Repair Procedures

Removal

1. Remove the 4WD coupling assembly bolts (A-3ea) mounted to the rear propeller shaft (B).

Tightening torque :
49.0 - 68.6N.m (5.0 - 7.0kgf.m, 36.2 - 50.6lb-ft)




2. Using a flat tool, separate the propeller shaft from 4WD coupling assembly.
3. Remove the electric magnetic clutch connector(A).




4. Remove the 4WD coupling assembly mounting bolts (A-4ea).

Tightening torque :
58.8 - 63.7N.m (6.0 - 6.5kgf.m, 43.4 - 47.0lb-ft)




5. Using a flat tool, separate the 4WD coupling assembly from the rear differential carrier assembly.

Installation

1. Installation is the reverse of removal.

NOTE:
- Grease the drive gear of the differential carrier assembly.
High pressure grease:
KLUBER MICROLUBE GNY 202 or equivalent
GREASE-TRANSMISSION (MS511-55, TMG-2)
- Spread sealant on the matching face of coupling & differential carrier.
Sealant material
FIPG(Formed in Place Gaskets)-B (MS721-40) or equivalent to LT5702
- Remove oil on the matching face before spread sealant.
- Refer to instruction drawing for spreading line.
- Staring point anding point should be overlapped (min.10mm(0.3937in.))
- Be sure to assemble part "Coupling & Differential carrier" within 3 minutes after spread sealant.