Removal and Replacement

REAR DIFFERENTIAL REMOVAL/INSTALLATION

CAUTION:
- Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Drain the rear differential oil. Service and Repair

2. Remove the rear auto leveling sensor. Rear Auto Leveling Sensor Removal/Installation

3. Remove the tunnel member. Service and Repair

4. Remove the middle pipe and main silencer. Service and Repair

5. Remove the TWC. Service and Repair

6. Remove the heat insulator. Transmission Removal/Installation Automatic Transmission Removal/Installation - SJ6A-EL

7. Remove the propeller shaft. Service and Repair

8. Remove in the order indicated in the table.

9. Install in the reverse order of removal.

10. Add rear differential oil. Service and Repair

11. Inspect the rear wheel alignment. Rear Wheel Alignment









Brake Caliper Component Removal Note

1. Suspend the brake calliper component using a cable or equivalent.






2. Temporarily tighten the wheel nut to prevent the disc plate from falling off.

Rear Drive Shaft, Rear Knuckle Component Removal Note

1. Insert a tire lever or equivalent between the rear differential and differential side outer ring, and remove the rear drive shaft.






CAUTION:
- The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when removing the drive shaft from the differential.

2. Pull the rear drive shaft and rear knuckle component to the outer side, and detach the rear drive shaft from the rear differential.

3. To hold the rear drive shaft and rear knuckle component, install the rear lateral link (upper) to the rear knuckle temporarily after disconnecting the rear drive shaft.

Power Plant Frame Removal Note

1. Support the transmission using a jack.






2. Support the rear differential using a jack.






3. Remove the power plant frame.

Rear Differential Removal Note

WARNING:
- If the rear differential falls off, it can cause serious injuries or death, and damage to the vehicle. When removing the rear differential, verify that it is supported securely with a jack.

1. Support the rear differential using a jack.






2. Remove the differential mounting installation bolts.

3. Lower the jack slowly and remove the rear differential.

Rear Differential, Power Plant Frame Installation Note

WARNING:
- If the rear differential falls off, it can cause serious injuries or death, and damage to the vehicle. When installing the rear differential, verify that it is supported securely with a jack.

CAUTION:
- Tighten the differential mounting installation bolts completely only after performing the power plant frame installation and adjustment. If the differential mounting bracket is installed at an incorrect angle, the differential mounting bracket bushings will twist and cause an abnormal noise while the vehicle is moving.

1. Support the rear differential using a jack.






2. Temporarily tighten the differential mounting installation bolts.

3. Install the power plant frame.

4. Install the plate.

5. Temporarily tighten the bolts and nuts as shown in the figure.






6. Tighten the nut B until the power plant frame is seated in the rear differential.

7. Install the heat insulator, TWC, middle pipe, main silencer and front tunnel member. Transmission Removal/Installation Automatic Transmission Removal/Installation - SJ6A-EL Service and Repair

8. Raise the power plant frame front end (transmission side) or transmission using a jack so that dimension A (between power plant frame lower surface and front tunnel member lower surface) shown in the figure is within the adjustment value.






Adjustment dimension A
- 55-57 mm {2.17-2.24 in}

NOTE:
- When raising the power plant frame without a transmission jack, use bolts (M12x1.25) with a thread length of 55 mm {2.17 in} or more. Tighten the bolts from the underside of the front tunnel member as shown in the figure and raise the power plant frame.
- When using bolts, the underside of the power plant frame could be damaged. Affix tape to the underside of the frame to prevent damage.
- If there is the possibility of age-related bending/deterioration of the mount, adjust dimension A to approx. 15 mm {0.59 in} higher than the adjustment value to facilitate obtaining the specification.

9. Tighten the bolts and nuts on the rear differential side in the order shown in the figure.










10. Tighten the bolts and nuts on the transmission side as shown in the figure.






Tightening torque
- 126.0-154.0 Nm {12.9-15.7 kgf-m, 93.0-113.5 ft-lbf}

11. Verify that dimension A is within the specification with the transmission jack and the adjustment bolt removed.

- If not within the specification, adjust dimension A again.

Standard dimension A
- 48.4-56.4 mm {1.91-2.22 in}

12. Temporarily loosen the differential mount installation bolts, straighten the differential mounting bracket bushings, and then tighten the differential mounting installation bolts again to the specified torque.

CAUTION:
- Never support the rear differential using a jack when tightening the differential mounting installation bolts. Otherwise, the differential mounting bracket bushings will twist and cause an abnormal noise while the vehicle is moving.

Tightening torque
- 74.5-105.0 Nm {7.60-10.70 kgf-m, 55.0-77.44 ft-lbf}

Rear Drive Shaft, Rear Knuckle Component Installation Note

1. Install a new drive shaft clip to the clip groove at the top of the rear drive shaft with the clip opening facing upward and the clip width within the specification.






Standard
- 32 mm {1.3 in}

2. After installing the clip, measure the outer diametric if it exceeds the specification, reinstall a new clip.

3. Apply differential oil to the differential oil seal lip.

CAUTION:
- The sharp edges of the rear drive shaft can slice or puncture the oil seal Be careful not to damage the oil seal when installing the rear drive shaft from the rear differential.

4. Insert the rear drive shaft into the rear differential with the clip opening facing upward.

5. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side towards the axle.