Chapter 9: Driveline Components

Covers the full driveline: driveshafts, front axle/hub/CV-joint/differential (4WD), free-wheel locking hub system, and rear axle/differential (including LSD carrier). Longest chapter in the manual — 17 sections across 60 printed pages.

Our truck is 4A30 DOHC turbo, 3A/T automatic, full-time/selectable 4WD — the 4WD-specific procedures below (front axle, free-wheel locking hub, front differential carrier) apply directly.

1. Driveshaft: Front-Rear — components, warpage measurement, oil seal inspection.
2. Driveshaft U-Joint Replacement — U-joint removal/assembly, snap ring installation and thickness/color chart.
3. Front Axel Specifications & Tools (4WD) — spec table, lubrication, special tools.
4. Run Out Testing — front hub run out limit, driveshaft backlash inspection.
5. Hub & Knuckle Overhaul (4WD) — removal, tie rod/drive axle removal, wheel bearing replacement, hub run out test.
6. Front Axels & CV Joints Overhaul (4WD) — removal, BJ/DOJ boot kits, boot inspection.
7. Main Shaft Assembly (4WD) — components, bearing removal/installation.
8. Front Differential Carrier Overhaul (4WD) — components, backlash/run-out inspection, full disassembly/assembly.
9. Free Wheel Locking System Overhaul (4WD) — actuator pin, switch, bearing, clutch sleeve.
10. Free Wheel Solenoid & Vacuum Hose System (4WD) — components & routing.
11. Front Differential Cross Member System (4WD) — mount brackets, cross member.
12. Rear Axel Data & Tools — spec table, lubrication, special tools (shared with front axle set).
13. Rear Driveline Inspection — driveshaft backlash, differential oil level, rear axle run out.
14. Rear Differential Assembly — surrounding suspension/brake/driveline components overview.
15. Axel Shaft — components, oil seal replacement, ABS rotor pickup gear removal, wheel bearing replacement.
16. Differential Carrier Overhaul — Normal vs. LSD carrier, full disassembly/assembly, LSD engagement torque test.
17. LSD Components — LSD clutch pack exploded view, engagement torque spec.

Flagged items requiring verification against a clean copy

See each file’s (verify printed p.X) notes for full context. Summary list:

• p.193 — Driveshaft spec table’s oil column (SAE 75/85W GL-4) may belong to transfer case/differential rather than driveshaft; row/column alignment unclear.
• p.196 — Snap ring thickness/color chart: 4th thickness (1.37mm) has no recovered color name.
• p.197 — Front axle spec table row/value alignment; “Front Axle Backlash” limit value not recovered.
• p.200 — Tool MB990560 labeled “Rear Axel Bearing Remover” inside front-axle tools list — confirmed correct via cross-reference to p.229-231, not an error.
• p.202/203/208 — Several tool part numbers printed inconsistently between duplicate procedure instances (e.g. “MB995635” vs “MB990635”; “MB990244” vs “MB9990244”; “MB990242” vs “MB990241”).
• p.205 — Wheel bearing adapter printed both “MB991337” and “MB991387”.
• p.206 — Hub run out limit conflict: 0.05mm (confirmed, p.201) vs. 0.005mm (this page) — treat 0.05mm as correct pending verification.
• p.209 — BJ/DOJ boot kit component list item 11 (“BJ”) ambiguous; several stray OCR tokens unresolved.
• p.210 — Boot size codes (“20-112#BJ75L”, “20-113#BJ75L”) not confidently attributed to BJ vs. DOJ.
• p.212 — Tool numbers MB990938/MB990926/MB990927 not present in the front-axle tools table; unverified.
• p.213 — Component item 2 label ambiguous (“Front Differential / Differential Assembly RH”).
• p.217 — Tool number also printed “MB990919”; likely OCR duplicate of MB990939.
• p.219 — Drive pinion preload torque of 0.98-1.28 Nm (10.0-13.0 kgf·cm) is unusually low; units unconfirmed.
• p.223 — Unlabeled 2-3mm clearance callout, component not specified.
• p.225 — Oil seal install tool printed “MB992938”/“MB190799”; likely MB990799 per following step.
• p.226 — Vacuum hose routing: two color-coded hose pairs (Blue Stripe, Yellow Stripe) each appear twice in the parts list; actual routing path not fully confirmed.
• p.227 — Cross member torque-to-fastener mapping unclear.
• p.233 — Rear differential assembly torque-to-fastener mapping unclear.
• p.242 — Two tool numbers illegible: “MB980339”/“MB990339” and “MB990990”/“MB990988”.
• p.245 — Rear pinion preload torque 0.9-1.20 Nm (9.0-12.0 kgf·cm), mirrors the same unusually-low-reading issue as p.219.
• p.246 — Cylinder gauge diameter formula term arrangement/units not fully clean; tool number “M0890654” illegible.
• p.247 — Note “Replace Pinion @ 0.2mm+” — exact meaning unclear.
• p.250 — No recoverable content; appears blank/end-of-chapter.