Part 3

70. 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.

71. 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

72. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Raise the ring gear side 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 of the side gear shaft shaft snap ring before removing the outer race. Write down the result.

73. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY

NOTICE: Do not damage the case bearing.

74. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the flange, remove the nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)

75. 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, 09956-03060, 09955-03040)

76. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Using a magnet hand, remove the differential drive pinion oil slinger.

77. 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.

78. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Remove the front bearing from the differential carrier.

79. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install the spacer to the drive pinion.

80. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, install the drive pinion (rear bearing RR inner race) and rear drive pinion tapered roller bearing FR inner race to the differential carrier.
SST 09316-60011 (09316-00011), 09608-04031

81. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the rear differential drive pinion oil slinger to the differential drive pinion.

82. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Apply a small amount of MP grease to a new oil seal lip.
(b) Using SST and a press, insert the new oil seal into the rear differential carrier.
SST 09316-60011 (09316-00011), 09710-04101

NOTICE: Be sure that the oil seal is straight when inserting.

Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)

83. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR

(a) Using SST install the companion flange to the differential carrier assy.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)

(b) Apply hypoid gear oil LSD to the threads of a new nut.

(c) Using SST, hold the flange and tighten the nut while observing the preload with SST and torque wrench.
SST 09229-55010, 09330-00021
Torque: 98 Nm to 490 Nm (1,000 kgf-cm to 5,000 kgf-cm, 72 ft-lbf to 361 ft-lbf)

NOTICE:
- Do not tighten excessively, otherwise the threads will be stripped.
- Apply hypoid gear oil LSD to the threads of the nut and drive pinion.

HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm, 72 ft lbf) of force and then tighten it further while observing the preload.

84. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
(a) Insert the differential case from the ring gear tooth side to install.

NOTICE: Do not damage the case bearing or ring gear.

85. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a hammer; install the drive pinion side outer race.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: Tap in the outer race until half of the side gear shaft shaft snap ring groove of the differential carrier can be seen.

(b) Place the SST to the differential carrier.
SST 09571-50010
(c) Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race).

(d) Using SST and a hammer, install the ring gear side outer race.
SST 09950-70010 (09951-07200), 09608-32010

HINT: Tap in the outer race until it touches the case bearing roller.

86. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
(a) Using snap ring pliers, install the side gear shaft shaft snap ring in the differential carrier on the ring gear side.

HINT: Use the side gear shaft shaft snap ring installed when performing tooth contact adjustment.

(b) Set a dial indicator on the differential carrier.
(c) Tighten the SST bolt to alter the differential carrier's shape.

NOTICE: Do not alter the shape excessively.

Shaped limit: 0.20 mm (0.0079 in.)

(d) Using snap ring pliers, install the side gear shaft snap ring on the drive pinion side.

HINT: Use the side gear shaft shaft snap ring installed at tooth contact adjustment.

(e) Remove the dial indicator, tap the differential carrier on the drive pinion side using a plastic hammer to stabilize the case bearing.

87. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST and a torque wrench, measure the preload.
SST 09229-55010
Preload (at starting):
New bearing: 1.44 to 2.01 Nm (14.8 to 20.5 kgf-cm, 12.7 to 17.8 in.-lbf) Reused bearing: 0.5 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 in.-lbf)

NOTICE: Rotate the flange clockwise and counterclockwise several times to stabilize the bearing before measuring the differential drive pinion preload.

(b) If the preload is greater than the specified maximum value, replace the bearing spacer.

NOTICE: Because the bearing spacer deforms with use, replace the bearing spacer with a new one if the drive pinion preload is greater than the maximum value.

(c) If the preload is less than the specified minimum value, check the preload while retightening the nut by 5 to 10 degrees to adjust it into the specified value range.
Torque: 98 to 490 Nm (1,000 to 5,000 kgf-cm, 72 to 361 ft-lbf)

HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm, 72 ft lbf) of force and then tighten it further while observing the preload.

(d) Even if the nut tightening torque is greater than the specified maximum value, if the preload is less than the specified minimum value, loosen the nut and check that the threads of the nut and drive pinion are not stripped.
(e) If the threads are not stripped, replace the spacer and apply hypoid gear oil LSD to the threads and repeat the procedure.

88. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
(a) Place a dial indicator where 10 mm (0.39 in.) away from the drive pinion shaft tip at a right angle.
(b) Measure the shaft runout.
Maximum runout: 0.08 mm (0.0031 in.)

89. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Apply MP grease to the 2 new oil seal lips.
(b) Using SST and a hammer, tap a new oil seal until the face becomes flush with the differential carrier surface.
SST 09223-15030, 09950-70010 (09951-07200)

90. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
(a) Using SST and a press, install the new rear differential side gear shaft dust cover.
SST 09550-55011 (09550-05061), 09950-70010 (09951-07100), 09502-24010

91. 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.

92. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, check the torque (at starting) with the drive pinion and ring gear teeth 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)

93. INSTALL REAR DRIVE PINION NUT
(a) Using a chisel and a hammer, calk the nut.

94. REMOVE DIFFERENTIAL CARRIER ASSY REAR
(a) Remove the differential carrier assy from the overhaul attach ment.

NOTICE: Clean the fitting surface between the differential carrier and carrier cover.

95. INSTALL REAR DIFFERENTIAL CARRIER COVER

(a) Clean the FIPG attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.

NOTICE: Be careful not to scratch the fitting surface.

(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover.
Torque: 7.0 Nm (70 kgf-cm, 62 in.-lbf)

(c) Apply FIPG to the differential carrier at the position shown in the illustration.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

NOTICE:
- Apply the seal packing in drops, approximately 2 to 3 mm in diameter entirely.
- Overlap the seal packing at least 10 mm at the beginning and the end of application.
- Install the differential carrier cover within 3 minutes of application.

(d) Install the differential carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 35 ft-lbf)

NOTICE: Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.

(e) Install the rear differential breather plug.
Torque: 21 Nm (210 kgf-cm, 15 ft-lbf)

96. 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-lbf)
(d) Torque the 2 front side set bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft-lbf)
(e) Lower the jack.

97. 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, 36 ft-lbf)

98. ADD DIFFERENTIAL OIL
(a) Fill the rear differential carrier assy with differential gear oil.
Oil type: Differential synthetic gear oil GL-5 75W-90 or eguivalent.
Capacity: 1.35 ± 0.05 liters (1.43 ± 0.05 US qts, 1.19 ± 0.04 Imp. qts)

99. INSPECT DIFFERENTIAL OIL
100. INSTALL REAR DIFFERENTIAL FILLER PLUG
(a) Using a hexagon wrench (10 mm), install the filler plug with a new gasket.

101. 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 (10 mm), install the 3 washers and 6 hexagon bolts, while applying the brakes.
Torque: 83 Nm (850 kgf-cm, 61 ft-lbf)

102. INSTALL REAR DRIVE SHAFT ASSY RH

HINT: Install the RH side by the same procedures with LH side.

103. 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.

104. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH

HINT: Install the RH side by the same procedures with LH side.

105. 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.

106. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH

HINT: Install the RH side by the same procedures with LH side.

107. INSTALL REAR SUSPENSION MEMBER BRACE LH
(a) Install the rear suspension member brace LH with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)

108. INSTALL REAR SUSPENSION MEMBER BRACE RH

HINT: Install the RH side by the same procedures with LH 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 in.-lbf)

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 in.-lbf)

111. INSTALL REAR WHEEL
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-lbf)

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-lbf)

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 WICENTER BEARING SHAFT ASSY
118. INSTALL EXHAUST PIPE ASSY

119. INSTALL BODY RR END MOUNTING BRACKET SU B-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-lbf)
Bolt (B): 69 Nm (704 kgf-cm, 51 ft-lbf)
Nut: 54 Nm (551 kgf-cm, 40 ft-lbf)

120. INSTALL RR END BODY MOUNTING SET PLATE
(a) Install the RR end body mounting set plate LH with the 4 bolts.
Torque: 56 Nm (570 kgf-cm, 41 ft-lbf)

121. INSTALL RR END BODY MOUNTING SET PLATE
(a) Install the RR end body mounting set plate RH with the 4 bolts.
Torque: 56 Nm (570 kgf-cm, 41 ft-lbf)

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-lbf)

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 center with the 4 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

125. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
126. CHECK FOR EXHAUST GAS LEAKS