Differential Alignment Adjustment
NOTE:This average measurement is the "target" position (maximum up and down) for the propeller shaft in relation to the locating bush in the transfer gearbox front output flange.
1. Calculate the average of the two noted measurements by adding the two figures together and dividing by two.
2. Slide the propeller shaft forwards, release the centering flange securing nut and bolt, rotate the centering flange and remove the alignment tool. (Figure 10)
3. Release the alignment tool slider screw and move the inside edge of the slider to the calculated "target" position.
4. Fully tighten the slider screw with an Allen wrench.
5. Position the alignment tool into the locating bushing in the transfer gearbox front output flange.
6. Rotate the centering flange into position and secure with suitable nut and bolt.
7. Slide the propeller shaft rearwards until it contacts the face of the ruler.
NOTE:
It may be necessary to slightly slide the propeller shaft, together with the alignment tool, toward the front of the vehicle. This will allow the alignment tool to be slightly extracted from the locating bushing in the transfer gearbox flange. The slide will move freely when this gap is created.
8. Ensure the alignment tool is vertical.
9. If the measured distance was larger below than above the centre line of the locating bushing, position the alignment tool vertically with the slider above the centering flange nipple.
10. If the measured distance was larger above than below the centre line of the locating bushing, position the alignment tool vertically with the slider below the centering flange nipple.
NOTE:
The initial movement of the propeller shaft will be due to the fit of the propeller shaft and the drive tube mating splines. When approaching the slider, resistance will be felt as the differential moves.
11. Perform differential alignment as follows:
^ Release the four differential attachment bolts sufficiently to secure the differential, but still allow slight rotation on its axis. (Figure 11)
^ Gently push the propeller shaft up or pull the propeller shaft down until the centering flange nipple touches the inside edge of the slider.
^ With assistance, hold the propeller shaft in this position and snugly tighten one of the differential fixing bolts to secure the differential.
^ Verify the measurement above and below the centering flange nipple is equal and the same as the "target" measurement.
12. Repeat adjustments in step 11 up and down as required to achieve equal alignment measurements.
CAUTION:
A Torque wrench MUST be used when tightening the differential fixing bolts to 110 Nm (81 lbf.ft).
13. When the measurement is equal above and below the locating bushing (within 1 mm of the target position), tighten all bolts securing the front differential to 110 Nm (81 lbf.ft).
14. Slide the propeller shaft forwards and remove the nut and bolt securing the centering flange to propeller shaft.
15. Remove the centering flange.
16. Remove the front propeller shaft.
PROPELLER SHAFT INSTALLATION
CAUTION:
ONLY use grease TIA500010. Use of any other grease or lubricant will result in premature spline wear.
*1. Obtain a new "0" ring (TYX000070) and perform the following:
^ Lubricate the "0" ring with grease from packet (TIA500010).
^ Install the "0" ring into the drive tube. (Figure 12)*
2. Evenly distribute all of the remaining grease in the packet onto the propeller shaft splines and the drive tube splines.
3. Install the propeller shaft into the differential drive tube.
4. Inspect the centering flange dust seal and install a new seal if indicated.
5. Clean the coupling and the centering flange mating faces.
6. Position the coupling and flange with the arrows on the coupling pointing towards the flange mounting. (Figure 13)
7. Install bolts securing the coupling and tighten new nuts to 110 Nm (81 lbf.ft).
8. Lower the vehicle onto its wheels.
9. Lower the lift.
10. Connect the battery ground cable.