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OVERHAUL
1. REMOVE REAR WHEEL
a. Remove the 10 bolts and ornament.
b. Remove the 5 nuts and rear wheel.
2. REMOVE FRONT FLOOR BRACE CENTER
a. Remove the 4 bolts and floor brace CTR.
3. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER RH
a. Remove the 2 bolts and RR suspension member brace rear lower RH.
4. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH
a. Remove the 2 bolts and RR suspension member brace rear lower LH.
5. REMOVE EXHAUST PIPE
6. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
a. Remove the 4 bolts and front floor heat insulator No.1.
7. REMOVE PARKING BRAKE CABLE HEAT INSULATOR
a. Remove the 4 bolts and parking brake cable heat insulator.
8. REMOVE RR END BODY MOUNTING SET PLATE
a. Remove the 4 bolts and RR end body mounting set plate.
9. REMOVE RR END BODY MOUNTING SET PLATE
a. Remove the 4 bolts and RR end body mounting set plate.
10. REMOVE BODY RR END MOUNTING BRACKET SUB-ASSY
a. Remove the 8 bolts, 3 nuts and body RR end mounting bracket sub-assy.
11. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY
SST 09922-10010
12. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), remove the filler plug and gasket.
13. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the drain plug and gasket.
b. Drain the differential oil.
14. REMOVE REAR SUSPENSION MEMBER BRACE RH
a. Remove the 2 bolts and rear suspension member brace RH.
HINT: Remove the LH side by the same procedures with RH side.
15. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
a. Remove the bolt and nut, disconnect the rear suspension arm assy No.1 LH from the axle hub.
16. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH
HINT: Separate the RH side by the same procedures with LH side.
17. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH
a. Place matchmarks on the adjusting cam and rear suspension arm assy No.2 LH.
b. Remove the cam bolt, cam plate and nut, disconnect the rear suspension arm assy No.2 LH from the axle hub.
18. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH
HINT: Separate the RH side by the same procedures with LH side.
19. SEPARATE REAR DRIVE SHAFT ASSY LH
a. Place matchmarks on the drive shaft and side gear shaft.
NOTICE: Do not punch to mark the matchmarks. Use paint, etc.
b. Using a hexagon wrench (12 mm), remove the 6 hexagon bolts and 2 washers with depressing the brake pedal.
c. Separate the drive shafts from the differential carrier.
20. SEPARATE REAR DRIVE SHAFT ASSY RH
HINT: Separate the RH side by the same procedures with LH side.
21. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Support the differential carrier with a jack.
b. Using a hexagon wrench (12 mm), remove the 3 hexagon bolts
c. Remove the 2 bolts and lower mount stoppers.
d. Remove the differential.
e. Remove the 2 upper mount stoppers from the differential carrier.
22. REMOVE REAR DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and a hammer, separate the cover from carrier.
c. If necessary, remove the breather plug from the differential carrier cover.
d. Remove the bolt and oil deflector form rear differential carrier cover.
23. FIX DIFFERENTIAL CARRIER ASSY REAR
a. Set the differential carrier to the overhaul stand, etc., as shown in the illustration.
24. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch) If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.
25. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, measure the backlash of the ring gear at 3 points at least and check that the average value is within the specification.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
NOTICE:
The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 inch).
If the backlash is not within the specification, adjust the backlash (See step 69)
26. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
27. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
a. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 inch)
NOTICE: Differential gears should be able to rotate. If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.
28. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
a. Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 inch) away from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 inch)
If the runout is greater than the maximum, replace the drive pinion and ring gear.
29. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST and a torque wrench, measure the preload using the backlash of the drive pinion and ring gear.
SST 09229-55010
Preload (at starting): 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
30. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Total preload (at starting):
Drive pinion preload plus 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
If necessary, disassemble and inspect the differential.
Fig. 23 Removing Side Gear Shaft:
31. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY
a. Using SST, remove the 2 side gear shafts.
SST 09520-24010
NOTICE: Be careful not to damage the oil seal.
G32. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Using a screwdriver, remove the 2 snap rings from the side gear shafts.
33. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using a screwdriver and a hammer remove the dust cover.
Fig. 24 Removing Side Gear Shaft Oil Seals:
34. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the 2 oil seals.
SST 09308-0010
35. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY
a. Remove the 16 bolts.
b. Using SST, remove the 2 carrier retainers and washers.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
36. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
NOTICE: Do not damage the case bearing.
37. REMOVE REAR DRIVE PINION NUT
a. Using a chisel and a hammer, loosen the staked part of the nut.
b. Using SST to hold the flange, remove the nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
38. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03060)
39. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)
40. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
41. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Using a magnet hand, remove the differential drive pinion oil slinger.
42. REMOVE DIFFERENTIAL DRIVE PINION
a. Using a press, remove the drive pinion with the rear bearing from the differential carrier.
NOTICE: Be careful not to drop the drive pinion.
43. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Remove the spacer from the drive pinion.
44. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Remove the front bearing from the differential carrier.
b. Using a brass bar and a hammer remove the front bearing outer race.
45. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the rear bearing from the drive pinion.
SST 09950-00020
b. Using a brass bar and a hammer remove the rear bearing outer race.
c. Remove the plate washer.
46. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Remove the 10 ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
47. REMOVE REAR DIFFERENTIAL CARRIER RETAINER D-RING
a. Using a screwdriver, remove the 2 O-rings from the differential carrier retainers.
NOTICE: Be careful not to damage the carrier retainer.
48. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSY
a. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
NOTICE: Do not damage the case bearing.
b. Using SST and a hammer, install 2 carrier retainers.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
c. Tighten the 16 bolts.
Torque: 22 Nm (225 kgf-cm,16 ft. lbs.)
d. Using a dial indicator, measure the differential case runout.
Maximum runout: 0.05 mm (0.0020 inch)
49. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY
a. Remove the 16 bolts.
b. Using SST, remove the 2 carrier retainers and washers.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09955-04061, 09954-04010, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
50. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
NOTICE: Do not damage the side bearing.
51. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 differential case bearings from the differential case.
SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010. 09953-04030, 09954-04010. 09955-04061, 09957-04010. 09958-04011)
Fig. 26 Removing Side Bearing Outer Race & Plate Washer:
b. Using SST and a press, remove the 2 outer races and adjusting plate washers.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
52. REMOVE REAR DIFFERENTIAL PINION SHAFT PIN
a. Using a chisel and a hammer, release the stake the out side of the differential case pin hole.
b. Using a pin punch (5 mm) and a hammer, remove the straight pin.
53. REMOVE REAR DIFFERENTIAL SIDE GEAR
a. Remove the pinion shaft from the differential case.
b. Remove the 2 pinion gears and thrust washers from the differential case.
c. Remove the 2 side gears and thrust washers from the differential case.
54. INSTALL REAR DIFFERENTIAL PINION
a. Install the 2 proper thrust washer on the side gears.
b. Install the 2 side gears to the differential case.
c. Install the 2 pinion gears and 2 pinion thrust washers on the differential case.
HINT: Using the table, select thrust washers which will ensure that the backlash is within the specification.
Thrust washer thickness
55. INSTALL REAR DIFFERENTIAL PINION SHAFT
a. Install the pinion shaft on the differential case.
56. ADJUST DIFFERENTIAL PINION GEAR BACKLASH
a. Install the 2 side gear shafts in the differential case.
b. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 inch)
NOTICE:
Differential gears should be able to rotate.
If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.
c. Remove the 2 side gear shafts.
57. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN
a. Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Using a chisel and a hammer, stake the differential case.
58. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.
b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT: Align the matchmarks on the ring gear and the differential case.
e. Tighten 2 new bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.
NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.
59. INSTALL REAR DIFFERENTIAL CASE BOLT
a. After the ring gear has cooled sufficiently, install new 8 ring gear set bolts to which thread lock has been applied.
Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent.
NOTICE: New ring gear set bolts should be used in every case.
b. Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
c. Tighten the bolts further by 60 - 90°.
NOTICE: Tighten the bolts in diagonally opposite pairs.
60. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 differential case bearings.
SST 09950-60010 (09951-00560), 09950-70010 (09951-07100)
Fig. 36 Installing Side Bearing Outer Race & Adjusting Washer:
b. Using SST and press install the adjusting plate washer and outer race.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
HINT:
^ The adjusting washer is used for adjusting the tooth contact pattern. 42 types of washer with different thicknesses are available.
^ First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.
^ When removing an adjusting washer, be sure to replace it with a new one.