6-2.REAR DIFFERENTIAL REAR DRIVE (REAR DIFFERENTIAL) A:4.2~4.4 kgf-m B:3.0~3.5 kgf-m C:0.7~0.9 kgf-m D:2.0~2.2 kgf-m E F:1.2~1.5 kgf-m G: 11~12kgf-m

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Holly Barrett
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1 6-2.REAR DIFFERENTIAL REAR DRIVE (REAR DIFFERENTIAL) A:4.2~4.4 kgf-m B:3.0~3.5 kgf-m C:0.7~0.9 kgf-m D:2.0~2.2 kgf-m E F:1.2~1.5 kgf-m G: 11~12kgf-m 6-2-1

6-2. REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL Caution Be sure the differential set temperature below 35 Drain the differential oil. Remove both drive shafts.

2 6-2. REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL Caution Be sure the differential set temperature below 35 Drain the differential oil. Remove both drive shafts. Detach vent hose from rear differential. Remove the lock mode cables. Remove the four bolts and bracket as shown. Remove the upper front end three bolts from the frame as shown. Remove front end upper and bottom bolts as shown. Lift up the differential and slide backward to detach from the propeller shaft. Remove the rear differential by pulling it from the RH side. NOTICE: Be careful not to knock or to bend vent hose fitting while removing front differential

Install the rear differential and insert the differential shaft into the connecting shaft, put and the boot on the

3 6-2.REAR DIFFERENTIAL INSTALLATION Reverse the removal procedure install the rear differential. Apply grease into the propeller shaft end. Install the rear differential and insert the differential shaft into the connecting shaft, put and the boot on the position. Install rear brackets and tighten with bolts, washers and nuts as shown. Torque : 4.5~5.5kgf-m Assemble the upper bracket and tighten with three bolts on the front top of rear differential as shown. Torque : 2.2~2.5kgf-m

6-2. REAR DIFFERENTIAL Tighten the upper and bottom front end bolt as shown. Torque : 4.5~5.5kgf-m. Install and fixed the vent hose as shown. NOTE: keep the vent hose away from the exhaust.

4 6-2. REAR DIFFERENTIAL Tighten the upper and bottom front end bolt as shown. Torque : 4.5~5.5kgf-m. Install and fixed the vent hose as shown. NOTE: keep the vent hose away from the exhaust. Install the cable, apply special tool # to adjust the length. Tighten the nut. Torque : 1.2~1.5kgf-m. Reverse the removal procedure; install the relative parts. Refill the gear oil to 500 cc and tighten the bolt and washer. Caution Oil standard:sae#90 hypoid gear oil Oil capacity: 500 c.c. Torque: 3.0~3.5 kgf-m 6-2-2

5 6-2.REAR DIFFERENTIAL REAR DIFFERENTIAL DISASSEMBLY Remove the differential housing eight bolts.. Apply rubber hammer lightly knock the case (red area as shown) to separate the half case. Check O ring, replace if necessary. Remove the anti-slip limited gear assy. and the shims

6 6-2. REAR DIFFERENTIAL Check the two bearing, replace if necessary. NOTE: beware the foreign object falling into the slip limited gear assy. Check the bearing on the left half case, replace if necessary. Check oil seal, replace if necessary. NOTE: Apply grease on rear area as shown before install oil seal

Apply Loctite #263 on the eight bolts and

7 6-2.REAR DIFFERENTIAL REAR DIFFERENTIAL ASSEMBLE Install shim into the case as shown. Install anti slip limited gear assy. into the case and apply rubber hammer lightly knock to the position as shown. Install two dowel pin on the left half case. Apply Loctite #263 on the eight bolts and cross tighten. NOTE: Ensure the O-ring install properly. Torque: 2.0~2.2kgf-m

Check the oil seal, replace if necessary.

8 6-2. REAR DIFFERENTIAL LOCK MODE ASSY. DISASSEMBLE Remove five bolts. Apply rubber hammer light knock to separate the case. Check the oil seal, replace if necessary. NOTE: shift shaft seal recommend replace after assemble. Check bearing, replace if necessary. Remove shift rod assy. and other parts

9 6-2.REAR DIFFERENTIAL LOCK MODE ASSY. ASSEMBLE Install the two dowel pin as shown. Install the lock sleeve and shift rod. Clean the old glue and apply Loctite #510 on the contact surface as shown. Assemble the case

6-2. REAR DIFFERENTIAL Apply Loctite #263 on the three bolts and cross tighten as shown. NOTE: S70810 is shortest bolt.. Torque : 1.2~1.5kgf-m NOTE: Check and test the shift rod function.

10 6-2. REAR DIFFERENTIAL Apply Loctite #263 on the three bolts and cross tighten as shown. NOTE: S70810 is shortest bolt.. Torque : 1.2~1.5kgf-m NOTE: Check and test the shift rod function. Install shift rod oil seal. Install bracket and tighten the two bolts. Install the LOCK cable. REAR DIFFERENTIAL ADJUSTMENT Using special tool to adjust the cable. Adjust the suitable length by the rotate the nuts 6-2-2

6-2.REAR DIFFERENTIAL PIVOT GEAR DISASSEMBLE Remove four bolts and lightly knock out the housing. Check the oil seal and O ring, replace if necessary.

11 6-2.REAR DIFFERENTIAL PIVOT GEAR DISASSEMBLE Remove four bolts and lightly knock out the housing. Check the oil seal and O ring, replace if necessary. Using special tool # to remove the ring snap. Apply rubber hammer from the inside of case lightly knock out the gear to remove the shaft from the case. NOTE: Beware the knocking might damage the bearing. Using special tool remove the needle bearing. Check the bearing, replace if necessary. Before install new bearing, apply some lubricate oil inside the bearing

Torque : 11~12kgf-m Apply Loctite #263 on the four bolts, and install the housing and tighten. Torque : 4.2~4.

12 6-2. REAR DIFFERENTIAL PIVOT GEAR ASSEMBLE Reverse the disassemble procedure install the shaft and bearing into case. Apply Loctite #263 on the ring snap, and Apply special tool # to install. Torque : 11~12kgf-m Apply Loctite #263 on the four bolts, and install the housing and tighten. Torque : 4.2~4.4kgf-m DIFFERENTIAL MOTOR REMOVAL Disconnected the wiring connector. Unscrew three differential motor bolts. INSTALLATION For installation, reverse the removal procedure

Bearing install tool Spacer disassembly tool Spacer disassembly tool. Handle Puller slide hammer Puller

Bearing install tool Spacer disassembly tool Spacer disassembly tool Handle Puller slide hammer Puller 5th gear lock tool E-ring install tool -98- Chapter 6 Propeller Shaft Universal joint This propeller