A/T

FRONT OIL SEAL

A/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. Refer to "A/ T : Removal and Installation" Removal and Installation and "A/T : Disassembly" 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.





- 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.
Refer to "A/T : Disassembly" Disassembly.






CAUTION:
Make a stamping after replacing front oil seal.
- 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 from left to right.





1.Drain gear oil. Refer to "Draining" Draining.
2.Make a judgment if a collapsible spacer replacement is required.
3.Remove center muffler with a power tool. Refer to "Exploded View" Exploded View.
4.Remove rear wheel sensors. Refer to "REAR WHEEL SENSOR : Exploded View" Exploded View.
5.Remove drive shafts from final drive. Refer to "Exploded View" Exploded View.
6.Remove the side flanges. Refer to "A/T : Exploded View" A/T

CAUTION:
Never damage side oil seal.
7.Remove rear propeller shaft. Refer to "Exploded View" 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 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 on the final drive companion flange indicates the maximum vertical runout position.





10.Remove drive pinion lock nut using the flange wrench (commercial service tool).





11.Remove companion flange using pullers (commercial service tool).





12.Remove front oil seal using the puller (A) [SST: KV381054S0 (J34286)].

INSTALLATION

1.Apply multi-purpose grease to front oil seal lip.





2.Install front oil seal using the drift (A) [SST: ST30720000 (J25405)] as shown in figure.

CAUTION:
- Never reuse oil seal.
- Never incline oil seal when installing.
- Apply multi-purpose grease onto oil seal lip and gear oil onto the circumference of oil seal.





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





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, using flange wrench (commercial service tool).






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, using preload gauge [SST: ST3127S000 (J-25765-A)].





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.Set a dial indicator (A) vertically to the tip of the drive pinion.
7.Rotate drive pinion to check for runout.

Limit
Drive pinion runout: Refer to "Drive Pinion Runout (A/T)" Drive Pinion Runout (A/T).

8.If the runout value is still outside of the limit after the phase has been changed, possible causes are an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
9.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.
10.Install rear propeller shaft. Refer to "Exploded View" Exploded View.





11.Install side flanges 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 flanges (1) installation measurement (A) in the figure comes into the following.





12.Install drive shafts. Refer to "Exploded View" Exploded View.
13.Install rear wheel sensors. Refer to "REAR WHEEL SENSOR : Exploded View" Exploded View.
14.Install center muffler. Refer to "Exploded View" Exploded View.
15.Refill gear oil to the final drive and check oil level. Refer to DLN29, "Refilling".
16.Check the final drive for oil leakage. Refer to "Inspection" Inspection.