Part 1
OVERHAUL1. REMOVE REAR WHEEL
2. REMOVE EXHAUST PIPE ASSEMBLY
3. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY
4. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), remove the filler plug and gasket.
5. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the drain plug and gasket, drain the oil.
6. SEPARATE STRUT ROD ASSY REAR
7. SEPARATE REAR SUSPENSION ARM ASSY NO. 1 LH
8. SEPARATE REAR SUSPENSION ARM ASSY NO. 1 RH
HINT: Remove the RH side by the same procedures with LH side.
9. SEPARATE REAR SUSPENSION ARM ASSY NO. 2 LH
10. SEPARATE REAR SUSPENSION ARM ASSY NO. 2 RH
HINT: Remove the RH side by the same procedures with LH side.
11. REMOVE REAR DRIVE SHAFT ASSY LH
12. REMOVE REAR DRIVE SHAFT ASSY RH
HINT: Remove the RH side by the same procedures with LH side.
13. REMOVE REAR SUSPENSION MEMBER SUB-ASSY
14. REMOVE REAR DIFFERENTIAL SUPPORT NO. 1
a. Support the differential carrier assy rear with a jack.
b. Remove the 2 bolts, 2 lock nuts differential support from the suspension member.
c. Remove the 2 bolts, 2 lock nuts and rear differential support No. 1 from the differential carrier assy.
15. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Remove the 3 bolts, dynamic damper and differential carrier assy rear.
NOTICE: Be careful not drop the differential carrier assy rear.
16. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO. 1
a. Only when the rear differential mount cushion No. 1 is damaged, perform this operation.
b. Using SST, remove the rear differential mount cushion No. 1.
SST 09316-12010, 09570-24010
NOTICE:
^ Do not bring SST into contact with the sub-frame.
^ Do not set SST's bolt obliquely.
^ Do not set the SST in wrong direction.
^ Screw the 2 bolts of SST equally into the 2 holes of the rear differential mount.
17. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO. 2
a. Only when the rear differential mount cushion NO. 2 is damaged, perform this operation.
b. Using SST, remove the rear differential mount cushion NO. 2.
SST 09316-12010, 09570-24010
NOTICE:
^ Do not bring SST into contact with the sub-frame.
^ Do not set SST's bolt obliquely.
^ Do not set the SST in wrong direction.
18. REMOVE REAR DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and a hammer, separate the carrier cover from differential carrier assy.
c. Remove the breather plug from the differential carrier cover.
d. w/Torque sensing LSD: Remove the bolt and oil deflector from the carrier cover.
19. FIX DIFFERENTIAL CARRIER ASSY REAR
20. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear with new one.
21. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
22. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 63)
23. DIFFERENTIAL PINION AND SIDE GEAR BACKLASH (W/O TORQUE SENSING LSD)
a. Using a dial indicator check the backlash of the side gear while holding 1 pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness (See step 51).
HINT: Measure the backlash of the side gear with the side gear shaft installed.
24. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.10 mm (0.0039 inch)
25. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the back lash between the drive pinion and ring gear.
Preload (at starting): 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.2 - 7.8 inch lbs.)
26. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
If necessary, disassemble and inspect the differential.
27. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY (W/O TORQUE SENSING LSD)
a. Using needle nose pliers, remove the 2 snap rings from the 2 side gear shafts.
b. Remove the 2 side gear shafts.
28. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY (W/TORQUE SENSING LSD)
a. Using SST and 2 nuts, remove the 2 side gear shafts from the differential.
SST 09520-24010 (09520-24010, 09520-32040)
b. Using 2 screwdrivers and a hammer, remove the 2 snap rings from the 2 side gear shafts.
29. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using a screwdriver and a hammer, remove the side gear shaft dust cover.
30. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL
a. Using SST, remove the 2 oil seals from the housing.
SST 09308-00010
31. REMOVE REAR DRIVE PINION NUT
a. Using a chisel and a hammer, unstake the staked part of the nut.
b. Using SST to hold the flange, remove the nut.
SST 09330-00021
32. 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, 09955-03030, 09956-03020)
33. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07150), 09950-00020
34. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
35. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
36. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
37. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
38. REMOVE DIFFERENTIAL CASE ASSY
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.
c. Using SST and a screwdriver, remove the 2 plate washers.
SST 09504-22011
HINT: Measure the plate washer and note down the thickness.
d. Remove the differential case assy and 2 bearing outer races from the differential carrier.
HINT: Tag the 2 bearing outer races to show the location for reassembling.
39. REMOVE DIFFERENTIAL DRIVE PINION
40. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the rear bearing from the drive pinion.
SST 09950-00020
HINT: If the drive pinion or ring gear are damaged, replace them as a set.
b. Remove the plate washer.
41. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the front bearing (outer race) from the carrier.
42. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the rear bearing (outer race) from the carrier.
43. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the 4 lock plates.
c. Remove the 8 ring gear set bolts and 4 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
44. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSY
a. Install the differential case in the differential carrier.
b. Install the right and left bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
c. Using a dial indicator, measure the differential case runout.
Maximum case runout: 0.07 mm (0.0028 inch)
d. Remove the differential case.
45. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing (LH) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
46. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing (RH) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
47. REMOVE REAR DIFFERENTIAL PINION SHAFT (W/O TORQUE SENSING LSD)
a. Using a pin punch (5 mm) and a hammer, remove the straight pin.
b. Remove the differential pinion shaft.
c. Remove the 2 differential pinions.
d. Remove the 2 differential pinion thrust washers.
e. Remove the 2 side gears.
f. Remove the 2 side gear thrust washers.
48. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that no damage is identified on the differential pinion and side gear. If the differential pinion and/or side gear is damaged, replace the differential.
49. INSPECT DIFFERENTIAL CASE
a. Check that no damage is differential case. If the differential case is damaged, replace the differential case.
50. INSTALL REAR DIFFERENTIAL PINION SHAFT (W/O TORQUE SENSING LSD)
a. Install the 2 thrust washers on the 2 side gears.
b. Install the 2 side gears, 2 differential pinions, 2 differential pinion thrust washers and differential pinion shaft in the differential case.
HINT: Align the holes of the differential case and differential pinion shaft.
51. ADJUST DIFFERENTIAL PINION GEAR BACKLASH (W/O TORQUE SENSING LSD)
a. Install the side gear shaft.
b. Measure the side gear backlash while holding 1 pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.
HINT:
^ Measure the backlash of the side gear with the side gear shaft installed.
^ Refer to the following table to select 2 thrust washers, which will ensure that the backlash is within the specification.
Thrust washer thickness
c. Remove the side gear shaft.
d. Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
e. Using a chisel and a hammer, stake the outside of the differential case pin hole.
52. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to approximately 100°C (212°F) in the boiling water.
c. Carefully take the ring gear out of the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
e. Align the matchmarks on the ring gear and differential case.
f. Temporarily install 4 new lock plates and 8 bolts.
g. After the ring gear cools down enough, torque the 8 bolts uniformly at a time.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)
HINT: Tighten the bolts in diagonal order little by little over several times.
h. Using a chisel and a hammer, stake the 4 lock plates.
HINT: Stake one claw so that it is flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the half on the tightening side.
53. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the case bearing (RH) into the differential case.
SST 09636-20010
54. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the case bearing (LH) into the differential case.
SST 09636-20010