Part 2
OVERHAUL55. INSPECT DIFFERENTIAL RING GEAR RUNOUT
a. Install the differential case on the carrier, and install the 2 adjusting nut so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)
c. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 2 bearing caps, 2 adjusting nuts and differential case.
56. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using a press, install the dust deflector.
NOTICE: Be careful not to damage the dust deflector.
SST 09636-20010
57. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, install the oil storage ring.
b. Using SST and a press, install the tapered roller bearing (outer) to the carrier.
SST 09316-60011 (09316-00011, 09316-00021)
58. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the tapered roller bearing (outer) to the carrier.
SST 09316-60011 (09316-00041, 09316-00011)
59. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the plate washer on the drive pinion.
b. Using SST and a press, install the tapered roller bearing (inner) onto the drive pinion.
SST 09506-30012
60. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion, rear drive pinion tapered roller bearing and rear differential drive oil slinger.
HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.
b. Using SST, install the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030), 09330-00021 (09330-00030)
c. Coat the threads of the nut with hypoid gear oil LSD.
d. Using SST to hold the drive pinion companion flange, torque the nut.
Torque: 370 Nm (3,770 kgf-cm, 273 ft. lbs.) or less
NOTICE:
^ As there is no spacer, torque a little at a time, being careful not to overtighten it.
^ Apply hypoid gear oil LSD of the nut.
e. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.05 - 1.64 Nm (10.7 - 16.7 kgf-cm, 9.3 - 14.5 inch lbs.)
Reused bearing: 0.56 - 0.85 Nm (5.7 - 8.7 kgf-cm, 5.0 - 7.5 inch lbs.)
61. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Place the 2 bearing outer races on their respective bearings.
HINT: Make sure the right and left races are not interchanged.
62. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT
a. Install the 2 adjusting nuts on the carrier, making sure the nuts are threaded properly.
63. INSPECT AND ADJUST ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Align the matchmarks on the cap and carrier.
b. Install the right and left bearing caps with the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)
If the bearing cap does fit tightly on the carrier, the adjusting nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
c. Torque the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST. (4 pinion, w/LSD)
SST 09504-00011
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)
d. Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 inch).
e. While turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side.
After the bearings as settled, loosen the adjusting nut on the drive pinion side.
f. Using SST, torque the adjusting nut 1 - 1.5 notches from the 0 preload position.
g. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
HINT: The backlash is adjusted by turning the left and right adjusting nuts for an equal amounts. For example, loosen the nut on the right side one notch.
h. Torque the bearing cap bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)
64. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4 - 7 kgf-cm, 3.5 - 5.8 inch lbs.)
65. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at 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 the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Plate Washer thickness
66. REMOVE REAR DRIVE PINION NUT
SST 09330-00021 (09330-00030)
67. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
68. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
69. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
SST 09556-22010
70. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer to the drive pinion.
71. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
72. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
73. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Coat MP grease to the oil seal lip.
b. Using SST and a hammer, install a new carrier oil seal.
SST 09554-30011
Oil seal drive in depth: 1.0 ± 0.45 mm (0.039 ± 0.018 inch)
74. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST, install the drive pinion companion flange on the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030).
b. Coat the threads of a new nut with hypoid gear oil LSD.
c. Using SST to hold the flange, torque the nut.
SST 09330-00021 (09330-00030)
Torque: 370 Nm (3,770 kgf-cm, 273 ft. lbs.) or less
75. INSPECT DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.05 - 1.64 Nm (11 - 17 kgf-cm, 9.3 - 14.5 inch lbs.)
Reused bearing: 0.56 - 0.85 Nm (6 - 9 kgf-cm, 5.0 - 1.5 inch lbs.)
If the preload is greater than the specification. replace the bearing spacer.
If the preload is less than the specification, retorque the nut with 13 Nm (130 kgf-cm, 9 ft. lbs.) of torque at a time until the specified preload is reached.
Torque: 370 Nm (3,770 kgf-cm, 27 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.
76. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4 - 6 kgf-cm, 4.0 - 5.2 inch lbs.)
If the necessary, disassemble and inspect the differential.
77. 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.
78. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using a dial indicator, measure the runout of the drive pinion companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
79. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and hammer, stake the drive pinion nut.
80. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Install 2 new adjust lock on the bearing caps.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. After tightening belts, bend the nut locks.
81. INSTALL DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Clean the contact surfaces of the rear differential carrier assembly and rear axle housing assembly.
b. Install the rear differential carrier assembly and gasket with the 10 nuts and washers.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
82. INSTALL REAR AXLE SHAFT LH OIL SEAL
83. INSTALL REAR AXLE SHAFT RH OIL SEAL
HINT: Install the RH side by the same procedures with the LH side.
84. INSTALL REAR AXLE SHAFT W/BACKING PLATE
85. INSTALL REAR AXLE SHAFT W/BACKING PLATE
HINT: Install the RH side by the same procedures with the LH side.
86. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3
87. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.2
HINT: Install the parking brake cable assembly No.2 by the same procedures with the parking brake cable assembly No.3.
88. INSTALL SPEED SENSOR REAR LH
89. INSTALL SPEED SENSOR REAR RH
HINT: Install the RH side by the same procedures with the LH side
90. INSTALL PARKING BRAKE SHOE
91. INSTALL PARKING BRAKE SHOE
HINT: Install the RH side by the same procedures with the LH side
92. INSTALL PARKING BRAKE SHOE STRUT LH
93. INSTALL PARKING BRAKE SHOE STRUT RH
HINT: Install the RH side by the same procedures with the LH side.
94. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING
95. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING
HINT: Install the RH side by the same procedures with the LH side.
96. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING
97. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING
HINT: Install the RH side by the same procedures with the LH side
98. CHECK PARKING BRAKE INSTALLATION
99. INSTALL REAR DISC
100. INSTALL REAR DISC
HINT: Install the RH side by the same procedures with the LH side
101. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH
SST 09023-00101
102. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH
HINT: Install the RH side by the same procedures with the LH side
SST 09023-00101
103. BLEED BRAKE LINE
104. CHECK FLUID LEVEL IN RESERVOIR
105. CHECK BRAKE FLUID LEAKAGE
106. REFILL DIFFERENTIAL OIL
107. INSPECT AND ADJUST DIFFERENTIAL OIL
108. INSTALL PROPELLER SHAFT ASSEMBLY
109. INSTALL REAR WHEEL
Torque: 112 Nm (1,140 kgf-cm, 83 ft. lbs.)
110. INSPECT PARKING BRAKE PEDAL TRAVEL
111. ADJUST PARKING BRAKE PEDAL TRAVEL
112. CHECK ABS SPEED SENSOR SIGNAL