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Up to 08/2009





REAR SUSPENSION: REAR SUSPENSION MEMBER (for AWD): INSTALLATION

1. INSTALL HOLE PLUG

(a) Install the 16 hole plugs to the rear suspension member sub-assembly as shown in the illustration.





HINT
The upper and lower suspension member hole plug shapes are different.

2. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for LH Side)

(a) Temporarily install the rear suspension member front body mounting cushion (LH Side) while confirming the installation direction.





Standard (A):

40° to 50°

(b) Install SST as shown in the illustration.





SST : 09527-17011

SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

HINT
Use SST with the "F" mark facing the rear suspension member front body mounting cushion.

(c) Using SST, install the rear suspension member front body mounting cushion (LH Side) until there is no clearance between the rear suspension member sub-assembly and the rear suspension member front body mounting cushion (LH Side).





Text in Illustration





SST : 09527-17011

SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

3. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for RH Side)

(a) Temporarily install the rear suspension member front body mounting cushion (RH Side) while confirming the installation direction.





Standard (A):

40° to 50°

(b) Install SST as shown in the illustration.





SST : 09527-17011

SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

HINT
Use SST with the "F" mark facing the rear suspension member front body mounting cushion.

(c) Using SST, install the rear suspension member front body mounting cushion (RH Side) until there is no clearance between the rear suspension member sub-assembly and the rear suspension member front body mounting cushion (RH Side).





Text in Illustration





SST : 09527-17011

SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

4. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNT CUSHION LH

(a) Temporarily install the rear suspension member rear body mounting cushion LH while confirming the installation direction.





(b) Install SST as shown in the illustration.





SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

HINT
Use SST with the "F" mark facing the rear suspension member rear body mounting cushion.

(c) Using SST, install the rear suspension member rear body mounting cushion LH until there is no clearance between the rear suspension member sub-assembly and the rear suspension member rear body mounting cushion LH.





Text in Illustration





SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

5. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNT CUSHION RH

(a) Temporarily install the rear suspension member rear body mounting cushion RH while confirming the installation direction.





Standard (A):

10° to 20°

(b) Install SST as shown in the illustration.





SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

HINT
Use SST with the "F" mark facing the rear suspension member rear body mounting cushion.

(c) Using SST, install the rear suspension member rear body mounting cushion RH until there is no clearance between the rear suspension member sub-assembly and the rear suspension member rear body mounting cushion RH.





Text in Illustration





SST : 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

6. INSTALL REAR DIFFERENTIAL MOUNT CUSHION Replacement

7. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH Installation

8. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH Installation

9. INSTALL REAR SPEED SENSOR LH

(a) Install the rear speed sensor wire LH with the 2 bolts and nut as shown in the illustration.





Bolt - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

Nut - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTICE:
Do not twist the rear speed sensor wire when connecting it.

10. INSTALL REAR SPEED SENSOR RH

(a) Install the rear speed sensor wire RH with the 2 bolts and nut as shown in the illustration.





Bolt - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

Nut - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTICE:
Do not twist the rear speed sensor wire when connecting it.

11. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY RH (w/ HID Headlight System)

(a) Install the rear height control sensor sub-assembly RH to the rear suspension member sub-assembly with the bolt (A) and 2 nuts.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

NOTICE:
Do not twist the rear height control sensor wire when connecting it.

(b) Install the rear height control sensor sub-assembly RH to the rear upper control arm assembly RH with the bolt (B).

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

12. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH (w/ Air Suspension)

(a) Install the rear height control sensor sub-assembly LH to the rear suspension member sub-assembly with the bolt (A) and 2 nuts.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

NOTICE:
Do not twist the rear height control sensor wire when connecting it.

(b) Install the rear height control sensor sub-assembly LH to the rear upper control arm assembly LH with the bolt (B).

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

13. INSTALL REAR SUSPENSION MEMBER UPPER STOPPER

(a) Install the 2 rear suspension member upper stoppers as shown in the illustration.





NOTICE:
Be sure to install the rear suspension member upper stoppers in the correct direction shown in the illustration.

14. INSTALL REAR SUSPENSION MEMBER REAR UPPER STOPPER

(a) Install the 2 rear suspension member rear upper stoppers as shown in the illustration.





15. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH

(a) Temporarily tighten the rear No. 1 suspension arm assembly LH to the rear suspension member sub-assembly with the bolt and nut.





NOTICE:
* Insert the bolt with the threaded end facing the rear side of the vehicle.
* Since the stopper nut is used, tighten the bolt.
* Fully tighten the bolt after stabilizing the suspension.
16. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

17. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY

(a) Support the rear suspension member with a jack using 2 wooden blocks and 2 attachments or equivalent tools as shown in the illustration.





Text in Illustration





NOTICE:
Make sure to secure the rear suspension member to prevent it from dropping.

HINT
Keep the suspension member level.

(b) Raise the rear suspension member until there is no clearance between the rear suspension member and the body.





NOTICE:
When raising the rear suspension member, be careful not to damage the vehicle body or other components installed on the vehicle.

(c) Install the rear suspension member with the 2 rear lower suspension braces, 2 rear lower suspension member stoppers, 4 bolts and 2 nuts.





Text in Illustration





Bolt - Torque : 180 Nm (1837 kgf-cm, 133 ft-lbf)

Nut - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

NOTICE:
Be sure to install the rear suspension member with the rear lower suspension braces facing in the correct direction as shown in the illustration.

(d) Lower the jack.

18. INSTALL FRAME WIRE

(a) Install the bolt and engage the clamps, and then connect the connectors to install the frame wire to the rear suspension member as shown in the illustration.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

NOTICE:
Do not twist the frame wire when installing it.

HINT
* There are only the connector (A) and the clamp (A) on vehicles with the HID headlight system.
* There are only the connector (B) and the clamp (B) on vehicles with the air suspension.
19. TEMPORARILY TIGHTEN REAR DIFFERENTIAL CARRIER ASSEMBLY WITH DIFFERENTIAL SUPPORT Installation

20. FULLY TIGHTEN REAR DIFFERENTIAL CARRIER ASSEMBLY WITH DIFFERENTIAL SUPPORT Installation

21. INSTALL REAR DRIVE SHAFT SNAP RING LH

(a) Install the rear drive shaft snap ring LH.

* for TMC Made: Reassembly

* for TMC Made: Reassembly

22. INSTALL REAR DRIVE SHAFT SNAP RING RH

HINT
Perform the same procedure as the LH side.

23. INSTALL REAR DRIVE SHAFT ASSEMBLY LH

(a) Install the rear drive shaft assembly LH.

* for TMC Made: Installation

* for TMC Made: Installation

24. INSTALL REAR DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

25. TEMPORARILY TIGHTEN REAR AXLE CARRIER SUB-ASSEMBLY LH

(a) Hold the rear axle carrier sub-assembly LH between aluminium plates in a vise.





(b) Using a brass bar and a hammer, push out the bushing until it is positioned as shown in the illustration.

HINT
Pushing out the bushing makes it easier to install the rear axle carrier sub-assembly.

(c) Temporarily tighten the rear axle carrier sub-assembly LH with the spacer, nut (B) and 2 bolts (C).





NOTICE:
* Fully tighten the 2 bolts (C) after temporarily tightening the rear No. 2 suspension arm assembly.
* Fully tighten the nut (B) after stabilizing the suspension.
* Be careful not to damage the rear drive shaft outboard joint boot.
(d) Fully tighten the rear axle carrier sub-assembly LH to the rear upper control arm assembly LH with the bolt (A) and nut.

Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

NOTICE:
* Insert the bolt with the threaded end facing the rear side of the vehicle.
* Since the stopper nut is used, tighten the bolt (A).
26. TEMPORARILY TIGHTEN REAR AXLE CARRIER SUB-ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

27. TEMPORARILY TIGHTEN PARKING BRAKE ASSEMBLY LH Installation

28. TEMPORARILY TIGHTEN PARKING BRAKE ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

29. INSTALL REAR TRAILING ARM ASSEMBLY LH Installation

30. INSTALL REAR TRAILING ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

31. FULLY TIGHTEN PARKING BRAKE ASSEMBLY LH Installation

32. FULLY TIGHTEN PARKING BRAKE ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

33. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

(a) Temporarily tighten the rear No. 2 suspension arm assembly LH.

* w/o Air Suspension: Installation

* w/ Air Suspension: Installation

34. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

35. FULLY TIGHTEN REAR LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH

(a) Fully tighten the 2 bolts.





Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

36. FULLY TIGHTEN REAR LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

37. INSTALL REAR PNEUMATIC CYLINDER ABSORBER ASSEMBLY LH (w/ Air Suspension) Installation

38. INSTALL REAR PNEUMATIC CYLINDER ABSORBER ASSEMBLY RH (w/ Air Suspension)

HINT
Perform the same procedure as the LH side.

39. INSTALL REAR STABILIZER LINK SUB-ASSEMBLY LH Installation

40. INSTALL REAR STABILIZER LINK SUB-ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

41. INSTALL REAR STABILIZER BAR

(a) Install the rear stabilizer bar with 2 rear stabilizer bushings and 2 rear No. 1 stabilizer bar brackets with the 4 nuts.





Text in Illustration





Torque : 75 Nm (765 kgf-cm, 55 ft-lbf)

NOTICE:
Ensure that the identification mark faces the right side of the vehicle.

42. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH Installation

43. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

44. INSTALL REAR DISC LH Installation

45. INSTALL REAR DISC RH

HINT
Perform the same procedure as the LH side.

46. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG (for LH Side) Installation

47. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG (for RH Side)

HINT
Perform the same procedure as the LH side.

48. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH Installation

49. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

50. INSTALL REAR AXLE SHAFT NUT LH Installation

51. INSTALL REAR AXLE SHAFT NUT RH

HINT
Perform the same procedure as the LH side.

52. INSTALL REAR SPEED SENSOR LH Installation

53. INSTALL REAR SPEED SENSOR RH

HINT
Perform the same procedure as the LH side.

54. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation

55. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation

56. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation

57. STABILIZE SUSPENSION Installation

58. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH Installation

59. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

60. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH Installation

61. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

62. INSTALL REAR SUSPENSION ARM COVER LH

(a) Install the rear suspension arm cover.

* w/o Air Suspension: Installation

* w/ Air Suspension: Installation

63. INSTALL REAR SUSPENSION ARM COVER RH

HINT
Perform the same procedure as the LH side.

64. ADJUST PARKING BRAKE SHOE CLEARANCE AND PARKING BRAKE PEDAL TRAVEL Adjustments

65. INSPECT AND ADJUST TRANSFER OIL

(a) Inspect and adjust the transfer oil Testing and Inspection.

66. ADD DIFFERENTIAL OIL Replacement

67. INSPECT DIFFERENTIAL OIL Service and Repair

68. INSTALL DIFFERENTIAL INSPECTION PLUG Service and Repair

69. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ Air Suspension)

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

70. BLEED BRAKE SYSTEM

HINT
Refer to the instructions for Bleed Brake Line Service and Repair.

71. INSTALL REAR WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

72. INSPECT FOR EXHAUST GAS LEAK

73. INSPECT FOR AIR LEAK (w/ Air Suspension)

(a) Inspect for air leaks Suspension Control System.

74. CHECK VEHICLE HEIGHT (w/ Air Suspension) Installation

75. ADJUST VEHICLE HEIGHT (w/ Air Suspension) Installation

76. INSPECT AND ADJUST REAR WHEEL ALIGNMENT

(a) Inspect and adjust the rear wheel alignment Rear Wheel Alignment.

77. HEIGHT CONTROL SENSOR SIGNAL INITIALIZATION (w/ HID Headlight System)

(a) Initialize the height control sensor signal Initialization.

HINT
This step is not necessary for vehicles with air suspension.

78. INSPECT AND ADJUST HEADLIGHT AIMING (w/ HID Headlight System)

(a) Inspect and adjust the headlight aiming Adjustments.
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