Rear Axle
AXLE SHAFT
CAUTION: Before removing the rear axle, disconnect the ABS wheel sensor from the assembly. Then move it away from the axle. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative.
^ Wheel bearing does not require maintenance.
^ If growling noise is emitted from wheel bearing during operation, replace wheel bearing assembly.
^ If the wheel bearing assembly is removed, it must be replaced. The old assembly must not be re-used.
REMOVAL
1. Remove the ABS wheel sensor from the axle case and reposition out of the way.
2. Remove the rear brake caliper assembly without disconnecting the brake hose and reposition out of the way.
3. Remove the parking brake assembly from the back plate and torque member.
4. Remove the axle bearing nuts securing the axle shaft assembly to the axle case.
5. Draw the axle shaft assembly out of the axle case using Tools as shown.
Tool number
A: KV40101000 (J-25604-01)
B: ST36230000 (J-25840-A)
6. Remove the O-ring.
7. Remove the axle oil seal using Tools as shown.
Tool number
A: - (J-26941 part of J-46215)
B: - (J-23907)
^ Do not reuse the axle oil seal once it is removed. Always install a new axle oil seal.
^ Apply a constant pressure on the slide hammer while turning the slide hammer 180° degrees periodically while pulling the axle oil seal out.
8. Remove the ABS sensor rotor using Tool. Discard the ABS sensor rotor.
Tool number: KV40106500 (J-45073)
NOTE: Always replace the ABS sensor rotor with a new one.
9. Remove the snap ring and shim washer. Discard the snap ring and shim washer.
NOTE: Always replace the snap ring and shim washer with new ones.
10. Remove the bearing ring retainer from the axle shaft using Tool as shown. Discard the bearing ring retainer.
Tool number: KV40106500 (J-45073)
NOTE: Always replace the bearing ring retainer with a new one.
11. Remove the back plate and torque member with the axle bearing attached from the axle shaft using a suitable press.
12. Remove the axle bearing studs to release the axle bearing from the back plate and torque member using a suitable hammer or press.
13. Remove the wheel studs using a suitable hammer or press.
14. Remove the grease catcher from the axle shaft.
INSPECTION AFTER REMOVAL
Axle Shaft
^ Check axle shaft for straightness, cracks, damage, wear and distortion. Replace if necessary.
Axle Case
^ Check axle case for yield, deformation and cracks. Replace if necessary.
INSTALLATION
1. Install the grease catcher on the axle shaft.
2. Install the wheel studs through the grease catcher into the axle shaft using a suitable press.
NOTE: All six wheel studs must be pressed on at the same time and are flush with the grease catcher when installed.
3. Position the new axle bearing on the back plate and torque member.
4. Install the axle bearing studs using a suitable press to attach the axle bearing to the back plate and torque member.
NOTE: Always replace the axle bearing with a new one.
5. Install the back plate and torque member, new axle bearing and new bearing ring retainer on the axle shaft using a suitable press.
Maximum press load "P1": 98 kN (10 ton, 11.0 US ton, 9.8 Imp ton)
CAUTION: Press the new bearing ring retainer on the axle shaft with the taper side positioned as shown.
NOTE: Always replace the bearing ring retainer with a new one.
6. Select the correct size shim washer.
^ Select the size of shim washer so that the installed snap ring to shim washer clearance is within specification.
Snap ring to shim washer clearance: 0.2 mm (0.008 inch) or less
7. Install a new snap ring on the axle shaft.
^ Do not over spread the snap ring when installing, measure the outer diameter of the snap ring after installation and replace if the snap ring outer diameter exceeds specification.
Snap ring outer diameter installed: 47.5 mm (1.87 inch) maximum
NOTE: Always replace the snap ring with a new one.
8. Check the snap ring to shim washer clearance, repeat steps 7 and 8 as necessary until the installed snap ring to shim washer clearance is within specification.
9. Perform break-in rotation of the wheel bearing.
a. Rotate the wheel bearing in the forward direction for a minimum of 10 revolutions at 50 - 70 RPM.
b. Rotate the wheel bearing in the reverse direction for a minimum of 10 revolutions at 50 - 70 RPM.
10. Measure the rotational torque of the wheel bearing.
Rotational speed 8 - 12 RPM
Rotational torque 1.8 Nm (0.18 kg-m, 16 inch lbs.)
11. Inspect that the wheel bearing is free from axial play relative to the axle shaft.
12. Install a new ABS sensor rotor on the axle shaft using a suitable press.
CAUTION: Press the new ABS sensor rotor on the axle shaft with the notch side positioned as shown.
NOTE: Always replace the ABS sensor rotor with a new one.
13. Install the new axle seal into the axle case using Tool as shown.
^ After installing the new oil seal, coat the sealing lip with oil.
^ Install the new oil seal with the seal facing outwards so that the seal is fully seated in the axle case.
Tool number: - (J-34115 part of J-46215)
14. Apply multi-purpose grease to the recess of axle case end as shown.
15. Apply gear oil to the spline of axle shaft. Coat the axle oil seal surface of axle shaft with multi-purpose grease as shown.
16. Insert Tool into the new axle oil seal as a guide.
CAUTION: When inserting axle shaft, be careful not to damage oil seal.
NOTE: The split ends of the Tool must butt up together and not overlap as shown.
Tool number: - (J-34296-1 part of J-46215)
17. Insert the axle shaft assembly. Tighten the axle shaft nuts evenly in a criss-cross pattern to specification.
^ Remove the Tool when the axle shaft assembly is approximately 90% inserted to protect the new axle oil seal.
Tool number: - (J-34296-1 part of J-46215)
18. Install the parking brake assembly on the back plate and torque member.
19. Install the rear brake caliper assembly.
20. Install the ABS wheel sensor into the axle case.