Part 1
OVERHAULHINT:
COMPONENTS: See Diagrams; Exploded Views.
1. REMOVE REAR WHEEL
2. REMOVE PROPELLER SHAFT ASSY
3. REMOVE REAR AXLE HOUSING FILLER PLUG
4. REMOVE REAR AXLE HOUSING DRAIN PLUG
5. REMOVE REAR DISC BRAKE CALIPER ASSY LH
SST 09023-00100
6. REMOVE REAR DISC BRAKE CALIPER ASSY RH
HINT: Remove the RH side by the same procedures with the LH side
SST 09023-00100
7. REMOVE REAR DISC
8. REMOVE REAR DISC
HINT: Remove the RH side by the same procedures with the LH side.
9. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING
10. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING
HINT: Remove the RH side by the same procedures with the LH side
11. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING
12. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING
HINT: Remove the RH side by the same procedures with the LH side.
13. REMOVE PARKING BRAKE SHOE STRUT LH
14. REMOVE PARKING BRAKE SHOE STRUT RH
HINT: Remove the RH side by the same procedures with the LH side.
15. REMOVE PARKING BRAKE SHOE
16. REMOVE PARKING BRAKE SHOE
HINT: Remove the RH side by the same procedures with the LH side
17. SEPARATE SPEED SENSOR REAR LH
18. SEPARATE SPEED SENSOR REAR RH
HINT: Remove the RH side by the same procedures with the LH side
19. SEPARATE PARKING BRAKE CABLE ASSY NO.3
20. SEPARATE PARKING BRAKE CABLE ASSY NO.2
HINT: Remove the parking brake cable assy No.2 by the same procedures with the parking brake cable assy No.3.
21. REMOVE REAR AXLE SHAFT W/BACKING PLATE
22. REMOVE REAR AXLE SHAFT W/BACKING PLATE
HINT: Remove the RH side by the same procedures with the LH side
23. REMOVE REAR AXLE SHAFT LH OIL SEAL
SST 09308-00010
24. REMOVE REAR AXLE SHAFT RH OIL SEAL
HINT: Remove the RH side by the same procedures with the LH side.
SST 09308-00010
25. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Remove the 10 nuts and differential carrier assy.
NOTICE: Be careful not to damage the removal surface.
26. REMOVE REAR DIFFERENTIAL CARRIER GASKET
27. FIX DIFFERENTIAL CARRIER ASSY REAR
28. 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:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
29. 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.
30. 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.
31. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.56 - 0.85 Nm (6 - 9 kgf-cm, 4.9 - 7.5 inch lbs.)
32. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth ring gear in contact.
b. Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4 - 6 kgf-cm, 3.4 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
33. REMOVE REAR DRIVE PINION NUT
a. Using SST and a hammer, loosen the staked part of the nut.
SST 09930-00010
b. Using SST to hold the drive pinion companion flange, remove the nut.
SST 09330-00021
34. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
35. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00380), 09950-70010 (09951-07150), 09950-00020
36. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
37. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
38. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the drive pinion tapered roller bearing (inner) from the drive pinion.
SST 09556-22010
39. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Remove the 2 bolts and 2 rear differential bearing adjust locks.
40. REMOVE DIFFERENTIAL CASE ASSY
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 differential bearing caps.
c. Remove the 2 adjusting nuts.
d. Remove the rear differential case sub-assy and 2 case bearings from the differential carrier.
HINT: Tag the 2 case bearings outer races to show the location for reassembling.
41. REMOVE DIFFERENTIAL DRIVE PINION
a. Remove the differential drive pinion and bearing spacer from the differential carrier.
42. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the drive pinion tapered roller bearing (inner) from the drive pinion.
SST 09950-00020
If the drive pinion or ring gear are damaged, replace them as a set.
43. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
a. Remove the drive pinion plate washer from the drive pinion.
44. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a SST, remove the front tapered roller bearing (outer) from the carrier.
SST 09308-00010
b. Using a brass bar and a hammer, remove the oil storage ring from the carrier.
45. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the rear tapered roller bearing (outer) from the carrier.
46. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the lock plates.
c. Remove the 10 ring gear set bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
47. INSPECT DIFFERENTIAL CASE ASSY RUNOUT
HINT: It will be done only when it exceeds the limit at the ring gear run out check.
a. Install the rear differential case bearing to the differential case.
b. Install the differential case to the differential carrier.
c. Install the 2 bearing caps and 4 bolts to the differential carrier.
Torque: 85 Nm (867 kgf-cm, 63 ft. lbs.)
d. Inspect the differential case runout.
Maximum runout: 0.07 mm (0.0028 inch)
e. Remove the differential case.
f. Remove the rear differential case bearing.
48. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the rear differential case 2 bearings 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)
49. DISASSEMBLE DIFFERENTIAL CASE
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts.
c. Using a plastic hammer, separate the LH and RH case.
d. Remove these parts from the differential case.
1. Side gear (2 pieces)
2. Side gear thrust washer (2 pieces)
3. Spider
4. Pinion gear (4 pieces)
5. Pinion gear thrust washer (4 pieces)
50. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that no damage is identified on the differential pinion and differential side gear. If the differential pinion and/or differential side gear is damaged, replace the differential.
51. INSPECT DIFFERENTIAL CASE
a. Check that no damaged is differential case. If the differential case is damaged, replace the differential case.
52. INSTALL DIFFERENTIAL CASE ASSY
a. Install the rear differential side gear thrust washer to the rear differential side gear.
b. Install the rear differential pinion thrust washer and rear differential pinion to the rear differential spider.
c. Fix the differential case RH.
d. Install the rear differential side gear and rear differential spider to the differential case RH.
e. Using a dial indicator, measure the differential case RH side backlash while holding pinion toward the case.
Backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)
f. Remove the rear differential spider from the differential case RH.
g. Install the rear differential side gear and rear differential spider to the differential case LH.
h. Using a dial indicator, measure the differential case LH side backlash while holding pinion toward the case.
Backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers with different thickness.
Thrust washer thickness
i. Align the matchmarks and assemble the RH and LH cases.
j. Using a plastic hammer, install the differential case.
k. Install the 8 bolts.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)
53. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear 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 5 new lock plates and 10 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 5 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.
54. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the bearing on the differential case.
SST 09950-60010 (09951-00430, 09951-00480, 09951-00470, 09951-00550), 09950-70010 (09951-07150)