REAR DIFFERENTIAL REMOVAL/INSTALLATION

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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.

2.  Remove the insulator. (LF (MT)) (See TRANSMISSION REMOVAL/INSTALLATION [M15M-D].) (See TRANSMISSION REMOVAL/INSTALLATION [P66M-D].)

3.  Remove the tunnel member. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [M15M-D].) (See TRANSMISSION REMOVAL/INSTALLATION [P66M-D].)

4.  Remove the tunnel member component. (AT) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL].)

5.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L8, LF].)

6.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

7.  Disconnect the rear auto leveling sensor link. (Vehicle with discharge headlight system) (See REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Add rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

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1	ABS wheel-speed sensor
2	Parking brake cable
3	Brake caliper component (See Brake Caliper Component Removal Note.)
4	Rear lateral link (upper) ball joint (See REAR TRAILING LINK (UPPER) REMOVAL/INSTALLATION.)
5	Stabilizer control link (lower) (See REAR STABILIZER REMOVAL/INSTALLATION.)
6	Rear lateral link (lower) ball joint (See REAR LATERAL LINK (LOWER) REMOVAL/INSTALLATION.)
7	Shock absorber bolt (lower)
8	Toe control link ball joint
9	Rear trailing link (upper) ball joint (See REAR TRAILING LINK (UPPER) REMOVAL/INSTALLATION.)
10	Rear trailing link (lower)
11	Rear drive shaft, rear knuckle component (See Rear Drive Shaft, Rear Knuckle Component Removal Note.) (See Rear Drive Shaft, Rear Knuckle Component Installation Note.)
12	Power plant frame (See Power Plant Frame Removal Note.) (See Rear Differential, Power Plant Frame Installation Note.)
13	Rear differential (See Rear Differential Removal Note.) (See Rear Differential, Power Plant Frame Installation Note.)
14	Differential mount

Brake Caliper Component Removal Note

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

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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.

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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 transmission jack.

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2.  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.  Remove the rear differential, while supporting it securely with a jack, and moving the jack gradually.

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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 removing 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 moving.

1.  Support the rear differential using the jack.

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2.  Temporarily tighten the differential mounting installation bolts.

3.  Support the transmission and differential so that they are level using a transmission jack.

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4.  Install the power plant frame.

5.  Temporarily tighten the nuts 1, 2, 3 in order shown in the figure.

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6.  Tighten nut 2 until the power plant frame is seated in the rear differential.

7.  Temporarily tighten the nuts 4, 5 in order shown in the figure.

8.  Install the tunnel member (MT) or tunnel member component (AT). (See TRANSMISSION REMOVAL/INSTALLATION [M15M-D].) (See TRANSMISSION REMOVAL/INSTALLATION [P66M-D].) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL].)

9.  Raise the front end of the power plant frame (transmission side) or the transmission with the transmission jack, and adjust dimension A to 26.7—34.7 mm {1.06—1.36 in} (lower surface of power plant frame-upper surface of the tunnel member) as shown in the figure.

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Note

•  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.

10.  Tighten the power plant frame installation nuts.

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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.

12.  Remove the tunnel member (MT) or tunnel member component (AT).

13.  Temporarily loosen the differential mounting 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.

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.

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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.