GR00001300 26
GR00001300 26
GR00001300 26
GROUP 26
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 26-2
FRONT AXLE DIAGNOSIS . . . . . . . . 26-2
INTRODUCTION TO FRONT AXLE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 26-2
FRONT AXLE DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 26-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 26-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 26-3
SPECIAL TOOLS. . . . . . . . . . . . . . . . 26-9
ON-VEHICLE SERVICE. . . . . . . . . . . 26-14
WHEEL BEARING PLAY CHECK . . . . . . . 26-14
FRONT AXLE TOTAL BACKLASH CHECK 26-14
FRONT AXLE GEAR OIL LEVEL CHECK . 26-15
DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . 26-15
SOLENOID VALVE OPERATION CHECK. 26-16
HUB AND KNUCKLE ASSEMBLY . . 26-18
REMOVAL AND INSTALLATION . . . . . . . . 26-18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 26-20
INSPECTION OF HUB ROTATION
STARTING TORQUE . . . . . . . . . . . . . . . . . 26-21
WHEEL BEARING PLAY CHECK . . . . . . . 26-21
DISASSEMBLY AND ASSEMBLY. . . . . . . 26-22
DRIVE SHAFT ASSEMBLY. . . . . . . . 26-23
REMOVAL AND INSTALLATION . . . . . . . . 26-23
DISASSEMBLY AND ASSEMBLY . . . . . . . 26-25
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 26-26
UJ BOOT (RESIN BOOT) REPLACEMENT 26-27
INNER SHAFT ASSEMBLY . . . . . . . . 26-30
REMOVAL AND INSTALLATION . . . . . . . . 26-30
DISASSEMBLY AND ASSEMBLY . . . . . . . 26-32
DIFFERENTIAL CARRIER AND FREE
WHEELING CLUTCH . . . . . . . . . . . . . 26-35
REMOVAL AND INSTALLATION . . . . . . . . 26-35
DIFFERENTIAL CARRIER AND FREE
WHEELING CLUTCH INSPECTION. . . . . . 26-37
FREEWHEEL ENGAGE SWITCH CHECK. 26-37
FREE WHEELING CLUTCH DISASSEMBLY
AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 26-37
DIFFERENTIAL CARRIER DISASSEMBLY 26-41
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 26-47
SOLENOID VALVE AND VACUUM
HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 26-57
REMOVAL AND INSTALLATION . . . . . . . . 26-57
FRONT DIFFERENTIAL MOUNT. . . . 26-59
REMOVAL AND INSTALLATION . . . . . . . . 26-59
DIFFERENTIAL MOUNTING INSULATOR
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 26-60
SPECIFICATIONS . . . . . . . . . . . . . . . 26-61
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 26-61
GENERAL SPECIFICATIONS . . . . . . . . . . 26-62
SERVICE SPECIFICATIONS . . . . . . . . . . . 26-63
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 26-63
SEALANTS AND ADHESIVES . . . . . . . . . . 26-63
GENERAL DESCRIPTION
TSB Revision
FRONT AXLE
26-2
.
GENERAL DESCRIPTION
M1261000100273
The front axle consists of the front hubs, knuckles,
drive shaft, wheel bearings, ball joints, front differen-
tial, and freewheel clutch. The features are:
The structural method of press fitting unit bearing
into front hub is applied.
The wheel bearing uses a taper roller unit bear-
ing. A rotor for detecting the wheel speed is
press-fitted to the UJ outer wheel.
NOTE: DOJ: Double Offset Joint. UJ: Under cut
Joint.
Drive shafts incorporate UJ-DOJ-type constant
velocity ball joint has high power transmission
efficiency and reduces vibration and noise.
A vacuum-type freewheel clutch has been
adopted in the freewheel mechanism. Its solenoid
valve and actuator Switch powertrain between
2WD and 4WD.
The differential support method is a four-point
elastic support method which reduce vibration
and noise.
FRONT AXLE DIAGNOSIS
INTRODUCTION TO FRONT AXLE DIAGNOSIS
M1261005500209
The AWD vehicle incorporates a free-wheeling clutch
as the free-wheeling mechanism. The free-wheeling
clutch is configured of the mainshaft, shift fork and
clutch gears, etc., and is electrically controlled.
If the clutch does not lock or locks but does not
become free, there may be electrical trouble or the
component may be faulty. Noise from the driveshaft,
inner shaft or differential can be caused by a compo-
nent defect.
FRONT AXLE DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1261005600110
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
front axle fault.
1. Gather information from the customer.
2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1261005700139
SYMPTOMS INSPECTION
PROCEDURE
REFERENCE PAGE
Free-wheeling
Clutch
Does not lock 1
P.26-3
Locks but does not become free 2
P.26-3
Driveshaft,
inner shaft
Noise during wheel rotation 3
P.26-4
Noise due to excessive wheel play in
turning direction
4
P.26-4
Differential Constant noise 5
P.26-4
Gear noise while driving 6
P.26-6
Gear noise while coasting 7
P.26-7
Bearing noise while driving or coasting 8
P.26-7
Noise while turning 9
P.26-7
Heat 10
P.26-8
Oil leakage 11
P.26-8
FRONT AXLE DIAGNOSIS
TSB Revision
FRONT AXLE
26-3
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Does not Lock
DIAGNOSIS
STEP 1. Check for looseness in the actuator
assembly installation bolt.
Q: Is the actuator assembly installation bolt
loosened?
YES : Tighten to 17 Nm (13 ft-lb). Then go to Step
7.
NO : Go to Step 2.
STEP 2. Check the vacuum tank for damage.
Q: Is the vacuum tank damaged?
YES : Replace the tank. Then go to Step 7.
NO : Go to Step 3.
STEP 3. Check the check valve for damage.
Q: Is the check valve damaged?
YES : Replace the valve. Then go to Step 7.
NO : Go to Step 4.
STEP 4. Check the actuator assembly for
damage.
Q: Is the actuator assembly damaged?
YES : Replace the actuator assembly. Then go to
Step 7.
NO : Go to Step 5.
STEP 5. Check the solenoid valve operation.
Refer to P.26-16.
Q: Is the solenoid valve operation in good condition?
YES : Go to Step 6.
NO : Replace the valve. Then go to Step 7.
STEP 6. Check the shift fork, mainshaft and
clutch gear for damage.
Q: Is the shift fork, mainshaft or clutch gear
damaged?
YES : Replace the damaged part. Then go to Step
7.
NO : Go to Step 7.
STEP 7. Retest the system.
Q: Does clutch locks?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 2: Locks but does not Become Free
DIAGNOSIS
STEP 1. Check whether foreign material has
entered the mainshaft and clutch gear or clutch
sleeve and clutch gear teeth.
Q: Has foreign material entered the mainshaft and
clutch gear or clutch sleeve and clutch gear teeth?
YES : Clean the teeth or replace the part. Then go
to Step 2.
NO : There is no action to be taken.
STEP 2. Retest the system.
Q: Does clutch become free?
YES : The procedure is complete.
NO : Repeat from Step 1.
FRONT AXLE DIAGNOSIS
TSB Revision
FRONT AXLE
26-4
INSPECTION PROCEDURE 3: Noise during Wheel Rotation
DIAGNOSIS
STEP 1. Check the housing tube and inner shaft
for bending.
Q: Is the housing tube and inner shaft bent?
YES : Replace the part. Then go to Step 4.
NO : Go to step 2.
STEP 2. Check the inner shaft bearing for wear.
Q: Is the inner shaft bearing worn?
YES : Replace the bearings. Then go to Step 4.
NO : Go to Step 3.
STEP 3. Check the driveshaft assembly for wear,
damage or bending.
Q: Is the driveshaft assembly worn, damaged or bent?
YES : Replace the driveshaft assembly. Then go
to Step 4.
NO : There is no action to be taken.
STEP 4. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 4: Noise Due to Excessive Wheel Play in Turning Direction
DIAGNOSIS
STEP 1. Check for play in the inner shaft and side
gear serration, the driveshaft and side gear, or
the driveshaft and drive flange.
Q: Is play found?
YES : Adjust or replace the part. Then go to Step
2.
NO : The procedure is complete.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 5: Constant Noise
DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 9.
NO : Go to Step 2.
AC000439
UPPER LIMIT
LOWER LIMIT
AB
8 mm (0.3 in)
FRONT AXLE DIAGNOSIS
TSB Revision
FRONT AXLE
26-5
STEP 2. Check the tooth contact (engagement) of the drive
gear and drive pinion. Refer to P.26-41.
Q: Is the tooth contact (engagement) of the drive gear and
drive pinion correct?
YES : Go to Step 3.
NO : Adjust or replace the part. Then go to Step 9.
STEP 3. Check the side bearing for looseness, wear or
damage.
Q: Is the side bearing loosened, worn or damaged?
YES : Adjust or replace the part. Then go to Step 9.
NO : Go to Step 4.
STEP 4. Check the drive pinion bearing for wear or
damage.
Q: Is the drive pinion bearing worn or damaged?
YES : Adjust or replace the part. Then go to Step 9.
NO : Go to Step 5.
STEP 5. Check the drive gear and drive pinion for wear.
Q: Is the drive gear or drive pinion worn?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 6.
STEP 6. Check the side gear thrust washer or pinion shaft
for wear.
Q: Is the side gear thrust washer or pinion shaft worn?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.
STEP 7. Check the drive gear and differential case for
strain, and the gear for damage.
Q: Is the drive gear or differential case strained or
damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 8.
STEP 8. Check for the engagement of foreign material.
Q: Is foreign material found?
YES : Remove the foreign material and then inspect. If
necessary, replace the part. Then go to Step 9.
NO : Go to Step 9.
STEP 9. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
FRONT AXLE DIAGNOSIS
TSB Revision
FRONT AXLE
26-6
INSPECTION PROCEDURE 6: Gear Noise while Driving
DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 7.
NO : Go to Step 2.
STEP 2. Check the gear engagement.
Q: Is the gear engagement in good condition?
YES : Go to Step 3.
NO : Adjust the drive gear and drive pinion. Then go to
Step 6.
STEP 3. Check the drive pinion turning torque. Refer to
P.26-47.
Q: Is the drive pinion turning torque correct?
YES : Go to Step 4.
NO : Adjust the turning torque. Then go to Step 7.
STEP 4. Check the gear for damage.
Q: Is the gear damaged?
YES : Replace the gear. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for the engagement of foreign material.
Q: Is the foreign material found?
YES : Remove the foreign material and then inspect. If
necessary, replace the part. Then go to Step 7.
NO : Go to Step 6.
STEP 6. Retest the system.
Q: Is the abnormal noise eliminated?
YES : Replace the drive gear and drive pinion. Then go to
Step 7.
NO : The procedure is complete.
STEP 7. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
AC000439
UPPER LIMIT
LOWER LIMIT
AB
8 mm (0.3 in)
FRONT AXLE DIAGNOSIS
TSB Revision
FRONT AXLE
26-7
INSPECTION PROCEDURE 7: Gear Noise while Coasting
DIAGNOSIS
STEP 1. Check the drive pinion turning torque.
Refer to P.26-47.
Q: Is the drive pinion turning torque correct?
YES : Go to Step 2.
NO : Adjust the turning torque. Then go to Step 3.
STEP 2. Check the gear for damage.
Q: Is the gear damaged?
YES : Replace the gear. Then go to Step 3.
NO : There is no action to be taken.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 8: Bearing Noise while Driving or Coasting
DIAGNOSIS
STEP 1. Check the drive pinion rear bearing for
cracks or damage.
Q: Is the drive pinion rear bearing cracked or
damaged?
YES : Replace the part. Then go to Step 2.
NO : There is no action to be taken.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 9: Noise while Turning
DIAGNOSIS
STEP 1. Check the side bearing for wear or
damage.
Q: Is the side bearing worn or damaged?
YES : Replace the part. Then go to Step 3.
NO : Go to step 2.
STEP 2. Check the side gear, pinion gear or
pinion shaft for damage.
Q: Is the side gear, pinion gear or pinion shaft
damaged?
YES : Replace the part. Then go to Step 3.
NO : There is no action to be taken.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
FRONT AXLE DIAGNOSIS
TSB Revision
FRONT AXLE
26-8
INSPECTION PROCEDURE 10: Heat
DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 3.
NO : Go to Step 2.
STEP 2. Check the gear backlash (excessive) Refer to
P.26-47.
Q: Is the gear backlash correct?
YES : Go to Step 3.
NO : Adjust the backlash. Then go to step 3.
STEP 3. Retest the system.
Q: Is the heat eliminated?
YES : The procedure is complete.
NO : Repeat from Step 1.
INSPECTION PROCEDURE 11: Oil Leakage
DIAGNOSIS
STEP 1. Check the vent plug for clogging.
Q: Is the vent plug clogged?
YES : Clean or replace the part. Then go to Step 5.
NO : Go to step 2.
STEP 2. Check the cover installation.
Q: Is the cover installed properly?
YES : Go to Step 3.
NO : Repair. Then go to Step 5.
STEP 3. Check the oil seal for wear or damaged.
Q: Is the oil seal worn or damaged?
YES : Replace the seal. Then go to Step 5.
NO : Go to Step 4.
AC000439
UPPER LIMIT
LOWER LIMIT
AB
8 mm (0.3 in)
SPECIAL TOOLS
TSB Revision
FRONT AXLE
26-9
STEP 4. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 5.
NO : There is no action to be taken.
STEP 5. Retest the system.
Q: Is there oil leakage?
YES : Repeat from Step 1.
NO : The procedure is complete.
SPECIAL TOOLS
M1261000600289
AC000439
UPPER LIMIT
LOWER LIMIT
AB
8 mm (0.3 in)
TOOLS TOOL NUMBER
AND NAME
SUPERSESSION APPLICATION
MB990925
Bearing and oil
seal installer set
MB990925-01 or
General service
tool
Press-fitting of wheel bearing outer
race MB990935 MB990938
Press-fitting of oil seal (differential
carrier)
Press-fitting of drive pinion rear
bearing outer race MB990934
MB990938
Press-fitting of drive pinion front
bearing outer race MB990936
MB990938
Oil seal installation (free wheel
clutch) MB990926 MB990938
MB990590 Rear
axle shaft oil
seal remover
A: MB990212
Adapter
B: MB990211
Sliding
hammer
Removal of adhesive
TOOLS TOOL NUMBER
AND NAME
SUPERSESSION APPLICATION
MB990339
MB990648
MB990802
MB990031
SPECIAL TOOLS
TSB Revision
FRONT AXLE
26-13
MD999547 Oil
seal installer
MB991318
Lower arm
bushing arbor
MB990843
Draglink bushing
remover and
installer
Open circuit
ACX01021AB
OFF ON
1 2
BALL
AC101907AB
12
10
9
12
11
10
4
13
7
3
2
1
6
5
8
9
FREEWHEEL CLUTCH
DISASSEMBLY STEPS
<<A>> 1. MAIN SHAFT ASSEMBLY
<<A>> >>F<< 2. BEARING
>>E<< 3. SPACER
4. CLUTCH SLEEVE
>>D<< 5. SPRING PIN
6. SNAP RING
7. SHIFT FORK
8. SHIFT ROD
>>C<< 9. OIL SEAL
<<B>> >>B<< 10. CLUTCH GEAR
<<B>> >>B<< 11. BEARING
FREEWHEEL CLUTCH
DISASSEMBLY STEPS
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-38
Required Special Tools:
MB990560: Bearing Remover
MB990799: Ball Joint Remover and Installer
MB990890 or MB990891: Rear Suspension
Bushing Base
MB990926: Bearing and Oil Seal Installer Set
MB990938: Bearing and Oil Seal Installer Set
MB991168: Differential Oil Seal Installer
DISASSEMBLY SERVICE POINTS
.
<<A>> MAIN SHAFT/BEARING REMOVAL
1. After special tool MB990560 has been installed as shown,
tighten the nut of special tool MB990560 until portion "A" of
special tool MB990560 touches the bearing outer race.
CAUTION
Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing.
.
<<B>> CLUTCH GEAR/BEARING REMOVAL
1. Use a press and steel plate to remove the clutch gear and
bearing together.
2. Using a press, hold the supports against the bearing inner
race, and separate the clutch gear and bearing.
>>A<< 12. OIL SEAL
13. CLUTCH HOUSING
FREEWHEEL CLUTCH
DISASSEMBLY STEPS
ACX01023 AB
A
MB990560
ACX01024AB
METAL PLATE
ACX01025AB
METAL PLATE
SUPPORT
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-39
ASSEMBLY SERVICE POINTS
.
>>A<< OIL SEAL INSTALLATION
Use special tool MB991168 to tap the oil seal until it is flush
with the clutch housing.
.
>>B<< BEARING/CLUTCH GEAR INSTALLATION
1. Use special tool MB990799 to press-fit the bearing to the
shoulder of the clutch gear.
CAUTION
Place special tool MB990890 or MB990891 against the
outer race of the bearing.
2. Use special tools MB990890 or MB990891 to press-fit the
bearing to the side of the clutch housing.
.
>>C<< OIL SEAL INSTALLATION
.
ACX01026AB
OIL SEAL
CLUTCH
HOUSING
MB991168
ACX01027AB
MB990799
BEARING
CLUTCH
GEAR
ACX01028AB
MB990890
OR
MB990891
CLUTCH
HOUSING
ACX01029AC
OIL SEAL
MB990938
MB990926
CLUTCH
HOUSING
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-40
>>D<< SPRING PIN INSTALLATION
Tap the spring pin from the chamfered side of the shaft rod until
the projection length becomes the length shown in the illustra-
tion.
.
>>E<< SPACER INSTALLATION
1. Place the current spacer in the area shown in the illustration
to check that the dimensions shown in the illustration are
within the standard values.
Standard Value (A): 0.05 0.3 mm (0.002 0.012 inch)
2. If the dimensions are outside of the standard values, select
the correct spacer type to fit in the standard values.
Spacer type
.
>>F<< BEARING INSTALLATION
Press-fit the bearing to the shoulder of the mainshaft.
ACX01030AB
SPRING PIN
SHIFT ROD
0 1 mm
(0 0.03 in)
CHAMFER
Part Number Thickness
mm (in)
Part Number Thickness
mm (in)
MR111526 1.1 (0.04) MR111530 2.1 (0.08)
MR111527 1.35 (0.05) MR111531 2.35 (0.09)
MR111528 1.6 (0.06) MR111532 2.6 (0.10)
MR111529 1.85 (0.07) MR111533 2.85 (0.11)
AC101906AB
CLUTCH GEAR
MAIN SHAFT
ASSEMBLY
SPACER
A
ACX01031AB
MAIN SHAFT
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-41
DIFFERENTIAL CARRIER DISASSEMBLY
M1262002300113
Required Special Tools:
MB990810: Side Bearing Puller
MB990811: Differential Side Bearing Cap
MB990850: End Yoke Holder
MB990339: Bearing Puller
MB990648: Bearing Remover
MB990939: Bearing and Oil Seal Installer Set
ACX01032AB
1
28
2
3 4
5
22
27
26
23
24
25
6
30
15
14
9
11
12
19
29
20
21
18
17
16
10 8
7
13
DISASSEMBLY STEPS
<<A>>
ACX01061AB
MB990850
216 29 Nm
159 22 ft-m
ACX01062AB
MB990326
MB990685
ACX01063 AB
IDENTIFICATION
COLOR
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-53
NOTE: Apply gear oil around the circumference of compan-
ion flange (and the mating surface of oil seal) when press fit-
ting oil seal into companion flange.
5. Remove the companion flange and drive pinion again. Then,
after inserting the drive pinion rear bearing inner race into
the gear carrier, use special tool MB990031 or MB990699 to
press-fit the oil seal.
6. Install the drive pinion assembly and companion flange with
the mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified torque by
using special tool MB990850.
7. Measure the drive pinion turning torque (with the oil seal) by
using special tools.
Standard value: (With oil seal)
8. If the drive pinion turning torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal.
.
>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
1. Assemble the side gears, side gear spacers, pinion gears
and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE: Do not drive in the lock pin yet.
BEARING
DIVISION
BEARING
LUBRICATION
TURNING TORQUE
New None (with anti-
rust agent)
0.93 1.28 Nm (8.24
11.32 in-lb)
Gear oil applied 0.97 1.32 Nm (8.59
11.68 in-lb)
ACX01064AB
MB990031
OR
MB990699
ACX01065AB
MB990850
216 29 Nm
159 22 ft-lb
ACX01062AB
MB990326
MB990685
ACX01066AB
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-54
3. Insert a wedge between the side gear and the pinion shaft to
lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
Standard value: 0 0.076 mm (0 0.0030 inch)
Limit: 0.2 mm (0.007 inch)
5. If the differential gear backlash exceeds the limit, adjust the
backlash by installing thicker side gear spacers.
6. If adjustment is not possible, replace the side gears and
pinion gears as a set.
7. Measure the differential gear backlash once again, and
confirm that it is within the limit.
.
>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the differential case
lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch at two points.
.
>>H<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the
drive gear by turning the special tool MB990813 (tap M10 x
1.25), and then clean the threaded holes by applying
compressed air.
3. Apply the specified adhesive to the threaded holes of the
drive gear.
Specified adhesive: 3M AAD Part number 8730, 8731
or equivalent
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
Tightening torque: 83 5 Nm (62 3 ft-lb)
.
AC102885
WEDGE
SIDE GEAR
SPACER
SIDE GEAR
SPACER
AC
ACX01067AB
ACX01068AB TAP
AC000438 AB
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-55
>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tool MB990802 to press-fit the side bearing inner
races into the differential case.
.
>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than
those removed, to the side bearing outer races, and then
mount the differential case assembly into the gear carrier.
NOTE: Select side bearing spacers with the same thickness
for both the drive pinion side and the drive gear side.
2. Push the differential case assembly to one side, and
measure the clearance between the gear carrier and the
side bearing adjusting spacer with a feeler gauge.
3. Measure the thickness of the side bearing adjusting spacers
on one side, select two pairs of spacers which correspond to
that thickness plus one half of the clearance plus 0.05 mm
(0.002 inch), and then install one pair each to the drive
pinion side and the drive gear side.
ACX01069AB
MB990829
PIECE
OF
METAL
MB990829
PIECE OF
METAL
ACX01070AB
ACX01071AB
ACX01072 AB
CLEARANCE / 2 + 0.05 mm
= THICKNESS OF THE
SPACER ON ONE SIDE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
TSB Revision
FRONT AXLE
26-56
4. Install the side bearing adjusting spacers and differential
case assembly, as shown in the illustration, to the gear
carrier.
5. Tap the side bearing adjusting spacers with the special tool
to fit them to the side bearing outer race.
6. Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
7. With the drive pinion locked in place, measure the drive gear
backlash with a dial indicator on the drive gear.
NOTE: Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.11 0.16 mm (0.004 0.006 inch)
8. Change the side bearing adjusting spacers as illustrated,
and then adjust the drive gear backlash between the drive
gear and the drive pinion.
NOTE: When increasing the number of side bearing adjust-
ing spacers, use the same number for each, and as few as
possible.
9. Check the drive gear and drive pinion for tooth contact. If
poor contact is evident, make adjustment. (Refer to P.26-
41.)
ACX01070AB
ACX01073AB
MB990939
ACX01074AB
ACX01034AB
ACX01075
IF BACKLASH IS TOO SMALL
IF BACKLASH IS TOO LARGE
THINNER
SPACER
THICKER
SPACER
AB
THINNER
SPACER
THICKER
SPACER
SOLENOID VALVE AND VACUUM HOSE
TSB Revision
FRONT AXLE
26-57
10.Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm (0.002 inch)
11.If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12.If adjustment is not possible, replace the differential case or
replace the drive gear and drive pinion as a set.
SOLENOID VALVE AND VACUUM HOSE
REMOVAL AND INSTALLATION
M1262004500049
ACX01036AB
AC000432
12 2 Nm
107 17 in-lb
1
11
2
12
10
9
10
16
15
7
6
5
4
1
3
13
10
8
10
18
17
17 3 Nm
13 2 ft-lb
12 2 Nm
107 17 in-lb
AB
14
9.0 1.0 Nm
80 9 in-lb
SOLENOID VALVE AND VACUUM HOSE
TSB Revision
FRONT AXLE
26-58
REMOVAL SERVICE POINT
.
<<A>> PIN REMOVAL
1. Remove one side of dust cover mounting part on vacuum
actuator assembly.
2. Match color of pin hole with that of another pin hole to
remove a pin with a punch.
INSTALLATION SERVICE POINTS
.
>>A<< VACUUM HOSE INSTALLATION
Match the color of each vacuum hose and solenoid valve and
vacuum pipe during assembly.
.
>>B<< CHECK VALVE INSTALLATION
Install so that the air direction arrow points to the vacuum side.
SOLENOID VALVE ASSEMBLY,
VACUUM TANK ASSEMBLY
REMOVAL STEPS
>>A<< 1. VACUUM HOSE (WHITE STRIPE.)
>>A<< 2. VACUUM HOSE (BLUE STRIPE.)
>>A<< 3. VACUUM HOSE (YELLOW STRIPE.)
4. VACUUM PIPE ASSEMBLY
5. VACUUM HOSE ASSEMBLY
6. VACUUM PIPE ASSEMBLY
7. BREATHER CAP
8. SOLENOID VALVE ASSEMBLY
>>B<< 9. CHECK VALVE
10. VACUUM HOSE
11. VACUUM HOSE
12. VACUUM PIPE ASSEMBLY (6G7)
13. BREATHER PIPE
14. VACUUM TANK ASSEMBLY
VACUUM ACTUATOR ASSEMBLY
REMOVAL STEPS
>>A<< 15. VACUUM HOSE (BLUE STRIPE)
CONNECTION
>>A<< 16. VACUUM HOSE (YELLOW STRIPE)
CONNECTION
<<A>> 17. PIN
18. VACUUM ACTUATOR ASSEMBLY
SOLENOID VALVE ASSEMBLY,
VACUUM TANK ASSEMBLY
REMOVAL STEPS (Continued)
ACX01019AB
COLLAR
DUST COVER
PIN
ACX01077AB
VACUUM SIDE
AIR DIRECTION ARROW
SOLENOID
VALVE SIDE
FRONT DIFFERENTIAL MOUNT
TSB Revision
FRONT AXLE
26-59
FRONT DIFFERENTIAL MOUNT
REMOVAL AND INSTALLATION
M1262001500040
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the ground in the unladen condition.
Pre-removal and Post-installation Operation
Under Cover Removal and Installation
Skid Plate Removal and Installation (Refer to GROUP 51-
Front Bumper P.51-3.)
Gear Oil Draining and Refill (Refer to P.26-15.)
Drive Shaft Removal and Installation (Refer to P.26-23.)
Inner Shaft Removal and Installation (Refer to P.26-30.)
ACX01078 AB
69 9 Nm *
51 7 ft-lb *
69 9 Nm *
51 7 ft-lb *
89 9 Nm
65 7 ft-lb
89 9 Nm
65 7 ft-lb
128 9 Nm
94 7 ft-lb
23 4 Nm
17 3 ft-lb
59 9 Nm
43 7 ft-lb
69 9 Nm *
51 7 ft-lb *
1
3
2
4
5
128 9 Nm
94 7 ft-lb
DIFFERENTIAL MOUNT
BRACKET ASSEMBLY (LH/RH)
REMOVAL STEPS
>>A<< 1. DIFFERENTIAL MOUNT
BRACKET ASSEMBLY (RH)
>>A<< 2. DIFFERENTIAL MOUNT
BRACKET ASSEMBLY (LH)
DIFFERENTIAL MOUNT
BRACKET ASSEMBLY (REAR)
REMOVAL STEPS
3. NO.2 CROSSMEMBER
4. DIFFERENTIAL SUPPORT
BRACKET