Part 2
Part 2
70. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heater the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
e. Align the matchmarks on the ring gear and differential case.
f. Temporarily install 10 new bolts.
g. After the ring gear cools down enough, torque the 10 bolts uniformly at a time.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)
71. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential case bearing RH (inner race) into the differential case.
SST 09223-46011
72. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential case bearing LH (inner race) into the differential case.
SST 09223-46011
NOTICE: Use the removed rear differential drive pinion washer when installation.
73. INSTALL STRAIGHT PIN
a. Using a plastic hammer, install 4 straight pins to the differential carrier.
74. INSTALL REAR DRIVE PINION REAR TAPE RED ROLLER BEARING
a. Rear side: Using SST, bolt, nut and a washer, install the rear drive pinion rear tapered roller bearing (outer race) to the differential carrier.
SST 09950-60010 (09951-00540, 09951-00620), 09950-60020 (09951-00680)
75. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Front side: Using SST, bolt, nut and a washer, install the rear drive pinion front tapered roller bearing (outer race) to the differential carrier.
SST 09950-60010 (09951-00490, 09951-00540, 09951-00620), 09950-60020 (09951-00680)
76. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the removed rear differential drive pinion plate washer on the drive pinion.
b. Using SST and a press, install the rear drive pinion rear tapered roller bearing (inner race) onto the drive pinion. SST 09316-60011 (09316-00071)
77. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential side gear shaft washer plate and rear differential case bearing RH (outer race) into the differential carrier.
SST 09950-60010 (09951-00580, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100)
NOTICE:
^ Use the removed rear differential side gear shaft washer when installation.
^ When replacing the bearing, replace the outer race and the inner race together.
HINT: Install the oil seal after adjusting the gear control pattern.
78. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the rear differential side gear shaft washer plate and rear differential case bearing LH (outer race) into the differential side bearing retainer.
SST 09950-60010 (09951-00580, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100)
NOTICE:
^ Use the removed rear differential side gear shaft washer when installation.
^ When replacing the bearing, replace the outer race and the inner race together.
HINT: Install the oil seal after adjusting the gear contact pattern.
79. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and rear drive pinion front tapered roller bearing (inner race) to the differential carrier.
b. Coat the threads of the rear drive pinion nut with hypoid gear oil.
c. Using SST, adjust the drive pinion preload by tightening rear drive pinion nut.
SST 09564-16020
Torque: 223 Nm (2,270 kgf-cm, 164 ft. lbs.) or less
NOTICE: Tighten the rear drive pinion nut gradually. Never tighten excessively.
HINT: Using a torque wrench with a fulcrum length of 500 mm (19.685 inch)
d. Using SST and a torque wrench, measure the preload. SST 09556-16011
Preload (at starting)
80. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a. Install the differential case to the differential carrier.
b. Install the side bearing retainer with 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
81. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Using SST and a dial indicator, measure the ring gear backlash during holding the drive pinion.
SST 09556-16011, 09564-32011
Backlash: 0.10 to 0.15 mm (0.0039 to 0.059 inch)
If the value is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by equal amount.
HINT:
^ When the backlash is smaller than specified value, select the thick washer in the RH side and thin washer in the LH side.
^ When the backlash is larger than the specified value, select the thin washer in the RH side and thick washer in the LH side.
Side gear shaft washer plate thickness
82. MEASURE TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09556-16011
Total preload (at starting):
Drive pinion preload plus 0.3 to 0.5 Nm (3 to 5 kgf-cm, 2.6 to 4.3 inch lbs.)
HINT: Turn the drive pinion counterclockwise and clockwise several times. If the preload non-standard again select proper washer (RH side)
NOTICE: When changing the rear differential side gear shaft washer, adjust the ring gear backlash first, then adjust the total pre load.
83. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Remove the 10 bolts and the differential side bearing retainer.
b. Remove the differential case from the differential carrier.
c. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead primer.
d. Install the differential case to the differential carrier.
e. Install the differential side bearing retainer with the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
f. Turn the differential drive pinion several times.
g. Remove the 10 bolts and the differential side bearing retainer.
h. Inspect the tooth pattern.
i. If the tooth contact is not good, perform the following procedures.
(1) In the case of face contact or frank contact, select the rear differential side gear shaft washer plate with the same thickness increased and decreased in the right and left, or vice versa, and install the rear differential case bearing outer race.
NOTICE: When changing the thickness of the rear differential side gear shaft washer, adjust the ring gear backlash and total preread before adjusting the tooth contact of the ring gear and that of the drive pinion.
(2) In the case of heel contact or toe contact, select the rear differential drive pinion plate washer again, and install the rear drive pinion tapered roller bearing RR.
NOTICE: When changing the thickness of the rear differential side gear shaft washer, adjust the drive pinion preload, ring gear backlash and total preload before adjusting the tooth contact of the ring gear and that of the drive pinion.
Drive pinion plate washer thickness
84. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
85. REMOVE DIFFERENTIAL DRIVE PINION
86. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
87. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the rear differential drive pinion oil slinger to the differential drive pinion.
NOTICE: Face the smaller inside diameter to the front.
88. INSTALL DIFFERENTIAL DRIVE PINION
a. Install the drive pinion and rear drive pinion front tapered roller bearing (inner race) to the differential carrier.
89. INSTALL REAR DRIVE PINION NUT
a. Coat the threads of a new rear drive pinion nut with hypoid gear oil.
b. Using SST, adjust the drive pinion preload by tightening rear drive pinion nut.
SST 09564-16020
Torque: 223 Nm (2,270 kgf-cm, 164 ft. lbs.) or less
HINT: Using a torque wrench with a fulcrum length of 500 mm (19.685 inch).
90. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST and a torque wrench, measure the preload of the drive pinion.
SST 09556-16011
Preload (at starting)
If the preload is less than the specification, retighten the nut 5° to 10° each at a time with SST, and adjust so that the starting torque meets the specified value.
Even if the tightening torque of the rear drive pinion nut exceeds 245 Nm (2,500 kgf-cm, 181 ft. lbs.), if the preload is less than the specification, loosen the rear drive pinion nut once and check if the screw top of the rear drive pinion nut and that of the differential drive pinion is crushed.
If the screw top is not crushed, replace the rear differential drive pinion spacer, apply hypoid gear oil API GL-5 L-5 to the screw, and repeat the procedure.
91. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
92. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Install the differential side bearing retainer with the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
93. INSPECT DIFFERENTIAL RING GEAR BACKLASH
SST 09556-16011, 09564-32011
94. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09556-16011
Total preload (at starting):
Drive pinion preread plus 0.3 to 0.5 Nm (3 to 5 kgf-cm, 2.6 to 4.3 inch lbs.)
HINT: Turn the drive pinion counterclockwise and clockwise several times. If the preload non-standard again select proper washer (RH side)
NOTICE: When changing the rear differential side gear shaft washer, adjust the ring gear backlash first, then adjust the total preload.
95. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Remove the 10 bolts and the differential side bearing retainer.
b. Install the 2 bolts and rear differential breather plug oil deflector to the side bearing retainer.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
c. Install the rear differential carrier cover breather plug to the side bearing retainer.
d. Using a scraper and a wire brush, clean the seal packing attached to the rear differential carrier and the differential side bearing retainer.
NOTICE: Do not damage the installation surface.
e. Clean contacting surfaces of any residual FIPG material by using gasoline or alcohol.
f. Apply FIPG to the side bearing retainer.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
HINT:
^ FIPG should be applied 2 to 3 (0.08 to 0.12 inch) mm in diameter with no break.
^ Allow on overlap of 10 mm (0.39 inch) or more between the start and end of FIPG application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Begin the application in the range of A.
^ 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.
g. Install the side bearing retainer with the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
96. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload.
SST 09556-16011
Total preload (at starting):
Drive pinion preload plus 0.3 to 0.5 Nm (3 to 5 kgf-cm, 2.6 to 4.3 inch lbs.)
HINT: Turn the drive pinion counterclockwise and clockwise several times.
97. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using SST and a dial indicator, measure the ring gear backlash during holding the drive pinion.
SST 09556-16011, 09564-32011
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)
98. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and a hammer, stake the rear drive pinion nut.
99. INSTALL REAR DIFFERENTIAL PRESSURE CONTROL HOSE
a. Align the matchmarks on the differential pressure control hose elbows and the differential carrier.
b. Using the 2 differential pressure control hose clips, install the differential pressure control hose to the differential pressure control hose elbows.
NOTICE: Confirm that the hose and the clips do not interfere with other parts.
100. INSTALL OIL DIAPHRAGM SEAL
a. Apply MP grease to the new oil diaphragm seal lip.
b. Using SST and a hammer, install a new oil diaphragm seal.
SST 09506-35010, 09554-22010
Oil seal drive in depth: 0.7 to 1.3 mm (0.03 to 0.05 inch)
101. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Apply MP grease to the 2 new side gear shaft oil seals lip.
b. Using SST and a hammer, install the 2 side gear shaft oil seals.
SST 09554-22010
Oil seal drive in depth: 4.2 to 4.8 mm (0.17 to 0.19 inch)
102. INSTALL TRANSMISSION COUPLING RADIAL BALL BEARING
a. Using SST and a press, install the transmission coupling radial ball bearing (No.1).
SST 09502-12010, 09550-55011 (09550-05061), 09950-70010 (09951-07150)
103. INSTALL TRANSMISSION COUPLING RADIAL BALL BEARING
a. Using SST and a press, install the transmission coupling radial ball bearing (No.2).
SST 09223-15030, 09950-70010 (09951-07150)
NOTICE: Be sure to install with the black seal on the bearing facing towards front of the vehicle (propeller shaft side).
104. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Install the transmission coupling assembly to the rear differential carrier cover.
105. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, install the new rear differential dust deflector.
SST 09518-36020, 09950-70010 (09951-07150)
106. INSTALL TRANSMISSION COUPLING SPACER
107. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER
NOTICE: Install the transmission coupling conical spring washer so that the side marked orange faces to the front of the vehicle (coupling side).
108. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Install the differential carrier cover with the 4 bolts to the differential carrier.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
109. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a. Install a new gasket with the rear differential drain plug.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
110. INSTALL REAR DIFFERENTIAL FILLER PLUG
a. Install a new gasket with the rear differential filler plug (inspection plug).
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
111. INSPECT RUNOUT OF DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Using SST and a dial indicator, measure the runout of the transmission coupling vertically.
SST 09564-32011
Maximum runout: 0.05 mm (0.002 inch)
b. Using SST and a dial indicator, measure the runout of the transmission coupling horizontally.
SST 09564-32011
Minimum runout: 0.05 mm (0.002 inch)
112. INSTALL REAR DIFFERENTIAL SUPPORT NO.1
a. Install the rear differential support assembly No.1 with the 2 bolts and 2 nuts to the differential carrier assembly.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
113. INSTALL DIFFERENTIAL SUPPORT
a. Install the differential support with the 3 bolts to the differential carrier assembly.
Torque: 167 Nm (1,700 kgf-cm, 123 ft. lbs.)
114. INSTALL DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Install the differential w/support rear side with the 2 bolts and 2 nuts to the rear suspension member front side.
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
b. Install the differential w/support with the 2 bolts to the rear suspension member rear side.
Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)
115. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY
116. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
117. INSTALL REAR DRIVE SHAFT ASSEMBLY RH
HINT: Install the RH side by the same procedures as LH side.
118. TEMPORARILY TIGHTEN UPPER CONTROL ARM ASSEMBLY
119. INSTALL REAR AXLE ASSEMBLY LH
120. INSTALL REAR AXLE ASSEMBLY RH
HINT: Install the RH side by the same procedures as LH side.
121. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 LH
122. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 RH
HINT: Install the RH side by the same procedures as LH side.
123. INSTALL REAR BRAKE TUBE NO.4
SST 09023-00101
124. INSTALL REAR BRAKE TUBE NO.3
HINT: Install the tube No.3 by the same procedures as tube No.4.
SST 09023-00101
125. CONNECT PARKING BRAKE CABLE ASSEMBLY NO.3
126. CONNECT PARKING BRAKE CABLE ASSEMBLY NO.2
HINT: Install the No.2 by the same procedures as No.3.
127. APPLICATION HIGH TEMPERATURE GREASE
128. INSTALL REAR BRAKE SHOE
SST 09718-00010
129. INSTALL PARKING BRAKE SHOE STRUT SET LH
SST 09703-30010
130. INSTALL PARKING BRAKE SHOE STRUT SET RH
SST 09703-30010
HINT: Install the RH side by the same procedures as LH side.
131. INSTALL FRONT BRAKE SHOE
SST 09718-00010
132. INSTALL SPEED SENSOR REAR LH
133. INSTALL SPEED SENSOR REAR RH
HINT: Install the RH side by the same procedures as LH side.
134. CHECK REAR DRUM BRAKE INSTALLATION
135. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY
136. INSTALL REAR AXLE SHAFT LH NUT
137. INSTALL REAR AXLE SHAFT RH N UT
HINT: Install the RH side by the same procedures as LH side.
138. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
139. INSTALL REAR STABILIZER LINK ASSEMBLY LH
140. INSTALL REAR STABILIZER LINK ASSEMBLY RH
HINT: Install the RH side by the same procedures as LH side.
141. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
142. INSTALL EXHAUST PIPE ASSEMBLY
143. BLEED BRAKE LINE
144. ADD DIFFERENTIAL OIL
145. INSPECT AND ADJUST DIFFERENTIAL OIL
146. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
147. STABILIZE SUSPENSION
148. FULLY TIGHTEN UPPER CONTROL ARM ASSEMBLY
149. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 LH
150. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 RH
HINT: Install the RH side by the same procedures as LH side.
151. CHECK FLUID LEVEL IN RESERVOIR
152. CHECK FOR EXHAUST GAS LEAKS
153. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
154. CHECK ABS SPEED SENSOR SIGNAL