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OVERHAUL
61. INSTALL 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 side bearing.
b. Using SST and a hammer, install the 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.)
62. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
63. 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, 09958-04011, 09957-04010), 09950-60010 (09951-00480)
c. Take the differential case out of the carrier with lifting ring gear side as show in the illustration.
NOTICE: Do not damage the side bearing.
64. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the rear bearing.
SST 09502-24010 (09250-10011), 09950-70010 (09951-07100)
b. Using SST and a press, install the rear bearing outer race and adjusting washer.
SST 09502-24010 (09250-10011), 09950-70010 (09951-07100)
65. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, install the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
b. Install the drive pinion in the differential carrier.
c. Using SST and a press, install the front bearing on the drive pinion.
SST 09316-60011 (09316-00011), 09608-04031,
HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern.
Fig. 14 Pinion Flange Installation:
d. Using SST and a press, install the companion flange.
SST 09223-46011, 09325-40010
66. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Adjust the drive pinion preload by tightening the companion flange nut.
Torque: 490 Nm (5,000 kgf-cm, 361 ft. lbs.) or less
HINT: Using SST to hold the flange, tighten the nut.
SST 09950-30012 (09955-03040), 09229-55010, 09330-00021
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
b. Using SST and a torque wrench, measure the preload.
SST 09229-55010
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (15 - 18 kgf-cm, 13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
HINT: For vehicles which have run 8,000 km (5,000 miles) or less, if the preload value measured before disassembly is greater than the specification for a reused bearing, return the preload to the same as before disassembly.
67. INSTALL 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.
68. INSTALL REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY
a. Using SST and a hammer, install the 2 carrier retainers.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
b. Tighten the 16 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)
69. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
NOTICE: The difference between the maximum and minimum measure values must be less than 0.05 mm (0.0020 inch).
HINT: The measured values should be used as reference when selecting washers, so take a note of the values.
If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.
Adjusting washer thickness
70. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
Fig. 17 Proper Contact Pattern:
c. Inspect the tooth contact pattern.
If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.
NOTICE: Make sure to always use a new one when replacing adjusting washer.
HINT: Refer to the table for selection of the adjusting washer.
HINT: Adjust washers in 42 different thickness in 0.01 mm (0.004 inch) units are available
71. 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 the measured preload is less than the specification, replace the washer of the ring gear's tooth surface side with a thicker one.
If the preload is greater than the specification, replace the washer of the ring gear's tooth surface side with a thinner one.
HINT: Changing the snap ring thickness by 0 02 mm (0.0008 inch) will change the total preload by approximately 0.1 Nm (1 kgf-cm, 0.9 inch lbs.)
72. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY
SST 0995-40011 (09951-04020, 09952-04010, 09953-04030, 09955-04061, 09954-04010, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
73. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY (See step 36)
74. REMOVE REAR DRIVE PINION NUT (See step 37)
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
75. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (See step 38)
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)
76. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER (See step 41)
77. REMOVE DIFFERENTIAL DRIVE PINION (See step 42)
78. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (See step 44)
79. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new spacer on the drive pinion.
80. INSTALL DIFFERENTIAL DRIVE PINION (See step 65)
SST 09316-60011 (09316-00011), 09608-04031
81. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
82. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, install a new dust deflector.
SST 09316-60011 (09316-00011)
83. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Apply MP grease to a new oil seal lip.
b. Using SST, install the oil seal until its end is flush with the surface of the differential carrier.
SST 09316-60011 (09316-00011, 09316-00041), 09502-12010
Fig. 14 Pinion Flange Installation:
84. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST and a press, install the companion flange.
SST 09950-30012, 09223-56010, 09325-40010
NOTICE: Be careful not to damage the oil seal.
85. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY (See step 61)
86. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
Fig. 26 Removing Side Bearing Outer Race & Plate Washer:
a. Using SST and a press, install 2 new oil seals to the carrier retainers.
SST 09608-32010, 09950-70010 (09951-07150)
b. Coat the MP grease to the oil seal lip.
87. INSTALL REAR DIFFERENTIAL CARRIER RETAINER D-RING
a. Coat 2 new O-rings with hypoid gear oil.
b. Install the 2 O-rings to the carrier retainers.
88. INSTALL REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY
a. Using SST and a hammer, install the carrier retainer.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
NOTICE: Do not damage the differential case.
b. Install the 16 bolts and carrier retainer.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)
89. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Coat the threads and flange of a new nut with hypoid gear oil for LSD.
b. Using SST, tighten the nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
c. Using SST and a torque wrench, measure the preload.
SST 09229-55010
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (15 - 18 kgf-cm, 13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
If the preload is greater than the specification, replace the spacer.
If the preload is less than the specification, retighten the nut with a force of 13 Nm (130 kgf-cm, 9 ft. lbs.) at a time until the specified preload is reached.
Torque: 490 Nm (5,000 kgf-cm, 361 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
90. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION (See step 28)
91. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using SST and a hammer, install a new dust cover.
SST 09550-55011 (09550-05061), 09950-70010 (09951-07100), 09502-24010
92. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY
a. Using needle nose pliers, install 2 new snap rings to the side gear shafts.
b. Coat the MP grease to the snap rings.
c. Using a brass bar and a hammer, install the 2 side gear shafts.
HINT: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
NOTICE: Be careful not to damage the oil seal.
93. INSPECT TOTAL PRELOAD (See step 30)
SST 09229-55010
94. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and a hammer, caulking the nut.
95. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Remove the differential carrier from the overhaul stand, etc.
96. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Clean the contact surfaces of the carrier and cover of any residual FIPG material using cleaner.
b. Coat FIPG to the carrier or cover.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
c. Install the carrier cover to the carrier with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
HINT:
Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is for an hour or more.
Also, for 12 hours or more, avoid rapid acceleration/deceleration.
d. Install the breather plug.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
97. INSTALL DIFFERENTIAL CARRIER ASSY REAR
a. Install the 2 upper mount stoppers on the rear differential carrier assembly.
HINT: Use the upper mount stopper which was removed.
b. Support the rear differential carrier assembly with a jack and temporally install the lower mount stoppers and 2 new front side set bolts.
NOTICE: Do not let the rear differential carrier assembly interfere with the drive shaft.
c. Using a hexagon wrench (12 mm), install the 3 rear side set hexagon bolts.
Torque: 142 Nm (1,450 kgf-cm, 105 ft. lbs.)
d. Torque the 2 front side set bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
e. Lower the jack.
98. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.)
99. ADD DIFFERENTIAL OIL
a. Fill the rear differential carrier assy with hypoid gear oil.
Oil grade: Hypoid gear oil API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W or 80W-90
Capacity: 1.35 ± 0.05 liters (1.43 ± 0.05 US qts, 1.19 ± 0.06 Imp. qts.)
100. INSPECT DIFFERENTIAL OIL
101. INSTALL REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), install the filler plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.)
102. INSTALL REAR DRIVE SHAFT ASSY LH
a. Align the matchmarks, and connect the drive shaft to the side gear shaft.
NOTICE: Be careful not to damage the boots and end cover.
b. Using a hexagon wrench (8 mm), install the 3 washers and 6 hexagon bolts, while applying the brakes.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
103. INSTALL REAR DRIVE SHAFT ASSY RH
HINT: Install the RH side by the same procedures with LH side.
104. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH
a. Connect the rear suspension arm assy No.2 LH to the axle carrier with the cam bolt, cam plate and nut.
NOTICE: Do not torque the nut.
105. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT: Install the LH side by the same procedures with RH side
106. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH
a. Connect the rear suspension arm assy No 1 LH to the axle carrier with the bolt and nut
NOTICE: Do not torque the nut.
107. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT: Install the RH side by the same procedures with LH side.
108. INSTALL REAR SUSPENSION MEMBER BRACE RH
a. Install the rear suspension member brace with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
HINT: Install the LH side by the same procedures with RH side
109. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the front floor heat insulator No.1 with the 4 bolts
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.7)
110. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
a. Install the parking brake cable heat insulator with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
111. INSTALL REAR WHEEL
a. Install the rear wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
112. STABILIZE SUSPENSION
113. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH
a. Align the matchmarks, and fully tighten the nut
Torque: 110 Nm (1,120 kgf-cm, 81 ft. lbs.)
114. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT: Install the RH side by the same procedures with LH side
115. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH
a. Fully tighten the nut
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
116. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT: Install the RH side by the same procedures with LH side
117. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY
118. INSTALL EXHAUST PIPE ASSY
119. INSTALL BODY RR END MOUNTING BRACKET SUB-ASSY
a. Install the body RR end mounting bracket sub-assy with the 8 bolts and 3 nuts.
Torque:
Bolt (A): 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
Bolt (B): 69 Nm (704 kgf-cm, 51 ft. lbs.)
Nut: 54 Nm (551 kgf-cm, 40 ft. lbs.)
120. INSTALL RR END BODY MOUNTING SET PLATE
a. Install the RR end body mounting set plate with the 4 bolts.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
121. INSTALL RR END BODY MOUNTING SET PLATE
a. Install the RR end body mounting set plate with the 4 bolts.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
122. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH
a. Install the RR suspension member brace rear lower RH with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
123. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH
HINT: Install the LH side by the same procedures with RH side.
124. INSTALL FRONT FLOOR BRACE CENTER
a. Install the front floor brace CTR with the 4 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
125. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
126. CHECK EXHAUST GAS LEAK