Part 1
OVERHAULHINT: See Diagrams; Exploded Views for additional images.
1. REMOVE REAR WHEEL
2. REMOVE FRONT FLOOR BRACE CENTER
(a) Remove the 4 bolts and floor brace center.
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 ASSY
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 LH.
9. REMOVE RR END BODY MOUNTING SET PLATE
(a) Remove the 4 bolts and RR end body mounting set plate RH.
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 LH
(a) Remove the 2 bolts and rear suspension member brace LH.
15. REMOVE REAR SUSPENSION MEMBER BRACE RH
HINT: Remove the RH side by the same procedures with LH side.
16. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Remove the bolt and nut, separate the rear suspension arm assy No.1 LH from the axle hub.
17. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH
HINT: Separate the RH side by the same procedures with LH side.
18. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH
(a) Place match marks on the adjusting cam and rear suspension arm assy No.2 LH.
(b) Remove the cam bolt, cam plate and nut, separate the rear suspension arm assy No.2 LH from the axle hub.
19. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH
HINT: Separate the RH side by the same procedures with LH side.
20. 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 (10 mm), remove the 6 hexagon bolts and 2 washers with depressing the brake pedal.
(c) Separate the drive shaft from the differential carrier.
21. SEPARATE REAR DRIVE SHAFT ASSY RH
HINT: Separate the RH side by the same procedures with LH side.
22. 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.
23. 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 from the differential carrier cover.
24. FIX DIFFERENTIAL CARRIER ASSY REAR
(a) Set the differential carrier to the overhaul stand, etc., as shown in the illustration.
25. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.
26. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the ring gear at least 3 points at least and check that the average value is within the specification.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
NOTICE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 in.).
If the backlash is not within the specification, adjust the backlash (see step 66).
27. 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 primer.
(b) Hold the companion flange firmly and rotate the ring gear in both directions.
(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 replace the adjusting washer with a new one.
HINT: There are 42 thicknesses of the rear differential drive pinion plate washers available in 0.01 mm (0.004 in.) difference.
28. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Using a vise, hold the differential case between two aluminium plates.
(b) Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.).
If the backlash is not within the specification, replace the rear differential case sub-assy with a new one.
29. 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 in.) away from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 in.)
If the runout is greater than the maximum, replace the drive pinion and ring gear.
30. 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 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 in.-lbf)
If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.
31. 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 0.46 to 1.37 Nm (4.69 to 13.97 kgf-cm, 4.07 to 12.13 in.-lbf)
If necessary, disassemble and inspect the differential.
32. 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.
(b) Using a screwdriver, remove the snap ring.
33. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
(a) Using a screwdriver and a hammer remove the dust cover.
34. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, remove the 2 oil seals.
SST 09308-00010
35. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
(a) Install the SST to the rear differential carrier assy.
SST 09571-50010
(b) Install a dial indicator to the rear differential carrier assy.
(c) Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and side gear shaft shaft snap ring.
NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 (0.008 in.) mm.
HINT:
- Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
- Approximately 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and the side gear shaft shaft snap ring is sufficient enough for the washer to move slightly.
(d) Using snap ring pliers, remove the side gear shaft shaft snap ring on the drive pinion side.
HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.
(e) Remove the dial indicator and loosen the SST bolt.
NOTICE: Do not remove the SST.
36. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
(a) Using SST and a hammer, create a clearance between the side bearing (outer) on the ring gear and side gear shaft shaft snap ring.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: The clearance cannot be seen, but tapping the SST with a hammer three or four times should be enough.
(b) Using snap ring pliers, remove the side gear shaft shaft snap ring on the ring gear side.
HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.
37. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Tighten the SST bolt and push out the outer race on the ring gear side.
SST 09571-50010
NOTICE: Do not drop the side bearing (outer race).
(b) Remove the SST
38. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Raise the ring gear of the differential case slightly to remove the drive pinion side outer race.
HINT: For reassembly, check the installation position of the outer race and the side gear shaft shaft snap ring before removing the outer race. Write down the result.
39. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
NOTICE: Do not damage the case bearing.
40. 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)