Part 1
OVERHAUL
HINT:
^ A bolt without a torque specification is shown in the standard bolt chart.
^ Use the same procedures for the RH side and LH side.
1. REMOVE REAR WHEEL
2. REMOVE FRONT FLOOR BRACE CENTER
3. REMOVE REAR SUSPENSION MEMBER BRACE REAR LOWER LH
4. REMOVE REAR SUSPENSION MEMBER BRACE REAR LOWER RH
5. REMOVE HEATED OXYGEN SENSOR
6. REMOVE EXHAUST PIPE ASSY
7. REMOVE FRONT FLOOR HEAT INSULATOR NO. 1
8. REMOVE PARKING BRAKE CABLE HEAT INSULATOR
9. REMOVE REAR END BODY MOUNTING SET PLATE LH
10. REMOVE REAR END BODY MOUNTING SET PLATE RH
11. REMOVE MAIN MUFFLER HEAT INSULATOR
12. REMOVE BODY REAR END MOUNTING BRACKET SUB-ASSY
13. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY
14. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a 10 mm hexagon wrench, remove the filler plug and gasket.
15. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a 10 mm hexagon wrench, remove the drain plug and gasket.
b. Drain the differential oil.
16. REMOVE REAR SUSPENSION MEMBER BRACE LH
17. REMOVE REAR SUSPENSION MEMBER BRACE RH
18. DISCONNECT REAR SUSPENSION ARM ASSY NO. 1 LH
19. DISCONNECT REAR SUSPENSION ARM ASSY NO. 1 RH
20. DISCONNECT REAR SUSPENSION ARM ASSY NO. 2 LH
21. DISCONNECT REAR SUSPENSION ARM ASSY NO. 2 RH
22. DISCONNECT REAR DRIVE SHAFT ASSY LH
23. DISCONNECT REAR DRIVE SHAFT ASSY RH
24. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Support the differential carrier with a jack.
b. Using a 12 mm hexagon wrench, remove the 3 hexagon bolts.
c. Remove the 2 bolts and 2 lower mount stoppers.
d. Remove the differential.
e. Remove the 2 upper mount stoppers from the differential carrier.
25. REMOVE REAR DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and hammer, tap out 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.
26. FIX DIFFERENTIAL CARRIER ASSY REAR
27. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, measure the runout of the ring gear.
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.
28. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, measure the backlash of the ring gear.
HINT: Perform the measurements at 3 or more positions around the side bearing preload.
Backlash: 0.08 to 0.13 mm (0.0031 to 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 as specified, adjust the backlash.
29. 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.
NOTICE: Make sure to always replace the adjusting washer with a new one.
HINT: Refer to the adjusting washer table on the next page.
d. Rear differential drive pinion plate washers are available in 42 sizes, each with a 0.01 mm (0.0004 inch) thickness difference.
30. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
a. Using a vise, hold the differential case between two aluminum 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 inch).
If the backlash is not within the specification, replace the rear differential case sub-assembly with a new one.