Seals and Gaskets: Service and Repair

Drive Pinion Flange/Yoke and/or Oil Seal Replacement

Removal Procedure

1. Remove the propeller shaft assembly. Refer to Propeller Shaft Replacement (Service and Repair).
2. Drain the differential oil. Refer to Axle Lubricant Change (Service and Repair).
3. Disconnect the electromagnetic control coupling sub-assembly connector and tube.




4. Remove the bolts (1).
5. Using a brass bar and a hammer, tap the electromagnetic control coupling sub-assembly to remove the rear differential carrier cover with the electromagnetic control coupling sub-assembly from the rear differential carrier assembly.





Note: Check the direction of the washer to face.

6. Remove the transmission coupling conical spring washer (1) from the rear differential carrier assembly.




7. Remove the transmission coupling spacer (1) from the rear differential carrier assembly.
8. Remove the rear differential carrier oil seal.

Installation Procedure

1. Apply MP grease to the lip of a new rear differential carrier oil seal.




2. Install the rear differential carrier oil seal using a suitable tool (1).

Oil seal installation depth (A): 0.7-1.3 mm (0.0276-0.0512 in)

3. Install the transmission coupling spacer to the rear differential carrier assembly.

Note: Install the washer so that the marked surface faces the front of the vehicle.

4. Install the transmission coupling conical spring washer to the rear differential carrier assembly.




5. Using a scraper and wire brush, remove the sealant from the rear differential carrier and differential side bearing retainer.
6. Using non-residue solvent, remove the grease and oil from the alignment surfaces of the rear differential carrier and the electromagnetic control coupling sub-assembly.

Note:
* Apply sealant in a continuous bead 2-3 mm (0.0787-0.118 in) in diameter.
* Install the electromagnetic control coupling sub-assembly within 3 minutes after applying sealant.
* Stop applying sealant after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in) within range A.

7. Apply sealant Three Bond 1281 or equivalent, to the areas indicated in the illustration of the electromagnetic control coupling sub-assembly.

* Area (B) : Apply sealant to 1.0 mm (0.0394 in)
* Area (C) : Apply sealant to 2.0 mm (0.0787 in)
* Area (D) : Apply sealant to 3.0 mm (0.0118 in)
* Area (E) : Apply sealant to 5.0 mm (0.1969 in)

Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the electromagnetic control coupling sub-assembly with the bolts and tighten to 20 Nm (15 lb ft).
9. Connect the electromagnetic control coupling subassembly connector and tube.
10. Add the differential oil. Refer to Axle Lubricant Change (Service and Repair).
11. Install the propeller shaft assembly. Refer to Propeller Shaft Replacement (Service and Repair)