6-2
Drive System
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 10.
General Information
All gear cases are tagged beneath a cover bolt. This
tag is marked with a production date code, sequence
code, and a ratio code. All gear cases are 4.0:1 ratio.
The die-cast aluminum housings have been assem-
bled with thread-rolling screws (trilobular). When
assembling with these screws, start the screws care-
fully into the housing; then use the following torque
values.
TROUBLESHOOTING
If a noise is heard from the gear case area, it can be
difficult to locate and/or diagnose. If the noise is
related to wheel speed, but not to engine RPM, the
problem is probably in the final drive or
engine/transmission bevel gear set. When a problem
is localized, a number of inspections must be made
to pinpoint that problem. The most obvious of the
inspections include CV boots, wheel and hub nut
tightness, wheel bearing damage, gear case lubricant
contamination, low lubricant level, seal leakage, CV
joints, or selector arm.
NOTE: Small metallic particles will collect on the
magnetic drain plug as a normal part of break-in
and will also give a metallic cast to drained lubri-
cant. Contamination would include large particles
or water which gives a “milky” look to the lubri-
cant.
NOTE: Lubricant on a new pinion housing
assembly could be grease. If the front of the gear
case is leaking at the rear drive boot, wipe excess
lubricant from the bottom of the pinion housing;
then operate the vehicle for a period of time.
Inspect the pinion housing area for any signs of
leakage. If lubricant is again on the bottom of the
pinion housing, the seal must be replaced.
Additional troubleshooting could include the fol-
lowing.
• Binding/abrupt motion: CV boot torn (grease loss,
foreign object damage, broken cage); gear lubri-
cant loss or not filled (bearing seizure, broken gear
teeth, seal leakage, bladder or hose leakage,
missing filler/drain plug).
• Noise from drive system: wheel or gear case bear-
ing damage, improper gear backlash, improper
assembly, low or no gear case lubricant.
• Lockup: gear case lubricant loss or not filled, water
contamination causing bearing seizure.
Front Drive Actuator
NOTE: The actuator is not a serviceable compo-
nent. If it is defective, it must be replaced.
NOTE: The actuator will operate only when the
ignition switch is in the ON position.
The front drive actuator is located on the right side
of the front drive input housing. With the engine
stopped and the ignition switch in the ON position, a
momentary “whirring” sound can be heard each
time the front drive selector switch is shifted. If no
sound is heard, see Section 5. If the actuator runs
constantly or makes squealing or grinding sounds,
the actuator must be replaced.
REMOVING
1. Select 4WD on the front drive selector switch;
then disconnect the connector on the actuator
harness.
2. Using a T-30 torx wrench, remove the mounting
cap screw from the driveshaft side of the actua-
tor.
Size New Housing
Reassembled
Housing
M6
(Torx T-30 Recess)
1.1-1.3 kg-m
(8-9.5 ft-lb)
0.9-1.2 kg-m
(6.5-9 ft-lb)
M8
(Torx T-40 Recess)
3.5-4.3 kg-m
(25-31 ft-lb)
2.9-3.5 kg-m
(21-25 ft-lb)
Back to TOC
Back to Section TOC
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