Part 3
DIFFERENTIAL CARRIER ASSEMBLY REAR (4WD)OVERHAUL
67. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the oil slinger, as shown in the illustration.
68. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install a new oil seal.
SST 09554-22010
Oil seal drive in depth: 2.0 ± 0.3 mm (0.079 ± 0.012 inch)
b. Apply MP grease to the oil seal lip.
69. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, install a new dust deflector.
SST 09223-00010
NOTICE: Be careful not to damage the dust deflector.
70. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST, install the companion flange on the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
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
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
71. INSPECT DIFFERENTIAL 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: 1.1 - 1.7 Nm (11 - 17 kgf-cm, 9.6 - 14.8 inch lbs.)
Reused bearing: 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.2 - 7.8 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: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) or less
^ If the torque exceeds the maximum while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.
72. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
73. INSPECT DIFFERENTIAL RING GEAR BACKLASH (See step 19)
74. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (See step 22)
75. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and a hammer, stake the drive pinion nut.
76. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL
a. Using SST and a hammer, install 2 new oil seals.
SST 09550-00032, 09950-70010 (09951-07200)
Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.019 inch)
b. Apply MP grease to the oil seal lip.
77. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using a steel plate and a press, install a new dust cover.
NOTICE: Be careful not to damage the dust cover.
78. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY
a. Install the 2 side gear shafts to the differential case.
b. Using needle nose pliers, install 2 new snap rings to the 2 side gear shafts.
c. Using vernier calipers, measure the distance between the right and left side gear shafts, as shown in the illustration.
Standard distance: 242 mm (9.528 inch)
79. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Install the oil deflector and bolt to the carrier cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
b. Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
c. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
d. Apply FIPG to the carrier.
FIPG: 08826-00090, THREE BOND 1281 or equivalent
HINT:
^ FIPG should be applied 2 to 3 mm in diameter with no break.
^ Allow for overlap of 10 mm (0.37 inch) or more between the start and end of FIPG application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is for an hour or more. Also, for 12 hours or more, avoid rapid acceleration/deceleration.
e. Install the carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
80. INSTALL REAR DIFFERENTIAL SUPPORT NO.1
a. Install the rear differential support No.1 to the differential carrier assembly rear with 2 bolts and 2 nuts.
Torque: 85 Nm (867 kgf-cm, 63 ft. lbs.)
HINT: Hold the bolt and tighten the nut.
81. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER
a. Install the rear differential dynamic damper to the rear differential support No.1 with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
82. INSTALL DIFFERENTIAL SUPPORT ASSEMBLY REAR
a. Install the differential support assembly rear to differential carrier assembly rear with the 3 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
83. INSTALL DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Jack up the differential carrier assembly rear.
b. Install the differential carrier assembly rear with the 2 bolts.
Torque: 106 Nm (1,081 kgf-cm, 78 ft. lbs.)
c. Connect the rear differential support assembly No.1 with the bolt and nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
HINT: Tighten the bolt.
84. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
85. INSTALL REAR DRIVE SHAFT ASSEMBLY RH
HINT: Install procedure of RH side is the same as that of LH side.
86. INSTALL REAR AXLE SHAFT LH NUT
SST 09930-00010
87. INSTALL REAR AXLE SHAFT RH NUT
SST 09930-00010
HINT: Install procedure of RH side is the same as that of LH side.
88. INSTALL SPEED SENSOR REAR LH
89. INSTALL SPEED SENSOR REAR RH
HINT: Install procedure of RH side is the same as that of LH side.
90. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
91. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
SST 09370-50010
92. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
93. ADD DIFFERENTIAL OIL
a. Fill the rear differential carrier assembly with hypoid gear oil.
Oil grade: Hypoid gear oil API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W-90
Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts., 0.79 ± 0.04 Imp. qts.)
94. INSPECT DIFFERENTIAL OIL
95. INSTALL REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), install the filler plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
96. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
97. INSTALL EXHAUST PIPE ASSEMBLY
98. CHECK FOR EXHAUST GAS LEAKS
99. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
100. CHECK ABS SPEED SENSOR SIGNAL
a. ABS WITH EBD & BA & TRAC & VSC SYSTEM