Check Differential Alignment

CAUTION:
Used propeller shafts and differentials must have the reference marks aligned to ensure proper mating of the components. If new components have been installed, alignment must be undertaken once the sub-frame is installed and engine mounts are tightened to the correct torque.

1. If reassembly of used components is being performed, ensure the reference marks are aligned.

2. Install the drilled propeller shaft to the differential drive tube.

3. Slide the propeller shaft forwards and fit the centering flange (A in Figure 6) to the propeller shaft.

4. Secure the flange with suitable nut and bolt. (B in Figure 6)





5. Rotate the centering flange to allow the alignment tool to be placed in position. (Figure 7)

6. Remove one slider from the alignment tool (LRT-54-032) and set aside.

7. Position the alignment tool (Arrowed in Figure 7) into the locating bushing in the transfer gearbox front output flange.

8. Using a 2 mm Allen key, loosen the slider screw so that the slider moves freely along the ruler.

9. Rotate the centering flange into position and secure with nut and bolt.

10. 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.

11. Position the alignment tool to the vertical with the slider below the centering flange nipple.

12. Gently pull the propeller shaft down to it's lowest position





NOTE:
The measurement should be made at the inside edge of the alignment tool slider.
(Inset in Figure 8). The alignment tool may have to be rotated into a horizontal position to read the measurement

13. Slide the slider up to the bottom of the centering flange nipple and tighten the slider screw using the Allen key.

14. Rotate the ruler tool to read the measurement and record the offset distance.

15. Loosen the slider screw so that the slider moves freely along the ruler.

16. Ensure the alignment tool is vertical and the slider is above the centering flange nipple.





17. Gently push the propeller shaft up to its highest position and slide the slider down to the top of the centering flange nipple. (Figure 9)

18. Tighten the slider screw using the Allen key.

19. Rotate the ruler tool to read the measurement and record the offset distance.

20. If the two noted measurements are the same within 1 mm, the differential is correctly aligned to the transfer box front output flange. No adjustment is necessary. Go to the "Propeller Shaft Installation Procedure below.

21. If the difference between the two noted measurements is greater than 1 mm, the front differential is misaligned to the transfer box output flange. Perform the Alignment Procedure.