Part 1 of 2
A: ON-CAR SERVICE1. Front Oil Seal
1. Disconnect ground cable from battery.
2. Move selector lever or gear shift lever to "N".
3. Release the parking brake.
4. Remove oil drain plug, and drain gear oil.
5. Jack-up rear wheels and support the vehicle body with sturdy racks.
6. Remove propeller shaft from body.
CAUTION: Wrap metal parts with a cloth or rubber material to prevent damage from adjacent metal parts.
7. Remove self-locking nut while holding companion flange with ST.
ST 498427200 FLANGE WRENCH
8. Extract companion flange with a puller.
9. Remove oil seal using ST.
ST 499705401 PULLER ASSEMBLY
10. Fit a new oil seal using ST.
ST 498447120 OIL SEAL INSTALLER
11. Install companion flange.
12. Tighten self-locking nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal.
CAUTION: Use a new self-locking nut.
ST 498427200 FLANGE WRENCH
Tightening torque:
181.4 ± 14.7 Nm (18.50-11.50 kg-m, 133.8 ± 10.8 ft. lbs.)
13. Reassembling procedure hereafter is the reverse of the disassembling.
2. Side Oil Seal
1. Disconnect ground cable from battery.
2. Move selector lever or gear shift lever to "N".
3. Release the parking brake.
4. Loosen both wheel nuts.
5. Jack-up the vehicle and support it with rigid racks.
6. Remove wheels.
7. Remove muffler.
8. Remove the ABS sensor cable clamp and parking brake cable clamp from bracket.
9. Remove the ABS sensor cable clamp from the trailing link.
10. Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link.
11. Remove the rear stabilizer link.
12. Remove the bolts which secure the trailing link to the rear housing.
13. Remove the bolts which secure the front and rear lateral link to the rear housing.
14. Remove the DOJ from the rear differential by using ST
CAUTION: When removing the DOJ from the rear differential, fit ST to the bolt as shown in figure so as not to damage the side bearing retainer.
ST 208099PA100 DRIVE SHAFT REMOVER
15. Secure rear drive shaft to rear crossmember using wire.
16. Remove side oil seal with ST.
ST 398527700 PULLER ASSEMBLY
17. Drive in a new side oil seal with ST.
CAUTION: Apply chassis grease between the oil seal lips.
ST 398437700 DRIFT
18. Install ST to rear differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
19. Insert the spline shaft until the spline portion is inside the side oil seal. (ST 28099PA090 SIDE OIL SEAL PROTECTOR)
20. Remove ST.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
21. Hereafter, re-assemble in reverse order of disassembly.
B: REMOVAL
1. Disconnect ground cable from battery.
2. Move selector lever or gear shift lever to "N".
3. Release the parking brake.
4. Loosen wheel nuts.
5. Jack-up vehicle and support it with sturdy racks.
6. Remove wheels.
7. Remove rear exhaust pipe and muffler.
8. Remove front exhaust cover.
9. Remove front cover of rear differential mount.
10. Remove propeller shaft.
CAUTION: When removing propeller shaft, pay attention not to damage the sliding surfaces of rear drive shaft (extension) spline, oil seal and sleeve yoke.
NOTE:
- Prepare an oil can and cap since the transmission oil flows out from the extension at removing propeller shaft.
- Insert the cap into the extension to prevent transmission oil from flowing out immediately after removing the propeller shaft.
11. Remove heat sealed cover.
12. Remove clamps and bracket of parking brake cable.
13. Remove DOJ of rear drive shaft from rear differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
14. Secure rear drive shaft to rear crossmember using wire.
15. Remove lower differential bracket.
16. Support rear differential with transmission jack.
17. Remove self-locking nuts connecting rear differential to rear crossmember.
18. Remove bolts which secure rear differential front member to body.
1. Loosen bolt A first, then remove bolts B.
NOTE: Support front member with the use of a helper to prevent it from dropping.
2. Remove bolt A.
19. While slowly lowering transmission jack, move rear differential forward and remove front member and rear differential from body.
20. Remove rear differential from front member.
C: DISASSEMBLY
NOTE: To detect real cause of trouble, inspect the following items before disassembling.
^ Tooth contact of crown gear and pinion, and backlash
^ Runout of crown gear at its back surface
^ Turning resistance of drive pinion
1. Set ST on vise and install the differential assembly to ST.
ST 398217700 ATTACHMENT
2. Drain gear oil by removing plug.
3. Remove the air breather cap.
NOTE: Do not attempt to replace the air breather cap unless necessary.
4. Remove rear cover by loosening retaining bolts.
5. Make right and left side bearing retainers in order to identify them at reassembly. Remove side bearing retainer attaching bolts, set ST to differential case, and extract right and left side bearing retainers with a puller.
CAUTION: Each shim, which is installed to adjust the side bearing preload, should be kept together with its mating retainer.
ST 398457700 ATTACHMENT
6. Pull out differential assembly from differential carrier.
CAUTION: Be careful not to hit the teeth against the case.
7. When replacing side bearing, pull bearing cup from side bearing retainer using ST.
ST 398527700 PULLER ASSEMBLY
8. Extract bearing cone with ST.
CAUTION: Do not attempt to disassemble the parts unless necessary.
NOTE:
- Set puller so that its claw catch the edge of the bearing cone.
- Never mix up the right and left hand bearing cups and cones.
ST 399527700 PULLER SET
9. Remove crown gear by loosening crown gear bolts.
CAUTION: Further disassembling is not allowed.
10. Drive out pinion shaft lock pin from crown gear side.
NOTE: The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
11. Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers.
NOTE: The gears as well as thrust washers should be marked or kept separated left and right, and front and rear.
12. Hold companion flange with ST and remove drive pinion nut.
ST 498427200 FLANGE WRENCH
13. Extract the companion flange with a puller.
14. Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer.
NOTE: Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
15. Remove rear bearing cone from drive pinion by supporting cone with ST.
NOTE: Place the replacer so that its center-recessed side faces the pinion gear.
ST 498515500 REPLACER
16. Remove front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSEMBLY
17. Remove pilot bearing together with front bearing cone using ST.
ST 398467700 DRIFT
18. When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.
D: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.
1. Crown gear and drive pinion
- If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
- If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.
2. Side gear and pinion mate gear
- Replace if crack, score, or other defects are evident on tooth surface.
- Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.
3. Bearing
- Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.
4. Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect is evident.
5. Oil seal
- Replace if deformed or damaged, and at every disassembling.
6. Differential carrier
- Replace if the bearing bores are worn or damaged.
7. Differential case
- Replace if its sliding surfaces are worn or cracked.
8. Companion flange
- Replace if the oil seal lip contacting surfaces have flaws.