Removal and Installation

FRONT OIL SEAL


M/T : Removal and Installation


REMOVAL

CAUTION:
Verify identification stamp of replacement frequency put in the lower part of gear carrier to determine replacement for collapsible spacer when replacing front oil seal. Refer to "Identification stamp of replacement frequency of front oil seal". If collapsible spacer replacement is necessary, remove final drive assembly and disassemble it to replace front oil seal and collapsible spacer. Removal and Installation and Disassembly.

NOTE:
The reuse of collapsible spacer is prohibited in principle. However, it is reusable on a one-time basis only in cases when replacing front oil seal.

Identification stamp of replacement frequency of front oil seal





- The diagonally shaded area in the figure shows stamping point for replacement frequency of front oil seal.
- The following table shows if collapsible spacer replacement is needed before replacing front oil seal.
When collapsible spacer replacement is required, disassemble final drive assembly to replace collapsible spacer and front oil seal. Disassembly.





- After replacing front oil seal, make a stamping on the stamping point in accordance with the table below in order to identify replacement frequency.

CAUTION:
Make a stamping made from left to right.





1. Drain gear oil. Draining.
2. Make a judgment if a collapsible spacer replacement is required.
3. Remove center muffler with a power tool. Exploded View.
4. Remove rear wheel sensor. Exploded View.
5. Remove drive shaft from final drive. Then suspend it by wire, etc. Exploded View.





6. Install attachment (A) [SST: KV40104100 ( -- )] to side flange, and then pull out the side flange with the sliding hammer
(B) [SST: ST36230000 (J-25840-A)].

NOTE:
Circular clip installation position: Final drive side
7. Remove propeller shaft. Exploded View.





8. Measure the total preload with the preload gauge (A) [SST:
ST3127S000 (J-25765-A)].

NOTE:
Record the preload measurement.





9. Put matching mark (B) on the end of the drive pinion. The matching mark (B) should be in line with the matching mark (A) on companion flange (1).

CAUTION:
For matching mark, use paint. Never damage companion flange and drive pinion.

NOTE:
The matching mark (A) on the final drive companion flange (1) indicates the maximum vertical runout position.





10. Remove drive pinion lock nut using the flange wrench.





11. Remove companion flange using a puller.





12. Remove front oil seal using the puller (A) [SST: KV381054S0 (J-34286)].

INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.





2. Install front oil seal using the drift (A) [SST: ST30720000 (J-25405)] as shown in figure.

CAUTION:
- Never reuse oil seal.
- Never incline oil seal when installing.





3. Align the matching mark (B) of drive pinion with the matching mark (A) of companion flange (1), and then install the companion flange (1).





4. Apply anti-corrosion oil to the thread and seat of new drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.

CAUTION:
Never reuse drive pinion lock nut.

5. Tighten drive pinion lock nut within the limits of specified torque so as to keep the pinion bearing preload within a standard values.
A: Preload gauge [SST: ST3127S000 (J-25765-A)]
Total preload torque : A value that add 0.1 - 0.4 Nm (0.01 - 0.04 kg-m) to the measured value when removing.

CAUTION:
- Adjust to the lower limit of the drive pinion lock nut tightening torque first.
- If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Never loosen drive pinion lock nut to adjust the preload torque.





6. Fit a dial indicator onto the companion flange face (inner side of the propeller shaft mounting bolt holes).
7. Rotate the companion flange to check for runout.
Limit
Companion flange runout : Refer to DLN-295, "Companion flange Runout (M/T Models)". Companion Flange Runout (M/T Models)

8. Fit a test indicator to the inner side of the companion flange
(socket diameter).
9. Rotate the companion flange to check for runout.
Limit
Companion flange runout : Refer to DLN-295, "Companion flange Runout (M/T Models)". Companion Flange Runout (M/T Models)

10. If the runout value is outside the repair limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion gear by 90� step, and search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible causes are be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
11. Make a stamping for identification of front oil seal replacement frequency. Refer to "Identification stamp of replacement frequency of front oil seal".

CAUTION:
Make a stamping after replacing front oil seal.
12. Install propeller shaft. Exploded View.





13. Install side flange with the following procedure.
a. Attach the protector [SST: KV38107900 (J-39352)] to side oil seal.
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.
c. Put a suitable drift on the center of side flange, then drive it until sound changes.

NOTE:
When installation is completed, driving sound of the side flange turns into a sound that seems to affect the whole final drive.





d. Confirm that the dimension of the side flange (1) installation
(Measurement A) in the figure comes into the following.
Measurement "A" : 326 - 328 mm (12.83 - 12.91 in)
14. Install drive shaft. Exploded View.
15. Install rear wheel sensor. Exploded View.
16. Install center muffler. Exploded View.
17. Refill gear oil to the final drive and check oil level. Refilling.
18. Check the final drive for oil leakage. Inspection.