Page 4B3-16

4 Push the boot back from the constant velocity joint and

back over the driveshaft.

5 Turn the constant velocity joint to maximum turn angle

and wipe excess grease from the inner race.

6 With the driveshaft held in a vice fitted with soft jaws,

use a brass drift on the inner race and hammer to

dislodge the snap ring on the end of the driveshaft and

remove the constant velocity joint.

Figure 4B3 – 17

7 Remove the snap ring (1) and discard, as it must be

replaced on reassembly of the outer const ant velocity

joint to the driveshaft.

8 Clean the driveshaft with suitable cleaning solvent an d

inspect the splines for damage.

Figure 4B3 – 18

9 Remove the small boot clamp from the driveshaft end of the boot and di scard.

10 Slide the boot from the driveshaft.

NOTE

If a constant velocity joint requires replacem ent, it

is strongly recommended that a new boot be

fitted.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–17

Page 4B3-17

Reinstall

1 Divide 155 gm of the specified grease into thirds. Apply one third into the new constant velocity joint, working into

the joint. Apply the remainder to the new boot.

2 Slide a new small clamp onto the driveshaft, then install the boot over the driveshaft, small end first. T ake care not

to damage the boot on the driveshaft splines during the installation pr ocess. Do not install any boot clamps at this

time.

3 After checking that a NEW driveshaft snap ring is

installed and undamaged, install the ne w constant

velocity joint onto the driveshaft, using a plastic faced

hammer.

NOTE

To check for correct installation, tug on the

driveshaft in an attempt to dislodge it from the

constant velocity joint.

Figure 4B3 – 19

4 Install a new, large boot clam p to secure the boot to the constant velocity joint end, using T ool No. J22610. Load

clamp until the gap between the 'ears' is reduced to 1 – 2 mm.

5 Position the small end of the boot into the groove in

the driveshaft, then install the small clam p into position

in the boot groove.

6 Use Tool No. J226 10 to secure the boot, again until

the gap between the 'ears' is between 1 and 2 mm.

7 Reinstall the driveshaft to the vehicle. Refer to

2.4 Driveshaft Assembly in this Section.

Figure 4B3 – 20

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–18

Page 4B3-18

2.6 Driveshaft Inner Tripot Joint

NOTE

There are two service kits available for the

driveshaft inner tripot joint:

• A Boot Kit comprising the boot, two boot

clamps, a slinger and a retaining ring.

• A constant velocity Joint Kit, that includes the

Boot Kit, plus a new constant velocity joint

and lubricant of the correct type and quantity.

• For lubricant quantities, refer to

5 Specifications, in this Section.

Disassemble

LT Section No. – 06-200

1 Remove the driveshaft. Refer to 2.4 Driveshaft Assembly, in this Section.

2 Clean the outside of the tripot assembly with suitable cleaning solvent before disassembly.

3 Clamp the driveshaft in a vice fitted with soft jaws.

4 Using a small s c rewdriver (1) or similar, lever the boot

clamp tang at the constant velocity joint (larger clamp),

while using long nosed pl iers (2) to tension the clamp

(3). Once released, remove and discard the clamp (3).

5 Push the boot from the tripot joint ho using and back

over the driveshaft.

Figure 4B3 – 21

6 If the reason for disassembli ng the tripot joint is to

replace the boot only, wipe excess lubricant from the

tripot spider and use whiteout or similar, to mark the

relationship of the spider to the tripot housing.

NOTE

This is necessary to ensure that worn parts are

reassembled in their original positions.

Figure 4B3 – 22

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–19

Page 4B3-19

NOTE

There may be some resistance to separating the

trunnions from the outer body because of

distortion (1) created for production purposes.

Removing one trunnion (2) at a time until the

three are released, will overc ome the pro blem.

Figure 4B3 – 23

7 Using suitable circlip pliers, remove the circlip securing

the tripot spider to the driveshaft.

8 Remove the tripot spider and trunnion assembly (2)

from the driveshaft, using a brass drift (1) and hammer

on the spider as shown and not on one of the

trunnions.

NOTE

Provided excessive force is not used, the

trunnions will remain on the spider.

9 Remove the small boot clamp, then slide the boot from

the driveshaft. Discard the removed clamp.

Figure 4B3 – 24

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–20

Page 4B3-20

Inspect

1 After cleaning components, check:

a. The tripot housing grooves for wear and/or scoring.

b Trunnions for excessive play or binding.

c Boot for cracks or other damage.

d The tripot and driveshaft splines (1) for wear or

damage.

NOTE

The groove (2) in the driveshaft is used to locate

the smaller end of the boot.

2 If any of the above conditions are found, then replace

the tripot assembly or the complete driveshaft.

Figure 4B3 – 25

Reassemble

1 Slide a NEW small clamp over the dr iveshaft, then slide the boot over the driveshaft splines, taking care not to

damage the boot on any sh arp edges. Do not apply any cl amps at this stage.

2 Reinstall the tripot spider and trunnions, noting the

following:

a The spider spline chamfer (1) faces inwards.

b Install the spider, using a tube or socket and a

plastic hammer.

c Retain the tripot spider usi ng a NEW circlip. Do

not over-stretch the circlip during installation.

Figure 4B3 – 26

3 Apply approximately 2/3 (140 g ± 5 grams) of the supplied lubricant to the inner half of the tripot hous ing and the

remainder (approximately 60 ± 5 grams) into the boot.

4 If reinstalling the orig inal tripot assembly (e.g. boot damage onl y), align the marks made before disassem bly and

carefully reinstall the trunnions into the tripot housing.

5 Gently stroke the driveshaft to the end of the housing to exude the grease aroun d the trunnions, then return the

spider to the mid-point position.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–21

Page 4B3-21

6 Slide the lar ger end of the boot over the end of the

tripot joint, then secure with a new clamp (1) ,

tightening with long nosed pliers (2) until the clamp

engages with the last of the retaining barbs.

Figure 4B3 – 27

7 Locate the small boot en d into driveshaft groove, then

install the new, small boot clamp.

8 After checking that the boot is not twisted, tighten the

small boot clamp, using clamp pliers, Tool No. J22612,

until the distance between the clamp 'ears' is between

1 to 2 mm.

9 Plunge the tripot joint in a nd out to check that there

are no leaks.

Figure 4B3 – 28

10 Reinstall the driveshaft. Refer to 2.4 Driveshaft Assembly, in this Section.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–22

Page 4B3-22

2.7 Bearing Housing/Final Drive Carrier

Outer Oil Seal

LT Section No. – 06-200

NOTE

If the bearing housing or front final drive

assembly, inner oil seal fails, then the respective

assembly will need to be removed from the

vehicle to effect repairs. Refer to

3.1 Bearing Housing Assembly, Remove or

3.2 Front Final Drive, Remove in this Section.

Replace

If the seal failure occurred at the outer final drive

location, drain the lubricant into a suitable

container, before proceeding. Refer to

2.2 Changing/Flushing Final Drive Lubricant, in

this Section.

• The removed driveshaft must be handled

with care. Do not rest th e shaft or bellows

for any longer than necessary. Shaft is

not to be allowed to hang free on one end.

• Driveshaft joint deflection should be kept

to a minimum by resting the driveshaft on

three wooden blo cks, as sh own.

1 Remove the driv eshaft on the side where the seal

failure has occurred. Refer to 2.4 Driveshaft Assembly,

in this Section.

Figure 4B3 – 29

2 Using a seal removal tool such as E308 or commercial equivalent, remove the failed seal from either the front final

drive ('A') or the driveshaft bearing support housing ('B'), refer to Figure 4B 3-30.

NOTE

The engine exhaust pipe is sho wn removed in ' B',

to more clearly show the oil seal removal.

Figure 4B3 – 30

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–23

Page 4B3-23

3 Carefully ins pe ct the seal running surface of the driveshaft for evidence of wear, nicks or scratches. If badly worn or

the damage is not repairable, then the particular tripot joint must be replaced.

Refer to 2.6 Driveshaft Inner Tripot Joint, in this Section.

4 Before installing a new oil seal, lightly lubricate with Mobilgrease XHP 222, with the recesses between the seal lips

being filled to approximately 50%.

5 Using seal i nstaller AU 410, install the oil seal (1) to

the final drive carrier housing (2) until fully seated.

NOTE

While the final drive is shown, use Tool No.

J 21426 to install the new seal to the support

bearing housing.

6 Reinstall the driveshaft.

Refer to 2.4 Driveshaft Assembly, in this Section.

7 If required, with the vehic le on level ground, fill the

front final drive with the recommended lu bricant.

Refer to 2.2 Changing/Flushi ng Final Drive Lubricant,

in this Section.

Figure 4B3 – 31

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–24

Page 4B3-24

2.8 Pinion Oil Seal

LT Section No. – 05-290

Replace

Apart from the fact that it is the front propeller shaft that needs to be removed (rather than the rear), the procedure for the

front final drive pinion oil seal replacement is the same as that described for the rear final drive assembly.

Refer to Section 4C2 Front Propeller Shaft & Universal Joints and Section 4B1 Rear Final Drive & Driveshafts.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–25

Page 4B3-25

2.9 Pinion Flange

LT Section No. – 05-290

Replace

Apart from the fact that it is the front propeller shaft that needs to be removed (rather than the rear), the procedure for the

front final drive pinion flange replacement is the same as that described for the rear final drive assembly.

Refer to Section 4C2 Front Propeller Shaft & Universal Joints and Section 4B1 Rear Final Drive & Driveshafts.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–26

Page 4B3-26

3 Major Service Operations

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. W h ere specified in this section, fasteners MUST be rep laced with parts of the

same part number or an approved equivalent. Do not use fasten ers of an inferior quality or substitute desig n.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be replaced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanic al thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 Bearing Housing Assembly

LT Section No. – 06-200

Remove

1 Remove the right driveshaft. Refer to 2.4 Driveshaft Assembly, Remove, in this Section.

2 Loosen the three bolts securing the bearing housing

assembly (1) to the oil pan. Remove the lo wer and

rear bolts.

NOTE

The right side exhaust pipe is only shown

removed to more clearly show the support

bearing location and mo unting.

3 For the V6 engine, remov e all three bolts.

NOTE

While the front bolt cannot be removed at this

stage, it can be fully unscrewed.

GEN III V8 Engine

4 To fully remove the third bolt, it will be necessary to

raise the engine. Working from under the vehicle,

remove the 18 mm nuts securing both front engine

mounts to the crossmember cradle, using a deep

socket and suitable socket equipment.

5 Remove c ylind er No. 2 spark plug lead by first t wisting

the boot to break the seal, then pull on the boot, taking

care not to pull on the lead itself.

6 Using a deep 18 mm socket, universal joint and

suitable socket equipment, ins erted between the front

two exhaust manifold branches, engage with, then

remove the upper, right hand engine mount nut.

Figure 4B3 – 32

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–27

Page 4B3-27

7 Raise the engine enough to allow the removal of the third b earing housing assembly retai nin g bolt. Once removed,

lower the engine back onto the mounts.

NOTE

Lowering the engine is necessary to achieve

optimum clearances for the bearing housing

assembly removal.

All AWD

8 Remove the bearing housing assembly from the engin e oil pan, rotating the assembly to provide sufficient

clearance.

Disassemble

1 With the bearin g housing supported in a vice fitted with

soft jaws (1), use seal remover E308 or a commercial

equivalent, to remove the outer oil seal (2) from the

support bearing housing (3).

Figure 4B3 – 33

2 Using suitable circlip pliers (1), remove the outer

bearing retaining circlip (2).

Figure 4B3 – 34

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–28

Page 4B3-28

3 Slide the conn ecting sleeve and outer ball b earing

race (1) from the housing (2).

NOTE

It may be necessary to bump the housing on a

piece of wood to dislodge the bearing/sleeve

assembly.

4 Remove the O-ring seal from the inner end of the

connecting sleeve and discard.

Figure 4B3 – 35

5 Using suitable circlip pliers (1), remove the ball

bearing retaini ng circlip (2) from the connecting sleeve

(3).

Figure 4B3 – 36

6 Using a drift/tube/socket (1) with an OD of 38 mm and

press plates J22912-01 or equ ivalent, press the

connecting sleeve (2) from the outer ball bearing (3).

• Do not allow the connecting sleeve to

drop to the floor.

• Discard the bearing after removal as the

ball bearings may have been damaged in

the removal process.

Figure 4B3 – 37

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–29

Page 4B3-29

7 Support the bearin g housing over press plates, then

use AU 410 and a drift (1) to press the needle roller

bearing and inner oil seal from the housing. Discard

the removed oil seal and needle roller bearing.

Figure 4B3 – 38

Inspect

Wear eye protection, to avoid personal injury.

1 Wash all components in a suitable solvent and blow dry.

2 Check for spline wear and/or damage in the connecting sleeve and for excess wear at both seal contact or roller

bearing areas. Repl ace the sleeve if damage/wear is detected.

3 Check the housing for cracks or other dam age. Also check that neither bearing is a loose f it in the housing. While

the outer ball bearing is a sliding fit, it should not be loose. If excess clearance or damage is determined, replace

the housing.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–30

Page 4B3-30

Reassemble

1 Pack a NEW needle rol ler bearing with Mobilgrease

XHP 222 and press into the housing (1) using Tool AU

410 and a suitable drift (2).

NOTE

There is no machined flange to limit the

installation depth of the needle roller bearing.

Therefore, the needle roller bearing should be

installed to a depth of 15 mm from the end face

of the housing (dimensio n ' A ').

Figure 4B3 – 39

2 Pack the ball bearing (1) with Mobilgrease XHP 222

and press the connecting sle eve (2) into th e bearing,

using Tool J22912-01 that has previously been

adjusted to a loose fit over the connecting shaft. With

the flat side of the press plates against the bearing,

the press load will be taken on the inner race.

3 Install a new bearing retaining circlip, using suitable

circlip pliers.

4 Smear a new O-ring with Mobilgrease XHP 222 and

install into the needle roll er end of the connecting

sleeve.

5 Pack 30 – 50% of the bearing housing recess volume

with Mobilgrease XHP 222 (approximately 9 grams).

Figure 4B3 – 40

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–31

Page 4B3-31

6 Slide the connecting sleeve and ball bearing (1) into

the bearing housing (2), seati ng with a plastic

hammer.

7 Install a new bearing to housing retaining cir c lip, using

suitable circlip pliers.

Figure 4B3 – 41

8 Before installing new oil seals, lubricate with

Mobilgrease XHP 222, with the recesses between the

seal lips being filled to approximately 50%.

9 Install the outer seal (1), using seal installer J 21426

until the seal is installed, flush with the end of the

housing.

Figure 4B3 – 42

10 Install the inner seal using sleeve E18 91-6 (also

released as 3A8-6), ensur ing that the seal is square to

the housing and installed until the outer seal surface is

flush with the housing (1).

Figure 4B3 – 43

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–32

Page 4B3-32

Reinstall

Reinstallation is the reverse of the removal procedure except for the items detailed here.

1 Ensure that the splines of the intercon necting shaft are lubricated with Mobilgrease XHP 222, then engage the

shaft splines with those in the connecting sle eve.

2 Slide the housing assembly into the interconnecting shaft a nd rotate to install until the housing flan ges contact the

engine oil pan.

NOTE

Insert the front bolt into the housing before

installing the housing into the vehicle.

3 Reinstall the th ree housing retaining bolts, then tighten to the correct torque specification.

Bearing housing to engine oil pan

retaining bolt torque specification.........................45 N.m

NOTE

On GEN III V8 engined vehicles, the engine must

be raised to allow clearance between the right

side engine mount and the bearing housing,

before installing the front bolt.

4 Lower the engi ne, ensuring that the heat shields are each located correctly on their locating pins.

5 Ensure that the inner splin es of the right side driveshaft are lubricated with Mobilgre ase XHP 222, then reinstall the

driveshaft. Refer to 2.4 Driveshaft Assembly, Reinstall, in this Section.

6 Install NEW engin e mounti ng nuts to the engine mountings and tig hten to the correct torq ue specification.

Engine mount retaining nut (u pper

and lower) torque specification ............................80 N.m

7 On GEN III V8 engined vehicles, reinstall the spark plug lead to cylinder No. 2.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–33

Page 4B3-33

3.2 Front Final Drive Assembly

LT Section No. – 05-250

Remove

GEN III V8 Engine

1 Remove the air cleaner assembly. Refer to Section 6C3-3 Service Operations.

2 Remove the heat shield (2) protecting the Powertrain

Control Module (PCM) by pulling up evenly on each

end. Set to one side.

3 Remove the PCM cover (1) and set to one side.

4 Remove the PCM (3) from the engin e compartment.

Refer to Section 6C3-3 Service Operations.

5 Remove the two screws (5) securing the PCM cradle

(4) to the inner fender skirt, then remove the cradle

from the engine compartment.

Figure 4B3 – 44

All AWD

6 Raise the vehicle, and support in a safe manner. Refer to Section 0A General Information, for the location of

jacking and support points.

7 Mark the relationship of the rear transmission crossmember to the two side rails. Remove the rear transmission

crossmember. Refer to Section 7F Transfer Case and Adapter Housing.

NOTE

Support of the transfer case is not required

unless the rear mount bracket is also removed.

Take care not to damage the heated oxygen

sensor/s during the exhaust pipe removal

procedure.

8 Disconnect the left side e xhau st pipe from the exhaust manifold and the flange behind the catalytic converter.

Refer to Section 8B Exhaust System.

9 Remove the left side exhaust manifold. Refer to Section 6A1 Engine Mechanical (V6 engine) or

Section 6A3 Engine Mech anical (GEN III V8 engine).

NOTE

For the GEN III V8 engine, remove the exhaust

manifold from the engine bay, in the gap left by

the removed air cleaner assembly.

10 Loosen the four bolts (1) securing the left side engine mount bracket to the engine block, then rem ove the upper

engine mount to bracket nut (2), using a deep socket. Discard the removed nut.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–34

Page 4B3-34

NOTE

View ‘A’ shows the GEN III V8 arrangement,

while view ‘B’ shows the V6.

Figure 4B3 – 45

11 Drain the lubricant from the front final driv e assembly. Refer to 2.2 Changing/F lushing Final Drive Lubricant, in this

Section.

12 Completely remove the front propeller shaft from the vehicle.

Refer to Section 4C2 Front Propeller Shaft & Universal Joints.

13 Remove both front driveshafts. Refer to 2.4 Driveshaft Assembly, Remove, in this Section.

NOTE

This operation will have disconnected the front

control arm ball joints.

14 Remove the four flanged nuts (1) securing the left

side, upper underbody front side ra il brace (2).

Remove the brace (2) from the vehicle.

NOTE

The view is from under the vehicle looking

upward.

Figure 4B3 – 46

15 Remove the bearing housing from the right side of the engine oil pan.

Refer to 3.1 Bearing Housing Assembl y, Remove , in this Section.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–35

Page 4B3-35

16 Insert final drive ring gear rotation T ool No. DT-47573

into the left side of the final drive and engage the

differential pinion pin.

17 Using a suitable length rod (1) and a plastic hammer,

tap the end of the rotation tool to disengag e the

intermediate shaft snap ring from the right side axle

gear in the differential. Remove the interconnecting

shaft from the engine oil pan, on the right side.

Figure 4B3 – 47

18 Support the engine, then remove the loose ned, left side engine mount bracket bolts (refer to Step 10 in this

procedure). Lift the bracket from the engine ba y and the heat shield from the mount.

19 Disconnect the final drive breather pipe bracket bolt (1), then remove the steel breather pipe (2) from the final drive

housing, using side cuttin g pli ers (3) to prise the pipe and O-ring free.

NOTE

While view ‘A’ shows the GEN III arrangement,

view ‘B’ shows the V6.

Figure 4B3 – 48

20 Remove the four final drive assembl y to engine oil pan securing bolts.

NOTE

At this stage, it will not be possible to remove an y

of the bolts completely from the final drive

housing.

21 Using a suitable lever, prise the fina l drive assembly from the engine oi l pan, releasing the locating do wel at the

pinion end and the final driv e cover boss from the engine oil pan.

22 Remove the final drive assembl y from under the vehic le by lowering, pinion end first and out through the space left

by the removed side rail brace.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–36

Page 4B3-36

Reinstall

Reinstallation of the front final drive assembly is the reverse of the removal procedure, except for the following:

1 Apply Loctite 2 43 or equivalent to the cleaned final drive attaching bolt threads, then insert the bolts into the final

drive mounting holes. The longest bolt should be in the pinion nose location.

2 Apply a smear of final drive lubricant to the locating boss on the final drive cover housing, before reinstalling into

place in the side of the engine oil pan. Levering the assembly into place may be required to fully install the pinion

locating dowel.

3 Reinstall the fo ur final drive assembly retainin g bolts and tighten to the correct torque specification.

 Front final drive assembly to engine

oil pan retaining bolts torque specification ...........70 N.m

4 Ensure that the splines on the interconnecting shaft are lubricated with the recommended final drive lubricant

before reinstalling into the final drive assembly. Gently tap the shaft snap ring into place in the left side differential

axle gear, using a plastic hammer. Once installed, tug on the shaft to check that the retaining ring is engaged in the

side gear groove.

5 Replace the high temperature O-ring seal to the end of the breather pipe, smear with the recommended final dr ive

lubricant, then reinstall the pipe into the final drive housing.

6 Secure the pipe with the breather pipe bracket bolt and tighten to the correct torque specification.

Front final drive breather pipe bracket

bolt torque specification GEN III V8....................22 N.m

HFV6..............................9 N.m

7 Reinstall the e ngine mount heat shield, then manoeuvre the engine mount bracket into position. Reinstall the four

bracket to engine block retaining bolts and tighten to the correct torque specification.

Right side engine mount brac ket to

cylinder black bolt torque specification.................50 N.m

8 Reinstall the e xhaust manifold after cleaning the mating surfaces and fitting a new gasket.

Refer to Section 6A1 Engine Mechanical – V6 Engine or S ection 6A3 Engine Mechanical – GEN III V8 Engine.

Tighten the retaining bolts to the correct torque specification in two stages, working from the centre, outwards.

GEN III V8 exhaust manifold

bolt torque specification ...................... Stage 1 – 15 N.m

Stage 2 – 25 N.m

V6 exhaust manifold to cylinder

head bolt torque specification ..............................20 N.m

9 Reinstall the u pper underbody front side rail brace, then se cure with the four retaining nuts, tightening to the correct

torque specification.

Underbody front side rail brace

nut torque specification........................................25 N.m

10 Reinstall the front propeller shaft. Refer to Section 4C2 Front Propeller Shaft & Universal Joints.

11 Reinstall the exhaust pipe. This will require a new gasket being fitted to the cleaned rear mounting flange.

12 Install all exhaust related fasteners and ti ghten to the correct torque specifications.

Refer to Section 8B Exhaust System.

13 Reinstall the rear transmission crossmember, aligning marks made before removal. Install all fasteners and tighten

to the correct torque specification.

Transmission rear crossmember

attaching bolts torque specification – All..............55 N.m

14 Ensure that the outer splines of the interconn ecting shaft are lubricated with Mobilgrease XHP 222, then slide the

housing assembly onto the interconnecting s haft, engaging the splines, until the housing flanges contact the oil

pan. Refer to 3.1 Bearing Housing Assembly, Reinstall, in this Section.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–37

Page 4B3-37

15 Reinstall the three bearing housing assembly to engine oi l pan retaining bolts and tighten to the correct torque

specification.

Bearing housing to engine oil pan

retaining bolt torque specification.........................45 N.m

16 Reinstall both driveshafts. Refer to 2.4 Driveshaft Assembly, Reinstal l, in this Section.

17 After checking that the engine mount heat shield/s are in the correct position, lower the engine weight onto the

engine mounts, reinstall and tighten NEW engine mount to crossmember nuts to the correct torque specification.

 Engine mount retaining nut

torque specification – All......................................80 N.m

18 Fill the front final drive with the recommended lubricant. Refer to 2.1 Checking Fin al Drive Lubricant Level and

2.2 Changing/Flushing Final Drive Lubric ant, in this Section.

19 Reinstall the road wheels, aligning marks made on removal but do not tighten at this stage.

20 Lower the vehicle to the ground, bou nce the front suspension several times, then push backwards and forwards to

settle the suspension.

21 Tighten the road wheel nuts working in a ‘star’ pattern to the correct torque specific ation.

Refer to Section 10 Wheels and Tyres.

Road wheel attaching

nut torque specification............................110 – 140 N.m

22 Check and correct (as required) the front wheel alignment.

Refer to 2.2 Wheel Alignment Checking a nd Adjustment, in Section 3 Front Suspension.

23 reinstall the centre wheel nut covers.

24 Road test the vehicle to check for correct vehicle operation.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–38

Page 4B3-38

3.3 Removed Final Drive Assembly

LT Section No. – 05-250

Figure 4B3-49

Legend

1 Pinion Nut

2 Pinion Flange

3 Slinger

4 Pinion Oil Seal

5 Pinion Outer (Tail) Bearing Cone

6 Pinion Outer (Tail) Bearing Cup

7 Collapsible Spacer

8 Pinion Position Shim

9 Pinion Inner (Head) Bearing Cup

10 Pinion Inner (Head) Bearing Cone

11 Hypoid Pinion Gear

12 Drain Plug

13 Filler Plug

14 Carrier Housing

15 Driveshaft Oil Seal

16 Differential Position Shim

17 Differential Bearing Cup

18 Differential Bearing Cone

19 Hypoid Ring Gear

20 Differential Case

21 Ring Gear Retaining Bolts (8 places)

22 Cover Aligning Hollow Dowel

23 Cover

24 Cover Retaining Bolts (10 places)

25 Pinion Nose Angle Locating Dowel

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–39

Page 4B3-39

Disassemble

Final Drive Cover

1 Using Tool No. E308 or a commercial equival ent,

remove the oil seal (1) from the cover housi ng (2) and

discard.

Figure 4B3 – 50

2 Support the final drive assembly, with the cover bolts

facing upward.

3 Remove the 10 cover bolts.

4 Use a suitable lever at each of the points provided ('A',

'B' and 'C'), break the sealant seal, then lift the cover

from the carrier housing and the sleeve dowel (1). Set

the cover to one side.

5 Using a suitable scraper, remove the sealant remains

from the cover and carrier housings.

Figure 4B3 – 51

Before proceeding with the disassembly process, the gear tooth contact should be e xami ned and recorded as a

comparison when the reassembly takes place.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–40

Page 4B3-40

Examining Gear Tooth Contact

Wear eye protection when using compressed

air to dry washed components.

Do not allow bearings to spin when applying

compressed ai r in the drying-off process.

1 Lift the differential and ring gear assembly from the carrier housing, then wash all components in a suitable solvent

and blow dry, using compressed air.

2 Apply light oil to the roller bearings, then apply a thin coating of a gear marking compound to the ring gear teeth.

3 Reinstall the ring gear and differentia l to the carrier housing, then reinstall the cover and the 10 bolts, tightening

each to the correct torque specification.

Final drive cover bolt

torque specification..............................................45 N.m

4 Install ring gear rotation tool DT-47573 to engage with the differential pin and grasp the tool to apply a load to the

ring gear while rotating the pin ion a bout 10 times in each direction.

5 Remove the 10 bolts securing the cover to the carrier housing, then remove the cover an d the ring gear/differential

assembly.

6 Examin e the ring gear tooth marking and record. The most convenient method would be to use a di gital camera.

Refer to 'Ring Gear and Pinion Contact Pattern', in 3.3 Removed F inal Drive Assembly, Reassemble,

Section 4B1 Rear Final Drive and Drive Shafts, for typical and acce ptable tooth contact patterns.

Drive Pinion

1 Mark the relationship of the pinion flange to the pinion

shaft (1), using correction fluid (e.g. 'whiteout'). This

step will minimise the chance of pinion flange runout,

should the pinion and flange not require replacement.

Figure 4B3 – 52

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–41

Page 4B3-41

2 Install packing ring, Tool No. DT-47580 into the pin ion

flange recess, aligning the holes with those in the

pinion flange.

3 Using two of the propeller shaft constant velocity joint

bolts (1), with flat washers, secure the holding bar,

Tool No. J 8614-10 (part of Tool No. J 8614-O1) to the

pinion flange (2). The central recesses in the holding

tool should face inward.

4 Using a 30 mm deep socket and bar (3), loosen then

remove the pinion flange retaining nut.

NOTE

A suitable length of pipe installed over the end of

the socket bar will reduce the effort required to

loosen the pinion flange nut.

Figure 4B3 – 53

5 With Tool No. J 8614- 10 and packing ring, Tool N o.

DT-47580 still installed, thread the forcing screw, Tool

No. J 8614-3, into the adaptor, Tool No. J 8614-2.

Install this sub-assembly into holder, Tool No. J 8614-

10, then rotate through 45° to locate in the recesses in

J 8614-10.

6 While holding J 8614-10, use a socket and b ar (1) to

rotate the forcing screw J 8614-3 to remove the pinion

flange (2).

7 Remove the tools from the pinion flange.

Figure 4B3 – 54

8 Prise the pinion oil se al (1) from the carrier housing,

using Tool E308 or a commercial equivalent.

9 Use a soft faced hammer, drive the pinion from the

outer (tail) bearing cone.

NOTE

With the offset of the carrier housing, it will be

necessary to hold the pinion to one side, as it is

being driven from the outer bearing. If not, the

pinion head will strike the carrier housing before

being released from the bearing.

10 Remove the outer (tail) pinion bearing and collapsible

spacer from the final drive housing.

Figure 4B3 – 55

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–42

Page 4B3-42

11 Again using Tool No. E308, re move the carrier bearing

oil seal from the carrier housing.

Figure 4B3 – 56

Wear eye protection when using compressed

air to dry washed components.

Do not allow bearings to spin when applying

compressed air in the drying off process.

12 Clean all components in a suitable cleaning solvent and blow dry, taking care not to spin an y of the roller bearings

with compressed air. Inspect the pinio n and the bearings for wear and/or damage.

13 To remove the inner pinion bearin g cup, first assemble

the bearing cup remover DT -47571 onto the bolt of

Tool No. E9293 and secure with a nut (1) on each

side.

Figure 4B3 – 57

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–43

Page 4B3-43

14 After clamping the carrier housing in a vice fitted with

soft jaws, insert the bolt and pinion bearing cup

removing tool DT-47571 into the pinion cavity, aligning

the tool with the two cut-outs in the housing.

15 Drive the inner pinion bearing cup from the housi ng

using a hammer.

Figure 4B3 – 58

16 If the pinion bearings are to be replaced, remove the

outer (tail) pinion bearing cup, as follows:

a Assemble pinion bearing cup remover, Tool No.

E9293 with the larger land of the remov er, Tool

No. DT-47571 into the outer (tail) cu p and the

plate (part of Tool No. E9293) over the pinio n

opening in the carrier housing .

b Install the bolt through the p inion bearing cup

remover, bearing cup and pla t e, then install the

thrust race, washer and nut.

c While holding the bolt head, tighten the nut to

remove the bearing cup from the carrier housing.

Figure 4B3 – 59

17 To remove inner bearing cone from the pinion, remove

legs from the ring of Tool No. E1673 MT.

18 Place ring on suitable press pl ates. Install pinion and

adaptors E 1673-A15 into the ring. Use a pr ess (1) to

remove the pinion (2) from the bearing (3). Discard the

removed bearing (3).

NOTE

Do not allow the pinion to drop and hit the floor.

Figure 4B3 – 60

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–44

Page 4B3-44

Differential Assembly

Figure 4B3-61

Legend

1 Differential Case

2 Side Gear Thrust Washer

3 Differential Side Gear

4 Differential Pinion Gear

5 Differential Pinion Gear Thrust Washer

6 Differential Pinion Shaft

7 Locking Roll Pin

1 Secure the differential ho using in a vice fitted with soft

jaws.

2 Using suitable socket equipment (1), loosen the ring

gear retaining bolts (2), working from opposite sides

until all bolts are loosened. Re move and discard all

bolts, as they must be renewed on reassembly.

NOTE

The ring gear bolts have a right hand thread.

Do not use a screwdriver to prise between

ring gear and case.

3 Remove the ring gear from the differential case, either

by using a press or a soft faced hammer. Support the

differential case (or ring gear) durin g this operation to

prevent it from dropping and striking the floor or bench

top.

Figure 4B3 – 62

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–45

Page 4B3-45

4 Using a suitable sized brass drift, separate the two

piece differential case.

Figure 4B3 – 63

5 Using a suitable sized pin punch (1) and ham m er,

remove the differential pinion cross shaft retainer roll

pin.

Figure 4B3 – 64

6 With the differential case (2) held in a vice fitted with

soft jaws, use a suitable sized brass drift (1) and

hammer to drive the differential pinion cross shaft out

from the differential case (2).

7 Lift the pinion gears and thrust washers from the case.

8 Remove the side gears and thrust washers from each

side of the case.

9 If inspection shows that the side bearing cones and

cups are undamaged, the bearing cones may be left

installed on each of the case halv es.

NOTE

If the bearing cones are removed, then the

cones and cups must be replaced with new parts

on reassembly.

Figure 4B3 – 65

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–46

Page 4B3-46

10 If the side bearings are to be replaced, use Tool No.

E1673MT, with E1673N15 adaptors an d distance

piece, E1673B16, to remove the bearing cones (1).

Discard the removed bearings.

Figure 4B3 – 66

Inspect

General Items

• Thoroughly cle an all parts with a suitable, clean solve nt.

• Oil the bearings immediately after cleaning and drying to prevent rust developing.

• Inspect the parts for any major defects.

• Clean the inside of the case before rebuilding and installing the parts, inspect individu al parts as detailed next:

Gears

• The pattern taken during the d ismantling process should help in judging if the ring gear and pinion can be re-used.

Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring is the result of excessive shock loading or

the use of an incorrect lubricant.

• Scored differential gears must be replaced. Examine the teeth and thrust surface of all differential gears.

• Check the fit of the side gear hubs in the case. Wear on the hub of the side gear can cause a “clunking” noise

when the vehicle is driven at low speeds.

• Check that none of the thrust washers shows signs of wear, cracks or burrs.

• Wear on splines, thrust surfaces, or thrust washers can contribute to excessive driv eline backlash.

• Inspect differential pinion gear bores an d shaft surfaces for scoring.

Bearing Cups

• Check bearing cups for rings, scores, gal ling or erratic wear patterns. For various roller bearing abnormal wear

conditions and their causes, refer to 4.4 Bearing Diagnosis, in Section 4B1 Final Drive & Driveshafts.

• Pinion bearings cups must be solidly seated. Check by attempting to insert a 0.05 mm feeler between these cups

and the bottom of their bores. Ensure that seating surfaces are clean and free from burrs or raised metal.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–47

Page 4B3-47

Bearing Cone and Roller Assemblies

• The bearings in the differential case a nd the rear (head) pinion should be checked before being removed from the

differential case or pinion. If these bearing cup and cone assemblies are removed, they must be discarded and

replaced with new parts.

• When lightly oiled and rotated in their respective cups, bearing cone rollers must turn without roughness. Examin e

the roller ends for wear. Step-wear on the roller ends indicat es the be aring preload was incorrect or the rollers were

slightly misaligned. Refer to 4.4 Bearing Diagnosis, in Section 4B1 Final Drive & Driveshafts, for examples of

abnormal bearing wear and their causes.

Pinion Flange

• Check the flange mating face run-out. Refer to 5 Specifications for the ma ximum Total Indicated Runout (TIR).

• The end of the flange that contacts the beari ng cone and the seal surface must be free from imperfections.

• Check that the constant velocity (constant velocity) joint bolt threads are in good condition. Clean out any residual

thread sealant by using an 8 mm tap.

Carrier and Cover Housings

• Check that the differential bearing bores are smooth and the differential carrier bearing preload spacer washer

abutment faces are not damaged.

Differential Case

• Carefully examine the cas e fo r damage and ensure that bearing seating surfaces are free from dirt and burrs. The

bearing assemblies will fail if they do not seat correctly against the shoulder on the housing.

• The ring gear spigot and mating surfaces for the differential case halves should be clean and free from burrs.

• Check that the differential pinion pin bores in the differential case are not oval.

• Check that the mating surfaces for the two case halves are clean and free from burrs.

• The differential side gear journal bores should be clean and free from scoring. The thrust surfaces for the

differential case halves should be clean and free from burrs.

Reassemble

Differential

1 Before assembly, lubricate all differential parts with the

recommended front final drive lubricant.

2 Reinstall a si de gear thrust washer (1) over each side

gear (2), ensuring that the thrust washer is installed in

the orientation shown.

3 Reinstall o ne side gear and thrust washer into the

recess in the larger differential case half.

4 Mesh the two pinion gears with the installed side gear

and align with the pinio n shaft roll pin hole in the

differential case.

NOTE

To overcome the risk of damaging the thrust

washers through misalignment, using a

fabricated wooden dowel of 18.5 mm diameter

(100 mm long) can be us ed to align both pi nions

and their thrust washers before installation of the

pinion shaft. Figure 4B3 – 67

5 Align the roll pin hole by sight, in the differential case with the hole in the differential pinion pin, then use a brass

drift and hammer to drive the pinion pin i nto position, until the roll pin hole is in alignment.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–48

Page 4B3-48

6 Using a suitable pin punch and hammer i nstall a new

roll pin (1) through the differential case until the pin

protrudes through on the machined case half by about

6 mm. This will ensure a positive location for the case

cover.

7 Reinstall the re maining side gear and thrust washer

into the smaller case half.

Figure 4B3 – 68

8 While holding the side gear and thrust washer in

position with a finger, reinstall the case cover over the

differential case, meshing the differential gears and

aligning the roll pin with the accompanying hole in the

case cover (1).

9 Turn the differential assembly over, then Install the

ring gear into position on the differential case, aligning

the bolt holes.

NOTE

• For ease of assembly, heating the ring gear

on an electric hot plate until it is hot to the

hand, before installation.

• Under no circumstances is a flame to be

used to heat the ring gear.

• Making up two threaded guide pins to align

the ring gear would be an advantage. The

thread is 7/16" UNF 20 TPI right hand thread. Figure 4B3 – 69

10 Install and gradually tighten new ring gear at taching

bolts (1) evenly until the ring gear is fully installed to

the differential case.

11 With the differential case held in a vice fitted with soft

jaws (2), use a torque wrench (3) to tighten the ring

gear bolts (1) to the correct torque specification.

Ring gear bolt

torque specification............................................140 N.m

Figure 4B3 – 70

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–49

Page 4B3-49

12 If removed, press new side bearing cones (1) to the

differential case (2), until fully installed, using installer,

Tool No. DT-47572.

Figure 4B3 – 71

Drive Pinion – Shim Selection

Gear Set Identification

The drive pinion and ring gear set identification marking ('A' )

('2C04' in this example) is the matching number that

appears on both the drive p inion and the ring gear. When a

new gear set is being installed in a final drive assembly, be

sure the same matching number appe ars on both the drive

pinion and the ring gear.

Gear Set Tolerance

The ring gear and pinio n are manufactured within a

tolerance of a specified distance. The head of each pinion is

marked ('B') with either: a positive (+) number, a negative (-)

number, or zero (0). This number indicates the best running

position for each particular gear set. This dimension is

controlled by the shimming behind the pinion head. When

the shim thickness is decreased the pini on gear is moved

away from the ring gear.

Figure 4B3 – 72

When the shim thickness is increased, the pinion is moved closer to the ring gear. A positive (+) number on the drive

pinion indicates that a thinner shim should be installed. A negative (–) number on the dri v e pinion indicates that a thicker

shim should be used. The marking o n the pi nion is in Imperial units.

Shim Selection Procedure

To select the correct shim thickness:

1 Install the outer (tail) pini on bearing cup (1) to the

carrier housing, as follows:

a Assemble T ool No. E9271 with installer E9271-A

to the outer cup and E9271-B (inverted) to the

inner cup, housing recess.

b Install the bolt through both installers, then the

thrust race, washer and nut.

c Tighten the nut, while holding the bolt head, to

install the bearing cup (1) until fully installed.

Figure 4B3 – 73

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–50

Page 4B3-50

2 Assemble and install the dummy pinion, as follows:

NOTE

Ensure all surfaces of the dummy pinion

components are clean and free from dirt.

a Fit the gauge block (Tool No. DT-47583-3) in to the pinion inner (head) bear ing cup bore.

b Place the oiled outer (tail) bearing cone into the outer (tail) bearing cup, then slide the dumm y pinion stem

(Tool No. DT-47583-1) through the gauge block and the outer (tail) bearing.

c Slide the inner (head) pinion bearing cup and the oiled cone onto the head of the dummy pinion stem. Secure

the pinion plate (Tool No. DT-47583-4) to the dummy pinion stem (T ool No. DT-47583-1) with the supplied

screw (Tool No. DT-47583-6) and tighten securely.

d Slide the pinion spacer (Tool No. DT-47583-2) onto the tail of the dummy pinion stem.

Figure 4B3-74

Legend

1 Dummy Pinion Stem Nut and Washer

2 Spacer

3 Gauge Block

4 Pinion Plate

5 Selection Gauge

6 Pinion Plate Cap Head Screw

7 Dummy Pinion Stem Nut

8 Dummy Pinion Stem Flat Washer

9 Pinion Inner (Head) Bearing Cup and Cone

10 Pinion Outer (Tail) Bearing Cup and Cone

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–51

Page 4B3-51

e Fit the pinion stem washer (1) (Tool No. DT -

47583-8), the nut (2) (Tool No. DT-47583-7) and

tighten until the specified pinion prel oad is

achieved.

NOTE

While tightening the pinion stem nut (2), use a

commercially available dial type torque wrench

to rotate the dummy pinion in both dir ections (as

far as the assembly will allow), a minimum of ten

times to ensure that the pinion be arings are fully

seated.

f Recheck and adjust preload if necessary.

NOTE

Both pinion bearings that are used with the

dummy pinion must be the bearings used for

reassembly.

Figure 4B3 – 75

3 The assembly should look the same as that shown next in a sectioned vi ew through the carrier housing.

4 Install the gauge block (Tool No. DT-47583-5) to the differential bearing bore in the carri er housing.

Figure 4B3-76

Legend

1 Dummy Pinion Stem Nut and Washer

2 Spacer

3 Gauge Block

4 Pinion Plate

5 Selection Gauge

6 Pinion Plate Cap Head Screw

7 Dummy Pinion Stem Nut

8 Dummy Pinion Stem Flat Washer

9 Pinion Inner (Head) Bearing Cup and Cone

10 Pinion Outer (Tail) Bearing Cup and Cone

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–52

Page 4B3-52

5 Using feeler ga uges measure the gap between the selection gauge and the plate of the dummy pinion. Note the

measurement taken. The correct shim thickness will be equal to this measurement plus/minus the marked pinion

adjustment.

• A positive (e.g. +0.002 in) marking indicates that this pinion must be set 2 thousandths of an inch further from

the drive gear, i.e. if the adjustment is +2, then 0.002 in. mu st be subtracted from the shim thickness.

• A negative (e.g. –0.002 in) marking indicates that this pinion must be set 2 thousandths of an inch closer to

the drive gear, i.e. if the adjustment is –2, then 0.002 in. mu st be added to the shim thickness.

6 Remove all tools from the carrier ho using.

7 Fit the selected shim (1) under the same inner (head)

pinion bearing cup (2) that was used to determine the

shim thickness and fully install the cup into the carrier

housing, using Tool No. E9271-B. Using Tool No.

E9271-A in the outer (tail) cup acts as a guide to

ensure that the inner (head) cup (2) is insta lled square

to its bore.

NOTE

If a 0.025 mm feeler gauge can be inserted

between a bearing cup and the bottom of its

bore at any point around the cup, the cup is not

fully seated.

Figure 4B3 – 77

Differential Assembly – Bearing Preload and Bac klash

1 Remove both differentia l bearing cups from the cover

and carrier housings, Using puller J 35280 and slide

hammer J 23907. As removal operations will distort

the shims under the cups they should be discarded,

along with the bearing cups.

NOTE

While the cover housing is shown, the operation

for either housing is similar.

Figure 4B3 – 78

2 Fit special bearing cups (Tool No. DT-47577) to the carrier and cover, without any shims. These bearing cups

have the outside diameters reduce d to all ow the cups to be a sliding fit in the housings.

3 Fit the differential assembl y with oiled bearing cones into the carrier housing.

4 Fit the cover and tighten the bolts to the correct torque sp ecification.

Final drive cover retaining

bolt torque specification.......................................45 N.m

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–53

Page 4B3-53

5 Position a dial indicator and magnetic base o n the

cover. The correct position is one where the dial

indicator stylus is in contact with bearing journal end of

the differential housing, such as position 'A'.

6 Zero the dial indicator.

7 Insert Tool No. DT-47573 into the lower side gear

opening and across the differ ential pinion pin.

8 Lift the differential up to measure the total end float,

note the reading, then lower and repeat at le ast

another two times, noting the end play in each

instance.

9 Take the avera ge reading as being the total differential

housing end float.

The total required shim thickness will be equal to the

measured end float value plus 0.1 mm. Select two

shims that equal the total thickness figure with one

shim being 0.15 mm thicker than the other.

10 Remove the cover, the differential case assembly and

the dummy bearing cups.

11 Position the thicker shim under the differential bearing

cup in the carrier housing.

Figure 4B3 – 79

12 Still using the dummy bearing cups, refit them in the

same positions. Refit the differential assembly and the

cover and progressively torqu e the bolts while

checking the bearing preload with a commercially

available dial type torque wrench (1).

NOTE

Rotate the differential, using Tool No. DT-47573

and a commercially available dial type torque

wrench (1), approximately 10 times in each

direction to ensure the preload is stabilised.

Readjust the differential if necessar y.

Side Bearing Preload Specification

(without pinion or axle shafts installed)

New Bearings

Koyo Bearings............................................0.6 – 1.9 N.m

Timken Bearings........................................1.1 – 2.8 N.m

Used Bearings

Koyo Bearings............................................0.3 – 1.0 N.m

Timken Bearings........................................0.6 – 1.4 N.m

Figure 4B3 – 80

13 If the bearing preload exceeds the specification by 0.1 N.m before the bolt s are fully torqued, then adjust the shim

thickness until the correct preload is set with the bolts fully torqued to specification.

Final drive cover retaining

bolt torque specification.......................................45 N.m

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–54

Page 4B3-54

NOTE

Reduction of shim thickness must be equal for

each side.

14 Remove the cover and the differential assem bl y. Keep the differenti al case bearing and shims in the co rrect

relationship.

15 Install the hypoid pinion to the carrier but without the collapsible spacer and pinion oil seal. Torque the pinion nut

to produce the correct bearing preload.

Drive Pinion Bearing Preload Specification

Without Pinion Oil Seal and New Bearings

Koyo Bearings............................................1.4 – 1.8 N.m

Timken Bearings........................................1.4 – 2.4 N.m

Without Pinion Oil Seal and Used Bearings

Koyo Bearings............................................0.8 – 1.1 N.m

Timken Bearings........................................0.7 – 1.2 N.m

16 Fit the differential and ring gear assembly to the carrier housing, fit the cover to the case housing, install the

retaining bolts and tighten to the correct torque specification.

Final drive cover retaining

bolt torque specification.......................................45 N.m

17 Fit the companion flange to the pinion, alig ning marks made before disassembly, if appr opriate (i.e. the pinion

and/or the pinion flange h as not bee n replaced.).

The dial gauge must be positioned at 90° to

the radius of the companion flange to

produce an accurate m easurement.

18 Measure the backlash by ins erting a bolt into one of

the six threaded holes in the c ompanion flange. Place

a dial indicator and magnetic base on the carrier

housing, so the dial indicator stylus contacts the bolt at

90°. Zero the dial indicator.

19 After installing ring gear rotation tool DT-47573 use a

socket and bar to hold the differential in a sta tionary

state.

20 While holding the ring gear stationary, rotate the pinion

flange back and forth, noting the di al indicator reading.

The backlash specification measured at the bolt,

should be between 0.14 – 0.26 mm (this equates to

0.10 to 0.18 at the ring gear).

Figure 4B3 – 81

21 Adjust the differential bearing shim s to achieve the correct backlash.

NOTE:

Always maintain the same total thickness of the

shims. If one is reduced by 0.15 mm, then the

other shim must be increased by 0.15 mm.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–55

Page 4B3-55

22 If backlash is excessive, decrease the shim thickness on the pinion side of the ring gear and increase shim

thickness on the ring gear side, by the same amount. If backlash is insufficient, increase the shim thickness on the

pinion side of the ring gear and decrease shim thickness on the ring gear s ide, b y the sam e amount.

23 With the backlash correct, rotate the pinion in both directio ns (approximately 10 times in each) sufficient to rotate

the ring gear 3 complete turns. Remove the cover & differential ass embl y to inspect the gear tooth markings. (The

markings should be the same as those for the rear drive unit. Refer to 'Ring Gear and Pinion Contact Pattern', in

3.3 Removed Final Drive Assembly, Reassemble, Section 4B1 Rear Final Drive and Drive Shafts). If the marking

is not acceptable, adjust the pinion position and/or backlash to achieve an acceptable tooth contact.

24 Once an acceptable marking has been achieved, remove the cover and the differential assembly. Remove the

dummy differential bearing cups (Tool No. DT-47577) from the carrier and the cover.

25 Install the established shim thicknesses and the correct bea ring cups to the cover and carrier housings, as follows:

a Assemble bear ing cup installer DT-47578 to the bearing cup and the bearing cup al igning plug, Tool No. DT-

47579 to the housing, then insert the bolt (p art of T ool No. E9271) through both.

b Install the thrust bearing, washer and nut (part of Tool No. E9271).

c Tighten the nut until the bearing cup is fully installed into the housing.

NOTE

While the cover housing is sho wn, the installation process for the carrier housi ng is e xactl y the same. Vie w 'A'

shows the tool arrangement outside the cove r, while View 'B' shows the inside view.

Figure 4B3 – 82

26 Reassemble the differential assembl y with the cover and recheck the backlash and the preload. Some change can

be expected due to slight variants in the bearing cups. Adjust the shim thickness if necessary, to correct the

backlash or preload.

27 Remove the cover, differential assembly, companion flange and pinion bearing for the final assembly of the drive

unit. Refer to "Final Drive Unit Assembly", in this Section.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–56

Page 4B3-56

Final Drive Unit Assembly

1 If not already completed, reassemble the differential assembly. Refer to "Reassemble – Differential", in this

Section.

2 Establish and install the correct pinion shim required, refer to "Drive Pinion – Shim Selection", in this Section.

3 Determine and install the correct differential carrier bearing shims, preload and backlash required, refer to

"Differential Assembly - Bearing Preload and Backlash", in this Section.

4 If the pinion inner (head) bearing (1) is to be replaced,

place the new head bearing cone (1) onto the pinion

(2) and press the bearing aga inst the pin ion shaft

shoulder, using Tool No. E3C10AER.

5 Lubricate the pinion inner (head) bearing with the

recommended final drive lubri c ant, refer to

"Lubrication", in 1.2 Final Drive Maintenance, in this

Section.

6 Install the pinion in the carrier housing and install a

new collapsible pinion sp acer.

NOTE:

The new outer (tail) pinion bearing cup was

installed during the pinion depth procedure.

7 Lubricate the outer (tail) pinion bearing cone with the

recommended final drive lubri c ant, refer to

"Lubrication", in 1.2 Final Drive Maintenance, in this

Section, then install the bearing onto the pinion. Figure 4B3 – 83

8 Lubricate the l ips and outside diameter of a new pinion

oil seal (1), with Mobilgrease XHP 222. The recess

between the lips shoul d be approximatel y 50 % filled

with grease. A light coating of grease is also to be

applied to the dirt lip that contacts the companio n

flange guard.

9 Install the pinion oil seal (1) in the carrier housing (2),

using Tool No. E 9055.

Figure 4B3 – 84

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–57

Page 4B3-57

10 Reinstall the pinion flange onto the pinion shaft, then apply a thread sealant such as Loctite 262 or equivalent to

the pinion nut, before reinstalling the nut.

11 Fully install the pinion flange, by tightening the pinion nut but, during this process, rotate the pinion backwards and

forwards to seat the bearings. Fit [packing flange, Tool No. DT-47580 and holding bar, Tool N o. J 8614-10 to the

flange during the installation process.

If the preload is exceeded, the collapsible

spacer must be replaced and the preload

process repeated.

12 Frequently check the bearing preload while tightening the nut to achieve the specifi ed bearing preload.

Refer to 2.11 Pinion Flange Replace, in Section 4B1 Rear Final Drive & Driveshafts.

NOTE

Even though the procedure in Section 4B1

relates to the rear final drive assembly, the

procedure is exactly the same for the front final

drive assembly.

Drive Pinion Bearing Preload Specification

With Pinion Oil Seal and Ne w Bearings

Koyo Bearings............................................1.5 – 2.1 N.m

Timken Bearings........................................1.4 – 2.4 N.m

With Pinion Oil Seal and Used Bearings

Koyo Bearings............................................0.8 – 1.1 N.m

Timken Bearings........................................0.7 – 1.2 N.m

13 Refit the differential assembly in the carrier with the correct bearing cup shims previously installed behind the

differential carrier bearing cups (refer to Step 24, in Differential Assembly – Bearing Prel oad and Backlash, in this

Section.

14 Apply a continuous 1 – 1.5 mm bead of Loctite "Ultra

Blue" sealant #58791 (1) or e quivalent, to the cover

mating face in the location shown.

15 Reinstall the cover to the carrier ho using, reinstall the

10 bolts and tighten to the correct torque spec ification.

Final drive cover retaining

bolt torque specification.......................................45 N.m

Figure 4B3 – 85

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–58

Page 4B3-58

16 Lubricate new carrier and cover housing seal lips, with Mobilgrease XHP 222. The recess between the lips should

be approximately 50% filled with grease.

17 Use Tool No. Tool No. AU 410 to install the s eal (1) to the carrier housing ( v iew 'A') and Tool No. J 21426 to install

the oil seal (2) to the case housing (view 'B').

Figure 4B3 – 86

18 Reinstall the final drive asse mbly into the vehicle. Refer to 3.2 Front Final Drive, Reinstall, in this Section.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–59

Page 4B3-59

4 Diagnosis

Apart from the fact that a limited slip differential is not available for the front final drive assembly, for diagnostic

procedures relating to the front final drive an d driveshafts, refer to 4 Diagnosis, in Section 4B1 Rear Final Drive and

Driveshafts.

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–60

Page 4B3-60

5 Specifications

General

Front Final Drive Assembly..................................................................................DANA – M70

Drive Type ..............................................................................................Independent Housing

Gear Type......................................................................................................................Hypoid

Gear Ratio (Refer ID label on Carrier Housing)..............................................................3.46:1

No. Teeth:

Ring Gear.....................................................................................................................45

Drive Pinion Gear.........................................................................................................13

Lubricant

Final Drive Assembly:

Capacity.............................................................................................................0.8 litres

Type – Synthetic Hypoid Gear Oil.............................................................SAE 80W-140

Final Drive Pinion Gear Bearings

Bearing Type ...................................................................................... Adjustable Taper Roller

Bearing Pre-Load Adjustment.....................................................................Collapsible Spacer

Pinion Depth of Mesh Adjustment.....................................................................Selective Shim

Bearing Pre-Load:...................................................................................Timken Koyo

New bearings without Oil Seal ......................................................1.4 – 2.4 1.4 – 1.8 N.m

Used bearings without Oil Seal.....................................................0.7 – 1.2 0.8 – 1.1 N.m

New Bearings With Oil Seal..........................................................1.4 – 2.4 1.5 – 2.1 N.m

Used Bearings With Oil Seal.........................................................0.7 – 1.2 0.8 – 1.1 N.m

Differential Carrier Bearings

Bearing Type ...................................................................................... Adjustable Taper Roller

Bearing Pre-Load Adjustment...........................................................................Selective Shim

Bearing Pre-Load, Measured without Axle Shafts or Pinion:..................Timken Koyo

New bearings ................................................................................1.1 – 2.8 0.6 – 1.9 N.m

Used bearings...............................................................................0.6 – 1.4 0.3 – 1.0 N.m

Backlash

Between Ring Gear and Pinion (at the tightest point)......................................0.10 – 0.18 mm

At the Pinion Flange Bolt Pitch Circle Diameter

(measured perpendicular to bolt).....................................................................0.14 – 0.26 mm

Run-Out Specifications

Maximum Ring Gear Run-Out (Assembled)

Measured on back face of ring gear ...........................................................................0.13 mm

Maximum Pinion Flange Run-Out........................................................................0.10 mm TIR

Sealants

Carrier to Cover Housing.............................................Loctite 58791 'Ultra Blue' or equivalent

Pinion Nut.........................................................................................Loctite 262 or equivalent.

Lubricants/Greases

Final Drive Oil Seal Lips, Bearing H ousing, Bearings,

Oil Seals and Shaft Splines ...................................................................Mobilgrease XHP 222

Driveshaft Lubricant Quantities

Outer, Fixed Constant Velocity Joint

Joint..................................................................55 ± 5 g

Boot................................................................100 ± 5 g

Inner Tripot Joint

Tripot ..............................................................140 ± 5 g

Boot..................................................................60 ± 5 g

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–61

Page 4B3-61

6 Torque Wrench Specifications

ATTENTION

 Fasteners must be repl aced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either ha ve micro encapsulated sealant a pplied or in corporate a mechani cal thread lock and

should only be re-used once. If in doubt, replacement is recommended.

Bearing housing to engine oil pan retaining bolt.....................................45 N.m

Exhaust manifold bolt – GEN III V8..............Stage 1.............................15 N.m

Stage 2.............................25 N.m

Exhaust manifold bolt – V6.....................................................................20 N.m

Engine mount bracket bolt .....................................................................50 N.m

Engine mount nut (Upper and lower)......................................................80 N.m

Final drive cover bolt ..............................................................................45 N.m

Final drive drain plug..............................................................................45 N.m

Final drive filler plug ...............................................................................28 N.m

 Front control arm ball joint stud..............................................................55 N.m

 Front driveshaft outer retaining nut...............Stage 1...........................130 N.m

Stage 2.. Loosen until nu t is loose

Stage 3...........................200 N.m

Front final drive breather pipe bracket bolt GEN III V8 Engine............22 N.m

HFV6 Engine......................9 N.m

Front final drive to engine oil pan retaining bolt......................................70 N.m

Ring gear bolt (right hand thread).........................................................140 N.m

Road wheel attaching nut...........................................................110 – 140 N.m

Transmission rear crossmem ber attaching bolt......................................55 N.m

Underbody front side rail brace attaching nut.........................................25 N.m

 Upper strut locating plate retaining nut .................................................. 55 N.m

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–62

Page 4B3-62

7 Special Tools

Tool Number Illustration Description Tool Classification

7208

Remover

Used to remove the front driveshaft

from front the hub.

Previously released.

Mandatory

AU 410

Seal Installer

Used to install the carrier cover oil

seal.

Previously released

Unique

C4150-C

Press Tool

Used to remove wheel studs from the

rear wheel trunnion.

Previously released as AJ24292-C.

Unique

DT-47570

Front Driveshaft Remover/Installer

Used in conjunction with slide

hammer J6125-1B to remove/install

the front driveshafts.

New release

Mandatory

DT-47571

Cup Removal Adaptor

Used in conjunction with E9293 to

remove both pinion bearing cups from

the carrier housing.

New release

Available

DT-47572

Side Bearing Installer

Used with a hydraulic press to install

the differential carrier bearing cones.

New release

Available

DT-47573

Ring Gear Rotation Tool

Used to rotate differential housing to

measure bearing preload.

New Release

Mandatory

DT-47577

Dummy Bearing Cups

Used when determining the

differential bearing preload and

position.

New release.

Available

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–63

Page 4B3-63

Tool Number Illustration Description Tool Classification

DT-47578

Bearing Cup Installer

Used in conjunction with bearing cup

alignment tool, DT-47579, to install

the ring gear carrier bearing cups to

the carrier and cover housings.

New release

Available

DT-47579

Bearing Cup Alignment Tool

Used in conjunction with bearing cup

installer, to ensure that bearing cups

are installed correctly.

New release.

Available

DT-47580

Spacer Ring

Fitted into the pinion flange to act as a

spacer for holding tool J8614-O1.

New Release

Available

DT-47583

Dummy Pinion

Used to determine the pinion bearing

preload and position.

New release

Available

E308

Seal Remover

Previously released

Available

E3C10AER

Pinion Bearing Cone Installer

Used to install the inner bearing cone

to the final drive pinion.

Previously released.

Unique

E1673MT

Basic Puller

Used with different adaptors to

remove tapered roller bearing cones,

Previously released

Unique

E 1673A15

Adaptor

Used in conjunction with E 1673-MT

to remove the inner pinion bearin g

cone.

Previously released

Unique

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–64

Page 4B3-64

Tool Number Illustration Description Tool Classification

E 1673B16

Stepped Plug

Used in conjunction with puller

E 1673MT and adaptors E 1673A15/

E 1673N15 to remove bearings from

the final drive assembly.

Previously released

Unique

E 1673N15

Adaptor

Used in conjunction with puller

E 1673MT and stepped plug

E 1673B15, to remove the bearing

cones from the differential case

halves.

Previously released

Unique

E 1891-6

Sleeve

Also released as 3A8-6.

Previously released

Unique

E 9055

Seal Installer

Used to install the pinion oil seal.

Previously released

Unique

E 9271

Pinion Bearing Cup Installer

Comprises adaptors E 9271-A and

E 9271-B, together with bolt, nut, flat

washer and thrust bearing.

Previously released

Unique

E 9293

Pinion Bearing Cup Remover

Used to remove pinion bearing cups.

Previously released.

Unique

J 2619-O1

Slide Hammer and Adaptor

Used with driveshaft Tool, DT-47570

to remove/reinstall front driveshafts.

Previously released

Unique

J 8614-O1 Flange Pulley Holding Tool

Includes J 8614-2, J 8614-3 and J

8614-10. Used to remove the pinion

flange nut and flange.

Previously released

Unique

Front Final Drive, Bearing Housing & Driveshafts Page 4B3–65

Page 4B3-65

Tool Number Illustration Description Tool Classification

J 21426

Seal Installer

Used to install oil seals in various

locations.

Previously released

Unique

J 22610

Clamp Pliers

Used to secure boot clamps to some

of the constant velocity boot clamps.

Previously released

Available

J 22912-01

Press Plates

Used in a variety of pressing

operations as a support.

Previously released

Desirable

J 23907

Slide Hammer

Used in conjunction with bush

remover J 35280.

Previously released

Unique

J 35280

Universal Bush Remover

Used in conjunction with slide

hammer J23907.

Previously released.

Unique

KM-468

Holding Tool

Used to hold the wheel hub from

rotating.

Previously released

Unique

Pinion Flange Pulley

Fabricate this pulley to incl ude all VZ applications.

1 Made from a 13 mm thick piece of wood with a 1 mm

deep groove (inset) turned around the circu m ference.

2 Drill a small hol e at '1' and attach a one metre length of

fine string at this point, looped at one end, knotted at the

other.

3 Drill two, 8.5 mm holes (2) opposite to each other on a

pitch circle diameter of 86 mm (AWD Wagon).

4 Drill three, 13 mm holes (3) on a pitch circle diameter of

96 mm, 120 mm apart (All VZ models with IRS).

5 Drill two, 10 mm holes (4) opposite to each other on a

pitch circle diameter of 94 mm (All VZ Live Axle models).