Part 4
DIFFERENTIAL CARRIER ASSEMBLY REAR
OVERHAUL
76. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
a. Using snap ring pliers, install the side shaft shaft snap ring in the differential carrier on the ring gear side.
HINT: Use the side shaft shaft snap ring installed when performing tooth contact adjustment.
b. Set a dial indicator on the differential carrier.
c. Tighten the SST bolt to alter the differential carrier's shape.
NOTICE: Do not alter the shape excessively.
Shaped limit: 0.20 mm (0.0079 inch)
d. Using snap ring pliers, install the side shaft shaft snap ring on the drive pinion side.
HINT: Use the side shaft shaft snap ring installed at tooth contact adjustment.
e. Remove the dial indicator, tap the differential carrier on the drive pinion side using a plastic hammer to stabilize the case bearing.
77. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09229-55010
Drive pinion preload (at starting):
New bearing: 1.5 to 2.0 Nm (15 to 21 kgf-cm, 13 to 18 inch lbs.)
Reused bearing: 0.5 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 inch lbs.)
NOTICE: Rotate the flange clockwise and counterclockwise several times to stabilize the bearing before measuring the differential drive pinion preload.
b. If the preload is greater than the specified maximum value, replace the bearing spacer.
NOTICE: Because the bearing spacer deforms with use, replace the bearing spacer with a new one if the drive pinion preload is greater than the maximum value.
c. If the preload is less than the specified minimum value, check the preload while retightening the nut by 5 to 10 degrees to adjust it into the specified value range.
Torque: 98 to 490 Nm (1,000 to 5000 kgf-cm, 72 to 361 ft. lbs.)
HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm) of force and then tighten it further while observing the preload.
d. Even if the nut tightening torque is greater than the specified maximum value, if the preload is less than the specified minimum value, loosen the nut and check that the threads of the nut and drive pinion are not stripped.
e. If the threads are not stripped, replace the spacer and apply hypoid gear oil LSD to the threads and repeat the procedure.
78. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
a. Place a dial indicator where 10 mm (0.39 inch) away from the drive pinion shaft tip at a right angle.
b. Measure the shaft runout.
Maximum runout: 0.08 mm (0.0031 inch)
79. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Apply MP grease to the 2 new oil seal lips.
b. Using SST and a hammer, tap a new oil seal until the face becomes flush with the differential carrier surface.
SST 09223-15030, 09950-70010 (09951-07200)
80. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, check the torque (at starting) with the drive pinion and ring gear teeth in contact.
SST 09229-55010
Total preload (at starting)
Drive pinion preload plus 0.46 to 1.37 Nm (4.69 to 13.97 kgf-cm, 4.07 to 12.13 inch lbs.)
81. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and a hammer, calk the nut.
82. REMOVE DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Remove the differential carrier assembly from the overhaul attachment.
NOTICE: Clean the fitting surface between the differential carrier and carrier cover.
83. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.
NOTICE: Be careful not to scratch the fitting surface.
b. Install the rear differential breather plug oil deflector to the rear differential carrier cover.
Torque: 7.0 Nm (70 kgf-cm, 62 ft. lbs.)
c. Apply seal packing 1281 to the differential carrier at the position shown in the illustration.
NOTICE:
^ Apply the seal packing in drops, approximately 2 to 3 mm (0.08 to 0.12 inch) in diameter entirely.
^ Overlap the seal packing at least 10 mm at the beginning and the end of application.
^ Install the differential carrier cover within 3 minutes of application.
d. Install the differential carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 35 ft. lbs.)
NOTICE: Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.
e. Install the rear differential breather plug.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
84. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO.1
a. This procedure is required only when replacing the rear differential mount.
b. Using SST, install the rear differential mount.
SST 09570-24010, 09316-12010
NOTICE:
^ The rear differential mount installation angle has a 3° tolerance.
^ Temporarily install the rear differential to the member to prevent its tilt and the finally tighten SST.
^ Install the SST in the correct direction.
^ Be sure to contact the SST with the entire circumference of the rear differential mount.
^ The rear differential mount direction can be identified by the mark on the outside.
85. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO.2
a. This procedure is required only when replacing the rear differential mount.
b. Using SST, install the rear differential mount.
SST 09570-24010, 09316-12010
NOTICE:
^ The rear differential mount installation angle has a 3° tolerance.
^ Temporarily install the rear differential to the member to prevent its tilt and the finally tighten SST.
^ Install the SST in the correct direction.
^ Be sure to contact the SST with the entire circumference of the rear differential mount.
^ The rear differential mount direction can be identified by the mark on the outside.
86. INSTALL DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Install the 2 upper mount stoppers on the rear differential carrier assembly.
HINT: Use the upper mount stopper which was removed.
b. Support the rear differential carrier assembly with a jack and wooden block.
c. Temporally install the lower mount stoppers and 2 new front side set bolts.
NOTICE: Do not let the rear differential carrier assembly interfere with the drive shaft.
d. Using a hexagon wrench (12 mm), install the 3 rear side set hexagon bolts.
Torque: 142 Nm (1,450 kgf-cm, 105 ft. lbs.)
e. Torque the 2 front side set bolts.
Torque: 105 Nm (1,065 kgf-cm, 77 ft. lbs.)
f. Lower the jack.
87. INSTALL HEIGHT CONTROL VALVE SUB-ASSEMBLY NO.2 (W/ AIR SUSPENSION)
HINT: Perform this operation only when the rear differential mount cushion is replaced.
88. INSTALL STABILIZER BAR REAR
HINT: Perform this operation only when the rear differential mount cushion is replaced.
89. 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.)
90. ADD DIFFERENTIAL OIL
a. Fill the rear differential carrier assembly with differential gear oil equivalent.
Oil type: Differential synthetic gear oil GL-5 75W-90 or equivalent
Capacity: 1.35 ± 0.05 liters (1.43 ± 0.05 US qts, 1.19 ± 0.04 Imp. qts)
91. INSPECT DIFFERENTIAL OIL
92. 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.)
93. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
94. INSTALL REAR DRIVE SHAFT ASSEMBLY RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
95. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the front floor heat insulator No. 1 with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
96. INSTALL REAR WHEEL
a. Install the rear wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
97. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
98. FULLY TIGHTEN CENTER SUPPORT BEARING ASSEMBLY NO.1
SST 09922-10010
99. INSPECT AND ADJUST NO.2 AND NO.3 JOINT ANGLE
100. INSTALL PROPELLER SHAFT HEAT INSULATOR
101. INSTALL EXHAUST PIPE ASSEMBLY
102. INSTALL OXYGEN SENSOR
103. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
104. ADJUST VEHICLE HEIGHT (W/ AIR SUSPENSION)
105. INSPECT HEADLIGHT AIM ONLY
106. CHECK ABS SPEED SENSOR SIGNAL
107. INSPECT AIR LEAK (W/ AIR SUSPENSION)
HINT: Perform this operation only when the rear differential mount cushion is replaced.