17 Axle

Drive train
Axle / differential
Axle system
Symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-3
Front axle hub bolt
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-5
Front axle hub
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-10
On-vehicle inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-10
Steering knuckle
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-12
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Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-15
Rear axle hub bolt
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-16
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-17
Rear axle hub
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-19
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-21
On-vehicle inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-22
Rear axle carrier
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AD-24
AD-24
AD
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-28
Differential system
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-30
Symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-30
Differential oil
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-31
Rear differential carrier oil seal
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-32
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-32
Rear differential side gear shaft oil seal
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-35
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-35
Rear differential carrier ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-37
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-40
AD–2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-41
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-70
Rear differential mount cushion
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD-74
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AD
Axle / differential － Axle system
AD–3
Axle system
Drive/ train
Axle differential
Symptom table
NOTE:
Use the following table to identify the trouble cause. The check points are listed in the order of priority from the viewpoint of pos-
sible trouble causes. Check each part in the sequence. If necessary, replace the parts.
Axle system
Symptoms Inspection items Reference pages
Tire (improper tire pressure, uneven wear) TW - 2
Front wheel alignment (improper) AL - 2
Rear wheel alignment (improper) AL - 7
Wobble of the vehicle
Steering linkage (looseness/wear) SL - 6
Front hub bearing (wear/play) AD - 10
Front stabilizer bar (bend/damage) FP - 21
Wheels (out of balance) TW - 2
Front shock absorber (spongy) FP - 11
Abnormal vibration of front wheel Front wheel alignment (improper) AL - 2
Front lower ball joint (wear/play) FP - 17
Front wheel alignment (improper) AL - 2
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Front lower ball joint (wear/play) FP - 17
Noise from the front
Front shock absorber (spongy) FP - 11
Rear hub bearing (wear/play) AD - 22
Noise from the rear
Rear shock absorber (spongy) RP - 8
AD
AD–4 Axle / differential － Front axle hub bolt
Front axle hub bolt

Drive/ train
Axle differential
Exploded view
Normal type
Front axle hub bolt LH
x5
80 {816,59.0} *1 135
{1377,99.6} *2
x2
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Front disc brake caliper ASSY LH Front disc
N*m {kgf*cm, ft*lbf} : Tightening torque
Non-reusable parts
AD
*1: Width across flat 17mm {0.6693in} *2: Width across flat 19mm {0.748in}
DS-10247
Axle / differential － Front axle hub bolt
AD–5
Brembo type
Front axle hub bolt LH
120 {1244,88.5}
x5
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Front disc brake caliper ASSY LH
Front disc
Non-reusable parts
DS-10248
AD
Replacement
NOTE:
• The following procedure is for LH side.
• Perform the same procedures for the RH and LH side.
1. Removal of front tire
2. Removal of front disc brake caliper ASSY LH
(1) Remove 2 bolts, and disconnect the disc brake caliper ASSY LH from the steering knuckle.
CAUTION:
Suspend the caliper using a wire, etc.
3. Removal of front disc (Refer to FB - 8)
4. Removal of front axle hub & bearing ASSY LH
Using the SST and a hydraulic press, push out the hub bolt from the front axle hub & bearing ASSY.
CAUTION:
• Do not hammer the hub bolts. This may deform the front axle hub & bearing ASSY.
• Do not reuse the hub bolt.
AD–6 Axle / differential － Front axle hub bolt
556
556
DS-00711
Captions in illustration
*1 Front axle hub & bearing ASSY *2 Hub bolt
SST 28399AG000
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NOTE:
Because the front axle hub & bearing ASSY can not be disassembled, only hub bolts can be removed.
5. Installation of front axle hub & bearing ASSY LH
(1) Install the front axle hub & bearing ASSY to the SST securely.
(2) Using a press, press the new hub bolts until their seating surfaces come in contact snugly with the front axle hub & bear-
ing ASSY.
556

AD
DS-00714
*1 Front axle hub & bearing ASSY *2 Hub bolt
SST 927080000
NOTE:
Use the 12 mm (0.47 in) dia. holes in the SST to prevent bolts from tilting.
6. Installation of front disc (Refer to FB - 14)
7. Installation of front disc brake caliper ASSY LH (normal type)
(1) Install the front disc brake caliper ASSY LH to the steering knuckle with 2 new bolts.
Standard value:Width across flat 17 mm {0.6693 in}
T=80N·m {816kgf·cm} {59.0ft·lbf}
Width across flat 19 mm {0.748 in}
T=135N·m {1377kgf·cm} {99.6ft·lbf}
Axle / differential － Front axle hub bolt
AD–7
8. Installation of front disc brake caliper ASSY LH (brembo type)

(1) Install the front disc brake caliper ASSY LH to the steering knuckle with 2 bolts.
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}
9. Installation of front tire
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AD
AD–8 Axle / differential － Front axle hub
Front axle hub

Drive/ train
Axle differential
Exploded view
Normal type
Speed sensor FR LH
95 {969,70.1} x4 7.5 {77,5.5}
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80 {816,59.0} *1
135 {1377,99.6} *2
x2
Front axle hub &

bearing ASSY LH
AD
N*m {kgf*cm,ft*lbf} : Tightening torque Front disc
Non-reusable parts
*1:Width across flat 17 mm {0.6693 in} *2:Width across flat 19 mm {0.748 in}
DS-10398
Axle / differential － Front axle hub
AD–9
Brembo type
Speed sensor FR LH
95 {969,70.1}
x4 7.5 {77,5.5}
120 {1244,88.5}
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Front axle hub & bearing
ASSY LH

AD
Front disc
N*m {kgf*cm,ft*lbf} : Tightening torque
Non-reusable parts
DS-10399
Removal
NOTE:
2. Removal of front disc brake caliper ASSY LH (Refer to AD - 5)
AD–10 Axle / differential － Front axle hub
4. Disconnection of speed sensor FR LH

(1) Remove the bolt, and disconnect the speed sensor FR LH from the
steering knuckle.
CAUTION:
• Keep the tip and mounting portion of the speed sensor FR LH free
from foreign matter.
• The speed sensor FR LH is easily damaged. When removing the
speed sensor FR LH from the front axle hub & bearing ASSY LH,
do not apply excessive force or turn the sensor.
5. Removal of front axle hub & bearing ASSY LH

(1) Remove 4 bolts, and remove the front axle hub & bearing ASSY
from the steering knuckle.
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Installation
NOTE:
1. Installation of front axle hub & bearing ASSY LH
(1) Install the front axle hub & bearing ASSY to the steering knuckle with 4 bolts.
2. Inspection of front axle hub & bearing ASSY axial play (Refer to AD - 11)
3. Inspection of front axle hub & bearing ASSY runout (Refer to AD - 11)
AD 4. Installation of speed sensor FR LH

(1) Install the speed sensor FR LH to the steering knuckle with a bolt.
Standard value:T=7.5N·m {77kgf·cm} {5.5ft·lbf}
CAUTION:
• Do not damage the tip of the speed sensor when installing the speed sensor body.
• Do not allow foreign matter to attach to the mounting surfaces.
• Be careful not to twist the speed sensor wire during installation.
6. Installation of front disc brake caliper ASSY LH (Refer to AD - 6)
8. Inspection of test mode (speed sensor check) (Refer to BC - 15)
On-vehicle inspection
NOTE:
2. Removal of front disc brake caliper ASSY LH (Refer to AD - 5)
Axle / differential － Front axle hub
AD–11
4. Inspection of front axle hub & bearing ASSY axial play

(1) Inspect axial play of the bearing near the axle hub inner periphery
(flange portion) using a dial gauge.
Limit: 0.05mm {0.00196in}
CAUTION:
If it exceeds the limit, replace the front axle hub with a new part.
5. Inspection of front axle hub & bearing ASSY runout

(1) Inspect runout of the axle hub near the axle hub outer periphery
using a dial gauge.
Limit: 0.05mm {0.00196in}
CAUTION:
If it exceeds the limit, replace the front axle hub with a new part.
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7. Installation of front disc brake caliper ASSY LH (Refer to AD - 6)
AD
AD–12 Axle / differential － Steering knuckle
Steering knuckle
Drive/ train
Axle differential
Exploded view
x2
155 {1581,114.3} Steering knuckle LH
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x3
18 {184,13.3}
Disc brake dust cover FR LH
AD
27 {275,19.9}
51 {520,37.6}
Tie-rod end SUB-ASSY LH
Front suspension lower arm ASSY LH

N•m {kgf•cm,ft•lbf} : Tightening torque
Non-reusable parts
DS-00719
Axle / differential － Steering knuckle
AD–13
Removal
NOTE:
1. Removal of front axle hub LH (Refer to AD - 9)
2. Removal of disc brake dust cover FR LH
(1) Remove 3 bolts, and remove the disc brake dust cover FR LH.
3. Disconnection of tie-rod end SUB-ASSY LH

(1) Remove the cotter pin, and then remove the castle nut.
(2) Use a tie-rod ball joint puller to detach the tie-rod end SUB-ASSY
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LH from the steering knuckle.
C
D
D
AD
#
$
E

PS-01509
*1 Nut - -
*a Tie the string without slack *b Application area of lubricant
*c Use a wrench here - -
WARNING:
Apply lubricant to the thread and the tip of the tie-rod ball joint puller
bolt.
CAUTION:
• Always tie a string to the steering knuckle without slack to prevent
the tie-rod ball joint puller from falling.
AD–14 Axle / differential － Steering knuckle
• Install the tie-rod ball joint puller so as to make A parallel to B with

the nut located in the center. Otherwise the dust cover may be
damaged.
• Always use a wrench at the point shown in the figure.
• Do not damage the ball joint boot of the tie-rod end SUB-ASSY LH.
• Do not damage the steering knuckle.
• Do not damage the disc brake dust cover FR.
4. Disconnection of front suspension lower arm ASSY LH
(1) Remove the cotter pin and nut.
(2) Install the tie-rod ball joint puller to the thread of the front suspen-
sion lower arm ASSY LH.
(3) Use a tie-rod ball joint puller to detach the front suspension lower
arm ASSY LH.
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C

AD DS-00713
*1 Claw *2 Body
*3 Nut *a Place the wrench here.
Application area of lubricant Drive
WARNING:
bolt.
CAUTION:
• Install the tie-rod ball joint puller so as to make the body parallel to
the claw with the nut located in the center. Otherwise the dust
cover of the front suspension lower arm ASSY may be damaged.
• Always tie a string to the vehicle without slack to prevent the tie-
rod ball joint puller from falling.
• Do not damage the dust cover of the front suspension lower arm
ASSY.
• Do not damage the front suspension lower arm ASSY.
• Do not damage the disc brake dust cover FR.
• Do not damage the steering knuckle.
Axle / differential － Steering knuckle
AD–15
5. Removal of steering knuckle LH

(1) Remove the 2 bolts and 2 nuts to remove the steering knuckle LH.
CAUTION:
Secure the bolt and turn the nut.
Installation
NOTE:
1. Installation of steering knuckle LH
(1) Install the steering knuckle LH with 2 bolts and 2 new nuts.
2. Installation of front suspension lower arm ASSY LH
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(1) Install the front suspension lower arm ASSY LH with the nut.
(2) Install a new cotter pin.
3. Installation of tie-rod end SUB-ASSY LH
(1) Install the tie-rod end SUB-ASSY LH to the steering knuckle LH with the nut.
(2) Install a new cotter pin.
CAUTION:
When aligning the clip holes after tightening the castle nut, tighten the castle nut further but within 60°.
4. Installation of disc brake dust cover FR LH
(1) Install the front disc brake dust cover to the steering knuckle with 3 bolts.
5. Installation of front axle hub & bearing ASSY LH (Refer to AD - 10) AD
6. Inspection and adjustment of front wheel alignment (Refer to AL - 2)
7. VDC sensor mid point setting (Refer to BC - 15)
AD–16 Axle / differential － Rear axle hub bolt
Rear axle hub bolt

Drive/ train
Axle differential
Exploded view
Normal type
66 {673,49.0} *1 110
{1122,81.1} *2 x2
Rear disc brake caliper ASSY LH
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x5
Rear axle hub bolt LH
AD
Non-reusable parts Rear disc
*1: Width across flat 14mm {0.5512in} *2: Width across flat 17mm {0.6693in}
DS-10252
Axle / differential － Rear axle hub bolt
AD–17
Brembo type
73 {744,53.8} x2
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x5
Rear axle hub bolt LH

AD
Rear disc
Non-reusable parts
DS-10253
Replacement
NOTE:
1. Removal of rear tire
2. Disconnection of rear disc brake caliper ASSY LH (Refer to PB - 16)
3. Removal of rear disc (Refer to RB - 7)
4. Removal of rear axle hub bolt & bearing ASSY LH
Using the SST and a hydraulic press, push out the hub bolt from the rear axle hub & bearing ASSY.
CAUTION:
• Do not hammer the hub bolts. This may deform the rear axle hub & bearing ASSY.
• Do not reuse the hub bolt.
AD–18 Axle / differential － Rear axle hub bolt
556
556
DS-00711
*1 Rear axle hub & bearing ASSY *2 Hub bolt
SST 28399AG000
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NOTE:
Because the rear axle hub & bearing ASSY can not be disassembled, only hub bolts can be removed.
5. Installation of rear axle hub bolt LH
(1) Install the rear axle hub & bearing ASSY to the SST securely.
(2) Using a press, press the new hub bolts until their seating surfaces come in contact snugly with the rear axle hub & bear-
ing ASSY.
556

AD
DS-00714
*1 Rear axle hub & bearing ASSY *2 Hub bolt
SST 927080000
NOTE:
Use the 12 mm (0.47 in) dia. holes in the SST to prevent bolts from tilting.
6. Installation of rear disc (Refer to RB - 16)
7. Connection of rear disc brake caliper ASSY LH (Refer to PB - 25)
8. Installation of rear tire
Axle / differential － Rear axle hub
AD–19
Rear axle hub

Drive/ train
Axle differential
Exploded view
Normal type
Speed sensor RR LH 7.5 {77,5.5}
x2
66 {673,49.0} *1
110 {1122,81.1} *2
7.5 {77,5.5}
x2
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Rear drive shaft ASSY LH
Rear disc
85 {867,62.7} x4
Rear axle hub & bearing ASSY LH
N*m {kgf*cm,ft*lbf} : Tightening torque

AD
Non-reusable parts 190 {1938,140.1}
Rear axle shaft nut LH

No oil on the threaded portion
*1: Width across flat 14 mm {0.5512 in} *2: Width across flat 17 mm {0.6693 in}
DS-10400
AD–20 Axle / differential － Rear axle hub
Brembo type
Speed sensor RR LH 7.5 {77,5.5}
x2
73 {744,53.8}
7.5 {77,5.5}
x2

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Rear disc
85 {867,62.7} x4
Rear axle hub and bearing ASSY LH
AD N*m {kgf*cm, ft*lbf} : Tightening torque

190 {1938,140.1}
Non-reusable parts Rear axle shaft nut LH
No oil on the threaded portion

DS-10401
Removal
NOTE:
AD–21
2. Disconnection of speed sensor RR LH

(1) Remove the bolt, and then remove the speed sensor.
CAUTION:
Keep the tip and mounting portion of the speed sensor RR free from
foreign matter.
3. Removal of rear axle shaft nut LH

(1) Remove the crimp of the rear axle shaft nut LH.
CAUTION:
Completely release the crimp of the nut to avoid damage to the thread
of the rear drive shaft ASSY LH.
(2) Remove the rear axle shaft nut using a socket wrench.
CAUTION:
Do not loosen the rear axle shaft nut LH with the rear axle loaded.
Doing so may damage the rear axle hub and bearing ASSY LH.
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DS-00715
4. Removal of rear drive shaft ASSY (Refer to DP - 5)

5. Disconnection of rear disc brake caliper ASSY LH (Refer to PB - 16)
7. Removal of rear axle hub and bearing ASSY LH
(1) Remove 4 bolts, and remove the rear axle hub and bearing ASSY
LH from the rear axle carrier.
NOTE:
Suspend the rear backing plate and the parking brake shoe with a
string, etc.
AD
Installation
NOTE:
1. Installation of rear axle hub and bearing ASSY LH
(1) Install the rear axle hub and bearing ASSY LH to the rear axle carrier with 4 bolts.
3. Installation of rear drive shaft ASSY (Refer to DP - 11)
5. Installation of rear axle shaft nut LH
CAUTION:
• Always clean the drive shaft even if it is new.
• Clean and remove oil, foreign matter, etc. completely.
(1) Install a new rear axle shaft nut LH using a socket wrench.
AD–22 Axle / differential － Rear axle hub
CAUTION:
Do not crimp the rear axle shaft nut LH.
NOTE:
After the inspection of the rear axle hub and bearing ASSY LH play and runout, crimp the rear axle shaft nut LH.
6. Inspection of rear axle hub & bearing ASSY axial play (Refer to AD - 22)
7. Inspection of rear axle hub & bearing ASSY runout (Refer to AD - 23)
8. Securing of rear axle shaft nut LH
(1) Crimp the rear axle shaft nut LH using a chisel and a hammer.
9. Installation of speed sensor RR LH

(1) Install the speed sensor RR LH with a bolt.
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CAUTION:
Keep the tip and mounting portion of the speed sensor RR LH free from foreign matter.
11. Adjustment of parking brake lever free play (Refer to PB - 2)
12. Inspection of test mode (speed sensor check) (Refer to BC - 15)
On-vehicle inspection
NOTE:
AD 2. Disconnection of rear disc brake caliper ASSY LH (Refer to PB - 16)
4. Inspection of rear axle hub & bearing ASSY axial play
(1) Inspect axial play of the bearing near the axle hub inner periphery
(flange portion) using a dial gauge.
Limit: 0.05mm {0.00196in}
CAUTION:
If it exceeds the limit, replace the rear axle hub & bearing ASSY with a
new part.
AD–23
5. Inspection of rear axle hub & bearing ASSY runout

(1) Inspect runout of the bearing near the axle hub outer periphery
using a dial gauge.
Limit: 0.05mm {0.00196in}
CAUTION:
If it exceeds the limit, replace the rear axle hub & bearing ASSY with a
new part.

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AD
AD–24 Axle / differential － Rear axle carrier
Rear axle carrier

Drive/ train
Axle differential
Exploded view
Upper control arm ASSY RR LH
Parking brake plate SUB-ASSY LH
80 {816,59.0}
60 {612,44.3}
Parking brake cable

ASSY No.3
Rear axle carrier LH
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Toe control link
SUB-ASSY LH
Rear suspension arm ASSY No. 1 bush LH
110 {1122,81.1}
Rear stabilizer link SUB-ASSY
Rear suspension arm ASSY No. 1 LH
AD 38 {388,28.0}
80 {816,59.0}
Rear suspension arm

ASSY No. 2 LH
N*m (kgf*cm, ft*lbf) : Tightening torque Non-reusable parts
DS-10008
Removal
NOTE:
1. Removal of rear axle hub & bearing ASSY LH (Refer to AD - 20)
2. Disassembly of parking brake (Refer to PB - 16)
Axle / differential － Rear axle carrier
AD–25
3. Disconnection of rear stabilizer link SUB-ASSY (installed on LH side) (Refer to RP - 6)

4. Disconnection of parking brake cable ASSY NO. 3
(1) Remove the clip, and detach the parking brake cable ASSY NO. 3
from the back plate.
5. Disconnection of upper control arm ASSY RR LH

(1) Remove the bolts and nuts, and detach the upper control arm
ASSY RR LH from the rear axle carrier.
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6. Disconnection of rear suspension arm ASSY NO. 1 LH
(1) Remove the bolts and nuts, and detach the rear suspension arm
ASSY NO. 1 LH from the rear axle carrier.
AD
7. Disconnection of rear suspension arm ASSY NO. 2 LH
(1) Remove the bolts and nuts, and detach the rear suspension arm
ASSY NO. 2 LH from the rear axle carrier.
8. Disconnection of toe control link SUB-ASSY LH

(1) Remove the cotter pin.
(2) Remove the nut.
(3) Using a tie-rod ball joint puller, detach the toe control link SUB-
ASSY LH from the rear axle carrier.

C
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DS-00716
*1 Nut *2 Body
*3 Claw *a Place the wrench here.
Application area of lubricant Direction of rotation
WARNING:
bolt.
CAUTION:
AD • Install the tie-rod ball joint puller so as to make the body parallel to
the claw with the nut located in the center. Otherwise the dust
cover of the toe control link SUB-ASSY may be damaged.
• Always tie a string to the vehicle without slack to prevent the tie-
rod ball joint puller from falling.
• Do not damage the dust cover portion of the toe control link SUB-
ASSY.
• Do not damage the toe control link SUB-ASSY.
• Do not damage the parking brake plate SUB-ASSY.
• Do not damage the rear axle carrier.
9. Removal of parking brake plate SUB-ASSY LH
10. Removal of rear axle carrier LH
(1) Remove the rear axle carrier LH while supporting the drive shaft.
CAUTION:
• Do not damage the drive shaft outboard joint boot.
• Do not push out the rear axle ASSY more than necessary to the vehicle outside.
NOTE:
Suspend the drive shaft ASSY using a rope or wire, etc.
Disassembly
NOTE:
AD–27
1. Extraction of rear suspension arm ASSY NO. 1 bushing LH

(1) Pull out the rear suspension arm ASSY NO. 1 bushing LH using the SST and a press.
556
556 556
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DS-00735
SST 20099FG000, 20099PA010
Press weighting direction - -
Assembly
NOTE:
• Perform the same procedures for the RH and LH side. AD
1. Installation of rear suspension arm ASSY NO. 1 bushing LH
(1) Install the rear suspension arm ASSY NO. 1 bushing LH using the SST and a press.
556
556
556
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DS-00736
SST 20099FG000, 20099PA010
Press weighting direction - -
Installation
NOTE:
AD 1. Installation of rear axle carrier LH

(1) Using a jack, lift the rear axle carrier and align the installation position of each arm.
CAUTION:
Use a jack with wooden blocks so that the rear axle carrier will not be damaged.
2. Temporary tightening of upper control arm ASSY RR LH
(1) Install the upper control arm ASSY RR LH to the rear axle carrier, and temporarily tighten it with new bolts and nuts.
3. Temporary tightening of rear suspension arm ASSY NO. 1 LH
(1) Install the rear suspension arm ASSY NO. 1 LH to the rear axle carrier, and temporarily tighten it with new bolts and nuts.
4. Temporary tightening of rear suspension arm ASSY NO. 2 LH
(1) Install the rear suspension arm ASSY NO. 2 LH to the rear axle carrier, and temporarily tighten it with new bolts and nuts.
5. Installation of toe control link SUB-ASSY LH
(1) Install the toe control link to the rear axle carrier with the nut.
(2) Install the cotter pin.
6. Temporary tightening of rear stabilizer link SUB-ASSY (installation position LH side) (Refer to RP - 11)
7. Installation of parking brake cable ASSY NO.3
(1) Install the parking brake cable ASSY NO. 3 to the rear axle carrier with the clip.
8. Assembly of parking brake (Refer to PB - 20)
9. Stabilization of vehicle (Refer to RP - 11)
10. Final tightening of upper control arm ASSY RR LH
(1) Tighten the mounting bolts and nuts of the upper control arm ASSY RR LH.
AD–29
11. Final tightening of rear suspension arm ASSY NO. 1 LH

(1) Tighten the mounting bolts and nuts of the rear suspension arm ASSY NO. 1 LH.
CAUTION:
Secure the nut and turn the bolt.
12. Final tightening of rear suspension arm ASSY NO. 2 LH
(1) Tighten the mounting bolts and nuts of the rear suspension arm ASSY NO. 2 LH.
13. Tightening of rear stabilizer link SUB-ASSY (installation position LH side) (Refer to RP - 11)
14. Installation of rear axle hub & bearing ASSY LH (Refer to AD - 21)
15. Inspection and adjustment of rear wheel alignment (Refer to AL - 7)
16. Inspection and adjustment of headlight (Refer to LE - 51)
17. VDC sensor mid point setting (Refer to BC - 15)
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AD
AD–30 Axle / differential － Differential system
Differential system
Drive/ train
Axle differential
Precautions
1. Wash the outside of the rear differential ASSY to remove sand, mud, etc. before disassembly so that they will not enter the
inside of the rear differential during disassembly and installation.
2. When disassembling the joint sections of light alloy parts such as the differential carrier cover, disassemble them by slightly
tapping with a plastic hammer. Do not pry apart with a screwdriver or other tools.
3. Keep the disassembled parts in order, and protect them from dust and dirt covering with a cloth.
4. Before installation, all disassembled parts should be thoroughly washed and dried, and then apply grease or oil to the neces-
sary sections. When washing aluminum and rubber parts, bolts with lubricant, etc., do not use alkaline chemical solvent. In
addition, do not wash rubber base parts such as O-rings and oil seals with wash oil (appropriate detergent, etc.).
5. Before installation, apply sufficient amount of differential oil used for each differential ASSY to the sliding surfaces and rotat-
ing sections.
6. When fixing the parts in a vise, do not place the parts directly in a vise but use an aluminum plates in between.
7. Be careful of handling the mating surfaces of the case. If they are damaged, oil leakage may occur.
8. Before applying seal material, completely remove the old seal material adhering to the sealing portions, and then wash the
sealing portion with wash oil (appropriate detergent, etc.).
9. After assembling the parts with seal material, leave them for 1 hour or more, and then fill them with oil. Avoid rapid accelera-
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tion and deceleration for 12 hours or more.
10. Be careful of handling the contact surfaces to the oil seals, O-rings and gaskets. If they are damaged, oil leakage may occur.
11. When press-fitting the oil seal farther than the end face of the differential carrier, oil leakage may occur. To avoid oil leakage,
measure the press-fitting amount at more than 3 points on the oil seal circumference. Then, make sure that the difference
between the maximum and the minimum of the measured values is within the specification.
12. Be careful not to damage the oil seal lip and outer circumference while press-fitting the oil seal.
13. When replacing the bearing, replace the outer race and the inner race as a set.
14. When replacing the bearing, do not apply excessive force to the roller, the holder and the rolling contact surface.
15. Anti-rust oil is applied to a new bearing. Do not wash off this oil.
16. If the seat or the thread of the bolt is heavily rusted, replace it with a new part.
Symptom table
AD NOTE:
Use the following table to identify the trouble cause. The check points are listed in the order of priority from the viewpoint of pos-
sible trouble causes. Check each part in the sequence. If necessary, replace the parts.
Rear differential
Symptoms Inspection items Reference pages
Oil level (too low) AD - 31
Ring gear or pinion (worn or chipped) AD - 41
Improper adjustment of backlash AD - 41
Noise from differential carrier
Improper adjustment of preload AD - 41
Improper adjustment of tooth contact AD - 41
Wear of bearing AD - 41
Oil level (too high) AD - 31
Oil leakage from differential carrier Side gear shaft oil seal (worn or damaged) AD - 35
Carrier oil seal (worn or damaged) AD - 32
Axle / differential － Differential oil
AD–31
Differential oil
Drive/ train
Axle differential
Adjustment
1. Inspection of differential oil
(1) Remove the filler plug and the gasket.
(2) Make sure that the oil level is within 0 to 5 mm {0 to 0.2 in} from the
bottom of filler plug hole.
CAUTION:
• Excess or shortage of oil may lead to trouble.
• Park the vehicle on a level road.
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(3) If the oil level is low, perform the inspection of oil leakage.
VQOO (4) Tighten the filler plug via a new gasket.
CAUTION:
When oil is replaced, check the oil level again after driving.
2. Refilling of differential oil

CAUTION:
Do not mix different types of oil.
(2) Refill with differential oil.
Recommended product: Differential gear oil LX (API GL-5, SAE
75W-85)
Substitute product: GL-5 75W-85 or GL-5 75W-90
CAUTION:
AD
When using the substitute product, the function and performance may
be inferior.
NOTE:
Oil level: 1.15±0.05 L {1.22±0.05 US qt, 1.01±0.04 Imp qt}
(3) Check the oil level.
(4) Tighten the filler plug via a new gasket.
CAUTION:
When oil is replaced, check the oil level again after driving.
AD–32 Axle / differential － Rear differential carrier oil seal

Drive/ train
Axle differential
Exploded view
49 {500, 36.1}
Rear differential Differential carrier ASSY RR

filler plug
Rear differential carrier cover
47 {479, 34.7}
Gasket x8
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Gasket
49 {500, 36.1}
Rear differential
drain plug
Rear differential drive pinion
bearing spacer
AD
Pre-load adjustment torque 338
{3447, 249.3} or less
Rear drive pinion tapered roller bearing FR
Rear drive pinion nut
Rear drive pinion

companion flange RR
Rear differential drive pinion oil slinger
N•m {kgf•cm, ft•lbf} : Tightening torque
Non-reusable parts
Differential gear oil DI-00943
Replacement
1. Removal of differential carrier ASSY RR (Refer to AD - 40)
Axle / differential － Rear differential carrier oil seal
AD–33
2. Fixation of differential carrier ASSY RR (Refer to AD - 41)

3. Removal of rear drive pinion nut (Refer to AD - 46)
4. Removal of rear drive pinion companion flange RR (Refer to AD - 46)
5. Removal of rear differential carrier oil seal
(1) Remove the oil seal from the differential carrier using a flat tip
screwdriver.
NOTE:
When replacing the oil seal, replace the rear differential drive pin-
ion bearing spacer and readjust the drive pinion preload.
DI-00900
6. Removal of rear differential drive pinion oil slinger (Refer to AD - 47)
7. Removal of rear drive pinion tapered roller bearing FR (Refer to AD - 47)
8. Replacement of rear differential drive pinion bearing spacer
(1) Replace the bearing spacer with a new part.
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9. Installation of rear drive pinion tapered roller bearing FR (Refer to AD - 65)
10. Installation of rear differential drive pinion oil slinger (Refer to AD - 65)
11. Installation of rear drive pinion companion flange RR (Refer to AD - 66)
13. Installation of rear differential carrier oil seal
(1) Press-fit a new oil seal into the bottom position of the differential AD
carrier taper portion using the SST and a hammer.
SST 498447120 , 499755502
*1 Rear differential carrier oil seal
556
CAUTION:
• Evenly tap and press-fit the oil seal in a straight forward direction.
• Do not press-fit the oil seal excessively.
(2) Measure the press-fitting amount of the oil seal using a caliper
gauge.
Standard value: 2±0.45 mm {0.08±0.018 in} (from the differential
carrier end face)
CAUTION:
Perform the measurement at 3 points or more on the oil seal circum-
ference, and the difference between the maximum and the minimum of
556 the measured values must be 0.65 mm {0.026 in} or less.
(3) Apply a thin coat of differential gear oil to the lip of the oil seal.
DI-00901
14. Installation of rear drive pinion companion flange RR (Refer to AD - 66)
AD–34 Axle / differential － Rear differential carrier oil seal
15. Adjustment of differential drive pinion preload (Refer to AD - 67)

16. Inspection of overall preload (Refer to AD - 68)
17. Fixation of rear drive pinion nut (Refer to AD - 69)
19. Installation of differential carrier ASSY RR (Refer to AD - 70)
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AD
Axle / differential － Rear differential side gear shaft oil seal
AD–35

Drive/ train
Axle differential
Exploded view
47 {479, 34.7}
x8
Rear differential
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carrier cover
Differential carrier ASSY RR Rear differential side gear

shaft oil seal
N•m {kgf•cm, ft•lbf} : Tightening torque Differential gear oil
Non-reusable parts AD
DI-00944
Replacement
2. Fixation of differential carrier ASSY RR (Refer to AD - 41)
3. Removal of rear differential side gear shaft oil seal
(1) Remove the right and left side oil seals using a flat tip screwdriver.
DI-00902
AD–36 Axle / differential － Rear differential side gear shaft oil seal
4. Installation of rear differential side gear shaft oil seal

(1) Press-fit 2 new oil seals into the position shown in the figure using
556 the SST and a hammer.
SST 20299AG010
*1 Rear differential side gear shaft oil seal
Standard value: 0±0.5 mm {0±0.02 in} (from the differential carrier

end face)
CAUTION:
Evenly tap and press-fit the oil seal in a straight forward direction.
(2) Apply a thin coat of differential gear oil to the lip of the oil seal.
556
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DI-00903
6. Installation of differential carrier ASSY RR (Refer to AD - 70)
AD
Axle / differential － Rear differential carrier ASSY
AD–37
Rear differential carrier ASSY

Drive/ train
Axle differential
Exploded view
62 {632, 45.7}
x2
Rear differential mount
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stopper UPP
Rear drive shaft

ASSY RH
Rear drive shaft inboard

joint snap ring RH
Rear drive shaft inboard AD

Differential carrier joint snap ring LH
ASSY RR
95 {969, 70.1}

N•m {kgf•cm, ft•lbf} : Tightening torque stopper LWR
Non-reusable parts
Differential gear oil

DI-00945
AD–38 Axle / differential － Rear differential carrier ASSY
49 {500, 36.1}
Rear differential filler plug
Rear differential breather

Rear differential carrier plug oil deflector
21 {214, 15.5}
Rear differential breather
plug
8.0 {82, 5.9}
85 {867, 62.7} Rear differential
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x4 carrier cover
x8
47 {479, 34.7}
Gasket Bearing cap
Rear differential side

Gasket gear shaft oil seal
AD 49 {500, 36.1} Rear differential drive

Rear differential drain plug pinion bearing spacer
Rear drive pinion tapered

roller bearing FR
Pre-load adjustment torque 338
{3447, 249.3} or less
Rear drive pinion nut Rear differential drive pinion oil slinger
Rear drive pinion
companion flange RR
N•m {kgf•cm, ft•lbf} : Tightening torque

Rear differential dust deflector
Non-reusable parts
Differential gear oil
DI-00946
AD–39
Rear differential ring

gear bolt lock plate
Differential ring gear
Rear differential case bearing
Rear differential side gear shaft

washer
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97 {989, 71.5}
x5 x10
Rear drive pinion tapered AD

roller bearing RR
Rear differential drive

pinion washer
Differential drive pinion
Differential case ASSY
Rear differential case bearing
Rear differential side

N•m {kgf•cm, ft•lbf} : Tightening torque gear shaft washer
Non-reusable parts
DI-00947
Removal
1. Draining of differential oil
(2) Remove the drain plug and the gasket, and then drain oil.
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2. Removal of propeller shaft with center bearing ASSY
(Refer to DP - 14)
3. Removal of differential carrier ASSY RR
(1) Using a tall transmission jack, support the differential carrier ASSY
RR.
WARNING:
• The differential carrier ASSY RR is heavy. Be sure to support it
with a tall transmission jack.
• In order to prevent the differential carrier ASSY RR from being
AD excessively tilted or coming off, perform the operation while hold-
ing it with several assistants.
DI-00939
(2) Remove 5 bolts, and then remove the rear differential mount stop-
per UPR and the rear differential mount stopper LWR.
AD–41
(3) Lower the tall transmission jack slowly. Using a tire lever, etc.,
detach the rear drive shaft ASSY from the differential carrier ASSY
RR as shown in the figure.
CAUTION:
If a tire lever, etc. contacts the rear cover, the cover may be damaged.
A tire lever, etc. is allowed to contact the differential carrier.
DI-00905
(4) Lower the tall transmission jack. Pull out the rear drive shaft ASSY
from the differential carrier ASSY RR, and then remove the differ-
ential carrier ASSY RR.
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NOTE:
Suspend the detached rear drive shaft ASSY using a string, etc.
AD
Disassembly
1. Fixation of rear differential carrier ASSY RR
(1) Install the rear differential carrier to the overhaul stand.
DI-00906
2. Removal of rear differential breather plug

(1) Remove the differential breather plug from the differential carrier.
3. Removal of rear differential carrier cover

(1) Remove the 8 bolts.
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(2) Using a plastic hammer, lightly tap the rib portion of the differential
carrier cover, and remove it from the differential carrier.
CAUTION:
Be careful not to damage the mating surface of the differential carrier.
AD
DI-00907
4. Removal of rear differential breather plug oil deflector
(1) Remove the bolts, and then remove the breather plug oil deflector
from the differential carrier cover.
AD–43
5. Inspection of differential ring gear runout

(1) Inspect the runout of the ring gear by contacting a dial gauge at a
right angle to the back surface of the ring gear.
Limit: 0.07 mm {0.003 in}
NOTE:
If it exceeds the limit, remove the ring gear and inspect runout of
the differential case.
DI-00908
6. Inspection of backlash between differential ring gear and differential

drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the
ring gear.
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(2) Secure the companion flange RR by hand, and inspect the ring
gear backlash.
Standard value: 0.13 to 0.18mm {0.005 to 0.007in}
NOTE:
Measure at 3 points or more on the ring gear circumference.
DI-00931
7. Inspection of tooth contact between differential ring gear and differen-

tial drive pinion
AD
(1) Apply a thin uniform coat of red lead on both teeth surfaces of the
ring gear.
(2) Rotate the companion flange RR forward and backward several
times.
(3) Check the tooth contact between the drive pinion and the ring
gear.
DI-00909
D E
G H
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F
*a Correct tooth contact *b Heel contact
Adjust the drive pinion and the ring gear in the direction of
*c Face contact *d
arrow.
*e Toe contact *f Flank contact
NOTE:
• Check the tooth contact condition at 4 points on the ring gear
circumference.
• The pattern shown on red lead is the position of tooth contact.
AD 8. Inspection of differential side gear backlash

differential side gear.
(2) Secure the differential pinion to the differential case side, and then
check that the backlash of differential side gear is 0 mm {0 in}.
DI-00910
AD–45
9. Inspection of rear drive pinion companion flange RR runout

C D (1) Wipe off the inner surface of the companion flange RR with a cloth
to remove dust or foreign matter.
*a Inspection of radial runout
*b Inspection of lateral runout
(2) Inspection of companion flange RR radial runout

(a)Contact the lever type probe of a dial gauge at a right angle to
the inner circumference of the companion flange RR.
OO (b)Inspect radial runout of the companion flange RR.
Limit: 0.09mm {0.004in}
(3) Inspection of companion flange RR lateral runout
(a)Contact a dial gauge at a right angle to the surface of the com-
panion flange RR as shown in the figure.
(b)Inspect lateral runout of the companion flange RR.
Limit: 0.09mm {0.004in}
10. Inspection of differential drive pinion preload
(1) Using a socket wrench (30 mm) and a torque wrench, check pre-
load of the drive pinion within the ring gear backlash.
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Standard value T = 1.87 to 2.17 N·m {19.1 to 22.1 kgf·cm} {1.38 to 1.60ft·lbf}
DI-00911
11. Inspection of overall preload

(1) Using a socket wrench (30 mm) and a torque wrench, check over-
all preload with the drive pinion contacting the ring gear tooth sur-
face.
Standard value T = 2.19 to 2.70N·m {22.3 to 27.5 kgf·cm} {1.62 to 1.99ft·lbf}
AD
DI-00911
12. Removal of rear differential side gear shaft oil seal

(1) Using a flat tip screwdriver, remove the right and left side oil seals
from the differential carrier.
DI-00955
13. Removal of rear drive pinion nut

(1) Release the crimp of the drive pinion nut using a chisel and a ham-
mer.
CAUTION:
In order to prevent the thread of the drive pinion from being damaged,
completely release the crimp of the nut.
DI-00913
(2) Using the SST, secure the companion flange RR.

SST 18355AA000, 18334AA000
D Captions in illustration
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*a Drive
*b Hold
(3) Using a socket wrench (30 mm), remove the drive pinion nut from
556 the differential carrier.
WARNING:
During operation, support the overhaul stand.
C
DI-00914
14. Removal of rear drive pinion companion flange RR
(1) Using the SST, remove the companion flange RR from the differ-
ential carrier.
SST 09950-30012 (09951-03010, 09953-03010, 09954-
556
C 03010, 09955-03030, 09956-03030)
AD Captions in illustration
*a Drive
*b Hold
D NOTE:
• Apply grease to the thread and end portions of the SST center
bolt (09953-03010) before using it.
• The bolts and nuts used for securing the SST and the compan-
ion flange RR are recommended to be M8 ×P1.25 with a bolt
556 length of approx. 40 mm {1.6 in}.
DI-00915
15. Removal of rear differential dust deflector
NOTE:
Perform the operation only when the dust deflector is damaged.
AD–47
(1) Using the SST and a press, remove the dust deflector from the
companion flange RR.
SST 09950-00020, 499877000
CAUTION:
Be careful not to drop the companion flange RR.
NOTE:
In order to ensure the contact surface between the SST and the
556 dust deflector, perform the operation while tightening the nut of the
SST.
DI-00916
16. Removal of rear differential carrier oil seal (Refer to AD - 33)

17. Removal of rear differential drive pinion oil slinger
(1) Using a magnet hand, remove the oil slinger from the differential
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carrier.
DI-00917
18. Removal of rear drive pinion tapered roller bearing FR
C (1) Using the SST, remove the tapered roller bearing FR (inner race)
556
from the differential carrier.
SST 09556-22010
*a Drive AD
*b Hold
D
NOTE:
Apply grease to the thread and end portions of the SST center bolt
556 before using it.
DI-00918
19. Removal of rear differential drive pinion bearing spacer

(1) Remove the bearing spacer from the drive pinion.
20. Removal of rear differential carrier

C
(1) Place an identification mark on the bearing cap and the differential
carrier.
*a Identification mark
NOTE:
Place an identification mark on one end only.
(2) Remove 4 bolts, and remove 2 bearing caps from the differential
carrier.
DI-00919 CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not
change the combination.
(3) Using the SST and a plastic hammer, remove the right and left side
gear shaft washers from the differential carrier.
SST 09504-22012
556 NOTE:
• For reference when reassembling, record thickness of the right
and left (back face side and tooth face side) side gear shaft
washers.
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556 • Place a right or left identification mark (back face side or tooth
face side) on the side gear shaft washers, and arrange them
DI-00920 separately.
(4) Remove the differential case and the case bearing (outer race) as
a single unit from the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing and the ring
gear.
NOTE:
Place a right or left identification mark (back face side or tooth face
side) on the case bearing (outer race), and arrange them sepa-
rately.
AD
DI-00921
21. Removal of rear drive pinion tapered roller bearing RR

(1) Remove the drive pinion from the differential carrier.
(2) Using the SST and a press, remove the tapered roller bearing RR
(inner race) from the drive pinion.
SST 09950-00020
CAUTION:
Be careful not to drop the drive pinion.
556 NOTE:
In order to ensure the contact surface between the SST and the
tapered roller bearing RR (inner race), perform the operation while
556 tightening the nut of the SST.
(3) Remove the drive pinion washer from the drive pinion.
AD–49
NOTE:
For reference when reassembling, record thickness of the drive pinion washer.
(4) Using a brass bar and a hammer, lightly and evenly tap the entire
perimeter of the tapered roller bearing RR (outer race), and

remove it from the differential carrier.
*1 Outer race
CAUTION:
Always let the brass bar come in contact with the range of the tapered
roller bearing RR (outer race) during operation. Be careful not to dam-
age the differential carrier.
22. Removal of rear drive pinion tapered roller bearing FR

(1) Using a brass bar and a hammer, lightly and evenly tap the entire
perimeter of the tapered roller bearing FR (outer race), and
remove it from the differential carrier.
*1 Outer race
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CAUTION:
Always let the brass bar come in contact with the range of the tapered
roller bearing RR (outer race) during operation. Be careful not to dam-
age the differential carrier.
23. Removal of differential ring gear

(1) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
Do not vise excessively.
(2) Place an alignment mark on the differential case and the ring gear.
*a Alignment marks
AD
C
(3) Release the crimps of 5 lock plates using a chisel and a hammer.
(4) Remove 10 bolts and 5 lock plates from the differential case.
(5) Using a plastic hammer, evenly tap the periphery of the ring gear,
and remove the ring gear from the differential case.
NOTE:
Cover the tooth surface side of the ring gear with a cloth to prevent
damage.
24. Inspection of differential case ASSY runout

NOTE:
Perform only when the inspection result of the differential ring gear runout exceeds the limit.
(1) Install the case bearing (outer race LH/RH) to the case bearing
(inner race LH/RH), and install the differential case to the differen-
tial carrier.
CAUTION:
• When installing the bearing outer races, do not confuse the left and
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right.
• Be careful not to damage the differential case bearing.
DI-00922
(2) Install the right and left (back face side and tooth face side) side gear shaft washer to the differential carrier while avoid-
ing play of the case bearing.
AD
C D
DI-00923
*a Back face side *b Tooth face side
AD–51
(3) Install the right and left bearing caps to the differential carrier with
C
4 bolts.

CAUTION:
DI-00924
(4) Contact a dial gauge at a right angle to the flange surface of the
differential case.
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DI-00925
(5) Check runout of the differential case.
Limit: 0.07 mm {0.003 in}
(6) Remove 4 bolts, and remove 2 bearing caps from the differential carrier.
(7) Remove the differential case, right and left case bearings and right and left side gear shaft washers from the differential
carrier.
CAUTION:
Be careful not to damage the differential case bearing.
25. Removal of rear differential case bearing
NOTE:
Perform the operation only when the case bearing or the differential case is replaced.
(1) Using the SST, remove the case bearings (inner race LH and RH)
from the differential case.
AD
C SST 09950-40011 (09951-04020, 09952-04010, 09953-
04030, 09954-04010, 09955-04061, 09957-04010,
09958-04011), 09950-60010 (09951-00350, 09951-
00480, 09952-06010)
556
D *a Drive
*b Hold
CAUTION:
Be careful not to deform the cage of the differential case bearing.
(When the bearing is reused)
NOTE:
556 bolt (09953-04030) before using it.
• Pinch the bearing inner race from the cutout portion of the dif-
ferential case using the claws of the SST.
• Place a right or left identification mark (back face side or tooth
face side) on the differential case bearings, and arrange them
separately.
26. Inspection of differential side gear backlash

(1) Using aluminum plates in between, secure the differential case in a
vise.
CAUTION:
differential side gear, secure the differential pinion gear to the dif-
ferential case, and then check that the backlash is 0 mm {0 in}.
NOTE:
If the backlash is not 0 mm {0 in}, replace the differential case
ASSY.
Assembly
1. Installation of differential ring gear
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(1) Clean the screw hole of the differential case.
(2) Heat the ring gear up to 100°C {212°F} with hot water.
͠ WARNING:
The ring gear becomes hot. Perform the operation after protecting
hands with thick gloves.
AD (3) Completely wipe off grease and water from the mating surface of the differential case and the ring gear.
(4) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
(5) Completely wipe off grease and water from the ring gear (mating surface of the differential case).
(6) Align the alignment marks on the differential case and the ring
gear, and then quickly install the ring gear to the differential case.
*a Alignment marks
CAUTION:
Align the bolt hole of the differential case and the screw hole of the ring
gear.
(7) Temporarily tighten 10 differential case bolts several times through 5 new lock plates, and then tighten them to the spec-
ified torque.
CAUTION:
Tighten the bolts after the ring gear cools down sufficiently.
NOTE:
Tighten the bolts diagonally in several stages.
AD–53
(8) Release the crimps of the lock plate using a chisel and a hammer
to counter the rotation.
*a Tightening direction
NOTE:
If the crimp contacts the angled portion of the bolt head and should
be divided into 2 sections, the section facing the tightening side of
the bolt head must be in close contact as shown in the figure.
C
2. Installation of rear differential case bearing
(1) Using the SST and a press, press-fit the case bearings (inner race
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LH and RH) into the differential case.
SST 09710-30012 (09710-04081), 398477702
NOTE:
556
• Press until the case bearing is in close contact with the differ-
ential case.
• Align the SST in the center of the differential case.
CAUTION:
• When using new bearings, do not apply differential gear oil.
• Be careful not to deform the cage of the bearing.
• When replacing the bearing, replace the outer race and the inner
race as a set.
DI-00926
AD
3. Inspection of differential ring gear runout
(1) Install the case bearing (outer race LH and RH) to the case bear-
ing (inner race LH and RH), and install the differential case to the
carrier.
CAUTION:
• When installing the bearing outer races, do not confuse the left and
right.
(2) Install the right and left (back face side and tooth face side) side
gear shaft washer to the differential carrier while avoiding play of
the case bearing.
DI-00921
C D
DI-00927
NOTE:
• When the final gear set (drive pinion & ring gear) and the case
bearings are replaced, select a side gear shaft washer with thin
thickness and install it.
• When the drive pinion, ring gear and case bearings are reused,
select a side gear shaft washer with the same thickness as that
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of the one before disassembly and install it.
(3) Install the right and left bearing caps to the differential carrier with
C
4 bolts.

CAUTION:
DI-00919
AD (4) Contact a dial gauge at a right angle to the back surface of the ring
gear.
(5) Check for runout of the ring gear.
Limit: 0.07 mm {0.003 in}
DI-00908
AD–55
(6) Remove 4 bolts, and remove 2 bearing caps from the differential
C
carrier.
(7) Remove the right and left side gear shaft washers from the differ-
ential carrier.
DI-00919
C D
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DI-00927
(8) Remove the differential case and right and left case bearings from
the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing and the ring
gear.
AD
DI-00921
4. Installation of rear drive pinion tapered roller bearing RR
(1) Install the drive pinion washer to the drive pinion.
*1 Drive pinion washer
*2 Inner race
NOTE:
• In order to prevent the drive pinion washer from dropping, tem-
porarily install the tapered roller bearing RR (inner race).
• Install the drive pinion washer with the same thickness as that
of the removed one.
• The drive pinion washer has no installation direction.
(2) Using the SST and a press, press-fit the tapered roller bearing RR
(inner race) into the drive pinion.
SST 09506-30012
CAUTION:
When using new bearings, do not apply differential gear oil.
556
(3) Using the SST and a press, press-fit the tapered roller bearing RR
(outer race) into the differential carrier.
556
SST 09950-60020 (09951-00890), 09950-70010 (09951-
556
07200)
*1 Outer race
CAUTION:
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5. Installation of rear drive pinion tapered roller bearing FR

(1) Using the SST and a press, press-fit the tapered roller bearing FR
556 556 (outer race) into the differential carrier.
SST 09950-60020 (00951-00720), 09950-70010 (09951-
07100)
*1 Outer race
CAUTION:
AD 6. Installation of rear differential dust deflector

(1) Using the SST and a press, press-fit a new dust deflector into the
companion flange RR.
SST 499277200, 499225500
556
CAUTION:
• When press-fitting, gradually insert the dust deflector while check-
ing the condition.
• Do not press-fit excessively.
• Remove a burr if it occurs when press-fitting.
DI-00928
AD–57
7. Adjustment of differential drive pinion preload

(1) While supporting the drive pinion by hand, install the drive pinion
tapered roller bearing FR (inner race) to the differential carrier.
CAUTION:
• Be careful not to drop the drive pinion.
• In order to check the tooth contact of the ring gear, install the
spacer and oil seal after checking and adjusting the tooth contact.
(2) Install the oil slinger to the differential carrier.
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DI-00917
(3) Using the SST, install the companion flange RR to the differential
carrier.
SST 09950-30012 (09951-03010, 09953-03010, 09954-
03010, 09955-03030, 09956-03030)
556 C Captions in illustration
*a Drive
*b Hold
CAUTION:
D • Be careful not to drop the drive pinion. Support it by hands until the
SST is installed.
• The bearing spacer is not installed, therefore, install the compan- AD
ion flange RR until there is a small play in the drive pinion.
NOTE:
556
length of approx. 40 mm {1.6 in}.
DI-00929

C SST 18355AA000, 18334AA000
*a Drive
556 *b Hold
(5) Using a socket wrench (30 mm) and a torque wrench, gradually
tighten a new drive pinion nut to the specified preload.
Limit: T = 338 N·m {3447 kgf·cm} {249.3 ft·lbf}
D WARNING:
DI-00930 During operation, support the overhaul stand.
CAUTION:
Note that no bearing spacer is inserted. Therefore, tighten the nut
gradually. Never overtighten it.
NOTE:
• Tighten to approx. 100 N·m {1020 kgf·cm} {73.8 ft·lbf} while
checking the preload.
• Apply differential gear oil to the thread portions of the nut and
the drive pinion.
(6) Turn it forward and backward several times to seat the bearing
properly.
load of the drive pinion.
T = 1.77 to 2.14N·m {18.0 to 21.8 kgf·cm} {1.31 to
When the bearing is new
Standard 1.58ft·lbf}
value When the bearing is T = 1.77 to 2.07N·m {18.0 to 21.1 kgf·cm} {1.31 to
reused 1.53ft·lbf}
CAUTION:
For inspection of overall preload, record the preload.
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DI-00911
8. Installation of rear differential case SUB-ASSY
(1) Install the case bearing (outer race LH and RH) to the case bear-
ing (inner race LH and RH), and install the differential case to the
differential carrier.
CAUTION:
When installing the bearing outer races, do not confuse the left and
right.
(2) Install the right and left (back face side and tooth face side) side
gear shaft washer to the differential carrier while avoiding play of
the case bearing.
AD
DI-00921
C D
DI-00927
NOTE:
• When the final gear set (drive pinion & ring gear) and the differ-
ential case bearings are replaced, select a differential side gear
shaft washer with thin thickness and install it.
AD–59
• When the drive pinion, ring gear and differential case bearings
are reused, select a differential side gear shaft washer with the
same thickness as that of the disassembled one and install it.
9. Inspection and adjustment of backlash between differential ring gear
and differential drive pinion
ring gear.
gear by moving it.
NOTE:
• Inspect at 3 points or more on the ring gear circumference.
• Record the measured value for reference when selecting the
side gear shaft washer.
• For reference when selecting the side gear shaft washer,
inspect the tooth contact between the differential ring gear and
the drive pinion.
DI-00931
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(3) Select the side gear shaft washer which allows the ring gear's
backlash to be within the standard value, and install it to the back
face side of the ring gear.
Type of rear differential side gear shaft washer
Identification Identification
Thickness (mm {in}) Thickness (mm {in})
mark mark
2.57 to 2.59 {0.1012 to 3.03 to 3.05 {0.1193 to
01 47
0.1020} 0.1201}
2.59 to 2.61 {0.1020 to 3.05 to 3.07 {0.1201 to
32 17
0.1028} 0.1209}
DI-00932 2.61 to 2.63 {0.1028 to 3.07 to 3.09 {0.1209 to
33 48
0.1035} 0.1217}
2.63 to 2.65 {0.1035 to 3.09 to 3.11 {0.1217 to
03 49
0.1043} 0.1224}
2.65 to 2.67 {0.1043 to
34
3.11 to 3.13 {0.1224 to
19
AD
0.1051} 0.1232}
2.67 to 2.69 {0.1051 to 3.13 to 3.15 {0.1232 to
35 50
0.1059} 0.1240}
2.69 to 2.71 {0.1059 to 3.15 to 3.17 {0.1240 to
05 51
0.1067} 0.1248}
2.71 to 2.73 {0.1067 to 3.17 to 3.19 {0.1248 to
36 21
0.1075} 0.1256}
2.73 to 2.75 {0.1075 to 3.19 to 3.21 {0.1256 to
37 52
0.1083} 0.1264}
2.75 to 2.77 {0.1083 to 3.21 to 3.23 {0.1264 to
07 53
0.1091} 0.1272}
2.77 to 2.79 {0.1091 to 3.23 to 3.25 {0.1272 to
38 23
0.1098} 0.1280}
2.79 to 2.81 {0.1098 to 3.25 to 3.27 {0.1280 to
39 54
0.1106} 0.1287}
2.81 to 2.83 {0.1106 to 3.27 to 3.29 {0.1287 to
09 55
0.1114} 0.1295}
2.83 to 2.85 {0.1114 to 3.29 to 3.31 {0.1295 to
40 25
0.1122} 0.1303}
2.85 to 2.87 {0.1122 to 3.31 to 3.33 {0.1303 to
41 56
0.1130} 0.1311}
2.87 to 2.89 {0.1130 to 3.33 to 3.35 {0.1311 to
11 57
0.1138} 0.1319}
Identification Identification
mark mark
2.89 to 2.91 {0.1138 to 3.35 to 3.37 {0.1319 to
42 27
0.1146} 0.1327}
2.91 to 2.93 {0.1146 to 3.37 to 3.39 {0.1327 to
43 58
0.1154} 0.1335}
2.93 to 2.95 {0.1154 to 3.39 to 3.41 {0.1335 to
13 59
0.1161} 0.1343}
2.95 to 2.97 {0.1161 to 3.41 to 3.43 {0.1343 to
44 29
0.1169} 0.1350}
2.97 to 2.99 {0.1169 to 3.43 to 3.45 {0.1350 to
45 60
0.1177} 0.1358}
2.99 to 3.01 {0.1177 to 3.45 to 3.47 {0.1358 to
15 61
0.1185} 0.1366}
3.01 to 3.03 {0.1185 to 3.47 to 3.49 {0.1366 to
46 31
0.1193} 0.1374}
(4) Using a plastic hammer, lightly tap the differential carrier for better
fitting of the case bearing and the side gear shaft washer.
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DI-00933
ring gear.
(6) Secure the companion flange RR by hand, and inspect the back-
lash by moving the ring gear.
AD
DI-00931
(7) If out of the standard, select the side gear shaft washer which
allows the ring gear's backlash to be around the standard value,
and install it to the back face side of the ring gear.
DI-00932
AD–61
(8) Select the thickest side gear shaft washer that provides no gap or
almost no gap between the end face of the case bearing outer
race on the tooth face side of the ring gear and the carrier.
*1 Side gear shaft washer
*2 Outer race

DI-00934
(9) Using a plastic hammer, lightly tap the differential carrier for better
fitting of the case bearing.
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DI-00933
ring gear.
(12) If out of the standard, adjust the thickness of the right and left side
gear shaft washers, increasing or decreasing by the same amount.
AD
NOTE:
• Record the measured value for reference when selecting the
the drive pinion.
DI-00931
10. Inspection and adjustment of differential case bearing preload

(1) After adjusting the backlash of the ring gear, remove the side gear
shaft washer on the tooth face side of the ring gear.
(2) Using a micrometer, inspect the thickness of the side gear shaft
washer.
(3) Select the side gear shaft washer that is 0.06 to 0.09 mm {0.002 to
0.004 in} thicker than the removed side gear shaft washer.
CAUTION:
Install the side gear shaft washer that can be inserted into about two
thirds of the way using a finger.
DI-00935
(4) Using the SST and a hammer, press-fit the side gear shaft wash-
ers into the differential carrier.
556 SST 09504-22012
DI-00936
(5) Align the alignment marks on the bearing cap and the differential
C
carrier, and install the bearing cap.
(6) Using 4 bolts, tighten the right and left bearing caps.
CAUTION:
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DI-00919
ring gear.
NOTE:
• Measure at 3 points or more on the ring gear circumference.
• If any small backlash is found, replace the side gear shaft
washer on the tooth face side of the ring gear with a thicker
one.
AD • Record the measured value for reference when selecting the

the drive pinion.
DI-00931 • When adjusting the backlash, bring the average value close to
0.1 mm {0.004 in}.
11. Inspection and adjustment of overall preload
(1) Using a socket wrench (30 mm) and a torque wrench, check over-
all preload with the drive pinion contacting the ring gear tooth sur-
face.
DI-00911
Preload for new drive pinion tapered roller bearing
When the differential case bearing is new T = 2.17 to 2.77 N·m {22.1 to 28.2 kgf·cm} {1.60 to 2.04 ft·lbf}
Standard value
When the differential case bearing is reused T = 2.09 to 2.67N·m {21.3 to 27.2 kgf·cm} {1.54 to 1.97ft·lbf}
AD–63
Preload with reused drive pinion tapered roller bearing

When the differential case bearing is new T = 2.17 to 2.70N·m {22.1 to 27.5 kgf·cm} {1.60 to 1.99 ft·lbf}
Standard value
NOTE:
• If out of the standard, perform the adjustment using the side
gear shaft washer on the tooth face side of the ring gear.
• If the measured preload is less than standard, replace the side
gear shaft washer with a thicker one.
• If the measured preload is more than standard, replace the
side gear shaft washer with a thinner one.
• Record the measured value for reference when reassembling.
ring gear.
NOTE:
• Measure at 3 points or more on the ring gear circumference.
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• If the backlash is out of the standard, adjust the thickness of
the right and left side gear shaft washers, increasing or
decreasing by the same amount.
• When adjusting the backlash, bring the average value close to
0.1 mm {0.004 in}.
• If any small backlash is found, replace the side gear shaft
washer on the tooth face side of the ring gear with a thicker
one.
DI-00931 • Record the measured value for reference when selecting the
the drive pinion.
(4) Recheck the overall preload. AD
12. Inspection of tooth contact between differential ring gear and differen-
tial drive pinion
(1) Apply a thin uniform coat of red lead on both teeth surfaces of the
ring gear.
(2) Rotate the companion flange forward and backward several times.
(3) Check the tooth contact between the drive pinion and the ring
gear.
DI-00909
D E
G H
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F
*a Correct tooth contact *b Heel contact
Adjust the drive pinion and the ring gear in the direction of
*c Face contact *d
arrow.
*e Toe contact *f Flank contact
NOTE:
• Check the contact condition at 4 points on the ring gear circum-
ference.
• The pattern shown on red lead is the position of tooth contact.
AD (4) If an improper tooth contact occurs, select a drive pinion washer

from the table, remove the tapered roller bearing RR, and then
reinstall it.
*1 Inner race
*2 Drive pinion washer
CAUTION:
If the thickness of the drive pinion washer is changed, adjust the back-

lash and perform the general preload inspection.
Type of rear differential drive pinion washer
1.69 to 1.71 {0.0665 to 0.0673} 2.02 to 2.04 {0.0795 to 0.0803}
1.72 to 1.74 {0.0677 to 0.0685} 2.05 to 2.07 {0.0807 to 0.0815}
1.75 to 1.77 {0.0689 to 0.0697} 2.08 to 2.10 {0.0819 to 0.0827}
1.78 to 1.80 {0.0701 to 0.0709} 2.11 to 2.13 {0.0831 to 0.0839}
1.81 to 1.83 {0.0713 to 0.0720} 2.14 to 2.16 {0.0843 to 0.0850}
1.84 to 1.86 {0.0724 to 0.0732} 2.17 to 2.19 {0.0854 to 0.0862}
1.87 to 1.89 {0.0736 to 0.0744} 2.20 to 2.22 {0.0866 to 0.0874}
1.90 to 1.92 {0.0748 to 0.0756} 2.23 to 2.25 {0.0878 to 0.0886}
1.93 to 1.95 {0.0760 to 0.0768} 2.26 to 2.28 {0.0890 to 0.0898}
1.96 to 1.98 {0.0772 to 0.0780} 2.29 to 2.31 {0.0902 to 0.0909}
1.99 to 2.01 {0.0783 to 0.0791} 2.32 to 2.34 {0.0913 to 0.0921}
AD–65
13. Removal of rear drive pinion nut

(1) Using the SST, secure the flange and remove the drive pinion nut
D from the differential carrier.
SST 18355AA000, 18334AA000
*a Drive
556 *b Hold
WARNING:
During operation, support the overhaul stand.
C NOTE:
DI-00914
The bolts and nuts used for securing the SST and the companion
flange RR are recommended to be M8 ×P1.25 with a bolt length of
approx. 45 mm {1.8 in}.
15. Removal of rear differential drive pinion oil slinger (Refer to AD - 47)
16. Removal of rear drive pinion tapered roller bearing FR (Refer to AD - 47)
17. Installation of rear differential drive pinion bearing spacer
(1) Install a new bearing spacer to the drive pinion.
CAUTION:
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Install the part with a larger inner diameter to the drive pinion side, and
the part with a smaller to the companion flange RR side.
18. Installation of rear drive pinion tapered roller bearing FR

(1) Install the tapered roller bearing FR (inner race) to the differential
carrier.
AD
19. Installation of rear differential drive pinion oil slinger

(1) Install the oil slinger to the differential carrier.
DI-00917
20. Installation of rear drive pinion companion flange RR

(1) Using the SST and the companion flange RR, press-fit the tapered
roller bearing RR (inner race) into the differential carrier.
SST 09950-30012 (09951-03010, 09953-03010, 09954-
556 C 03010, 09955-03030, 09956-03030)
*a Drive
*b Hold
D NOTE:
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DI-00937
22. Installation of rear differential carrier oil seal (Refer to AD - 33)
23. Installation of rear drive pinion companion flange RR
(1) Using the SST, install the companion flange RR to the differential
carrier.
SST 09950-30012 (09951-03010, 09953-03010, 09954-
556 C 03010, 09955-03030, 09956-03030)
*a Drive
*b Hold
AD D NOTE:
DI-00937
AD–67

C SST 18355AA000, 18334AA000
*a Drive
556 *b Hold
(3) Using a socket wrench (30 mm) and a torque wrench, tighten the
drive pinion nut while checking the preload.
D WARNING:
DI-00930 During operation, support the overhaul stand.
CAUTION:
Do not tighten excessively, or the thread portion may be damaged if it
exceeds the limit.
NOTE:
• Tighten to approx. 100 N·m {1020 kgf·cm} {73.8 ft·lbf} while
checking the preload.
• Apply differential gear oil to the thread portions of the nut and
the drive pinion.
24. Adjustment of differential drive pinion preload
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load within the backlash of the drive pinion and ring gear.
T = 1.87 to 2.24N·m {19.1 to 22.8 kgf·cm} {1.38 to
When the bearing is new
Standard 1.65ft·lbf}
value When the bearing is T = 1.87 to 2.17 N·m {19.1 to 22.1 kgf·cm} {1.38 to
reused 1.60ft·lbf}
NOTE:
• In order to seat the bearing properly, rotate the companion
DI-00911 flange forward and backward several times.
• For inspection of general preload, record the preload of the
drive pinion.
(2) Replace the bearing spacer if preload is excessive.
CAUTION:
The bearing spacer is used in plastic deformation, therefore, always
replace it with a new part if excessively high preload is set to the drive
AD
pinion by mistake.
(3) If the preload is insufficient, check the preload after further tighten-
ing the drive pinion nut by 5 to 10°, and repeat the adjustment to
be within the standard.
(4) If the preload is still insufficient after the tightening torque of the
drive pinion nut exceeds the limit, loosen the drive pinion nut, and
then check that the drive pinion nut and drive pinion thread are not
and broken.
(5) If there is no malfunction, replace the bearing spacer, apply differ-
ential gear oil to the thread of the drive pinion, and repeat the oper-
ation.
25. Inspection of overall preload

load with the drive pinion contacting the ring gear tooth surface.
DI-00911
Preload for new drive pinion tapered roller bearing
When the differential case bearing is new T = 2.27 to 2.87N·m {23.1 to 29.3 kgf·cm} {1.67 to 2.12ft·lbf}
Standard value
When the differential case bearing is reused T = 2.19 to 2.77 N·m {22.3 to 28.2 kgf·cm} {1.62 to 2.04 ft·lbf}
Preload with reused drive pinion tapered roller bearing

When the differential case bearing is new T = 2.27 to 2.80N·m {23.1 to 28.6 kgf·cm} {1.67 to 2.07ft·lbf}
Standard value
26. Inspection of backlash between differential ring gear and differential

drive pinion
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ring gear.
gear backlash.
NOTE:
Measure at 3 points or more on the ring gear circumference.
AD DI-00931
27. Inspection of rear drive pinion companion flange RR runout

C D (1) Wipe off the inner surface of the companion flange RR with a cloth
to remove dust or foreign matter.
*a Inspection of radial runout
*b Inspection of lateral runout
(2) Inspection of companion flange RR radial runout

(a)Contact the lever type probe of a dial gauge at a right angle to
the inner circumference of the companion flange RR.
OO (b)Inspect radial runout of the companion flange RR.
Limit: 0.09mm {0.004in}
(3) Inspection of companion flange RR lateral runout
(a)Contact a dial gauge at a right angle to the surface of the com-
panion flange RR as shown in the figure.
(b)Inspect lateral runout of the companion flange RR.
Limit: 0.09mm {0.004in}
AD–69
28. Fixation of rear drive pinion nut

(1) Crimp the drive pinion nut using a chisel and a hammer.
DI-00938
29. Installation of rear differential side gear shaft oil seal (Refer to AD - 36)
30. Installation of rear differential drain plug
(1) Install the drain plug to the differential carrier through a new gasket using a socket hexagon wrench 10.
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31. Installation of rear differential breather plug oil deflector
(1) Using a scraper and a wire brush, clean the seal gasket that is attached to the differential carrier and the carrier cover,
and then degrease it with a cleaning solvent, etc.
CAUTION:
Be careful not to damage the mating surface of the differential carrier.
(2) Using bolts, install the breather plug oil deflector to the differential
carrier cover.
AD
32. Installation of rear differential carrier cover

C (1) Apply Three Bond 1281 or equivalent to the position of the differ-
ential carrier cover as shown in the figure.
*a Applying position of Three Bond 1281 or equivalent
CAUTION:
• Apply seal gasket in a diameter of 2 to 3 mm {0.08 to 0.12 in}
seamlessly.
• There must be 10 mm {0.4 in} or more overlapped portion between
the starting and ending sections.
• Install within 3 minutes after applying seal gasket.
(2) Install the differential carrier cover to the differential carrier with 8
bolts.
Standard value:T=47N·m {479kgf·cm} {34.7 ft·lbf}
CAUTION:
Do not fill with oil or drive the vehicle immediately after installing the
differential carrier cover. Leave the vehicle unattended for one hour or
more. Also, avoid abrupt acceleration and deceleration for 12 hours or
more.
33. Installation of rear differential breather plug

(1) Install the differential breather plug to the differential carrier.
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34. Removal of rear differential carrier ASSY RR
(1) Remove the rear differential carrier ASSY RR from the overhaul stand.
Installation
1. Installation of differential carrier ASSY RR
AD (1) Using a tall transmission jack, support the differential carrier ASSY RR.
(2) Install a new snap ring to the rear drive shaft ASSY.
(3) Apply differential gear oil to the spline of the inboard joint ASSY.
(4) Align the spline of the rear drive shaft inboard joint, and then press-fit the rear drive shaft ASSY using a brass bar and a
hammer.
CAUTION:
• Place the snap ring with its cut end facing downward.
• Do not damage the oil seal during insertion.
• Be careful not to strike the tip of the outboard joint with a hammer.
• If there is a malfunction, such as dislocation, etc., in the inboard
joint of the drive shaft, replace it with a new part.
DS-00734
NOTE:
Check that the drive shaft is completely press-fit by feeling the change of reaction force or sound quality.
AD–71
(5) Gradually lift the tall transmission jack, and install the differential
# carrier ASSY RR through the rear differential mount stopper UPR
and the rear differential mount stopper LWR with 5 bolts
# SST 41399CA170
# CAUTION:
$ When tightening the bolt B, use the SST.
Standard value:T=62N·m {632kgf·cm} {45.7 ft·lbf} (bolt A)
$ T=95N·m {969kgf·cm} {70.1 ft·lbf} (bolt B)
*1 Rear differential mount stopper LWR
667 *a Apply the SST to the rear differential carrier.

667
667

667
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D
667
D
667
DI-10445
AD
2. Installation of propeller shaft with center bearing ASSY (Refer to DP - 16)
3. Filling of differential oil (Refer to AD - 31)
AD–72 Axle / differential － Rear differential mount cushion
Rear differential mount cushion

Drive/ train
Axle differential
Exploded view

cushion NO. 2
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cushion NO. 1
AD
Non-reusable parts
DI-00950
Axle / differential － Rear differential mount cushion
AD–73
Removal
1. Removal of rear differential carrier ASSY (Refer to AD - 40)
2. Removal of exhaust tail pipe ASSY (Refer to IE - 39)
3. Removal of stabilizer bar RR (Refer to RP - 25)
4. Removal of rear differential mount cushion NO. 1
(1) Using the SST, remove the rear differential mount cushion NO. 1.
SST 41399CA050 (41399CA060, 41399CA070,
41399CA100, 41399CA110, 41399CA120, 41399CA130,
41399CA140, 41399CA150)
CAUTION:
• Always make sure that the SST fits the periphery of the rear sus-
pension member cylinder and is not tilted.
V • Do not allow the SST to ride on the weld beads on the cylinder's
W
outer periphery.
*1 Rear suspension member
*2 Rear differential mount cushion NO. 1
. - * *3 SST(41399CA140)
, + )
&% *4 SST(41399CA120)
(
*5 SST(41399CA100)
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X
*6 SST(41399CA130)
*7 SST(41399CA150)
Y *8 SST(41399CA070)
*9 SST(41399CA060)
& *10 SST(41399CA110)
'
DI-00948 *a Hold
*b Drive
*c Start.
*d Complete
Rear side of vehicle
5. Removal of rear differential mount cushion NO. 2 AD

(1) Using the SST, remove the rear differential mount cushion NO. 2.
SST 41399CA000 (41399CA010, 41399CA020,
41399FG050, 41399FG061, 41399FG070,
41399FG080, 41399FG091)
C
*3 SST(41399FG091)
D
*4 SST(41399FG070)
*5 SST(41399FG050)
*6 SST(41399FG080)
*7 SST(41399CA020)

*8 SST(41399CA010)
*9 SST(41399FG061)
E *a Hold
*b Drive
F *c Start.
*d Complete

Installation
1. Installation of rear differential mount cushion NO. 2
(1) Place alignment marks on the new rear differential mount cushion
NO. 2 and the rear suspension member as shown in the figure.
CAUTION:
Install the rear differential mount cushion NO. 2 with the arrow marks
facing upward and downward.
C
NOTE:
Before installation, place alignment marks on the rear suspension
C member and the rear differential mount cushion NO. 2.
D Captions in illustration
*a Arrow mark
*b Alignment marks
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D
(2) Using the SST, install the rear differential mount cushion NO. 2.
SST 41399CA000 (41399CA030, 41399CA040,
41399FG050, 41399FG061, 41399FG070,
41399FG080, 41399FG091)
*3 SST(41399FG091)
C
*4 SST(41399FG070)
AD D
*5 SST(41399FG050)
*6 SST(41399FG080)
*7 SST(41399CA040)
*8 SST(41399CA030)

*9 SST(41399FG061)
*a Hold
E *b Drive
*c Start.
F *d Complete

NOTE:
• Align the alignment marks on the rear differential mount cush-
ion NO. 2 and the rear suspension member, and install it while
checking how it is off-centered.
• The allowable range of the rear differential mount cushion NO.
2 installation angle should be within 5°.
AD–75
• Insert the rear differential mount cushion NO. 2 until *7 (SST)

contacts the rear suspension member.
q
q
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2. Installation of rear differential mount cushion NO. 1
(1) Place alignment marks on the new rear differential mount cushion
NO. 1 and the rear suspension member as shown in the figure.
CAUTION:
C Install the rear differential mount cushion NO. 1 with the triangle mark
facing upward.
NOTE:
Before installation, place alignment marks on the rear suspension
member and the rear differential mount cushion NO. 1.
D
*a Triangle mark
*b Alignment marks AD
C
D
(2) Using the SST, install the rear differential mount cushion NO. 1.
SST 41399CA050 (41399CA080, 41399CA090,
41399CA100, 41399CA110, 41399CA120, 41399CA130,
41399CA140, 41399CA150)
W
*3 SST(41399CA110)
*4 SST(41399CA090)
V
*5 SST(41399CA150)
*6 SST(41399CA080)
*7 SST(41399CA130)
- + *8 SST(41399CA100)
)
. , * *9 SST(41399CA120)
(
*10 SST(41399CA140)
&%
X *a Hold
*b Drive
*c Start.
Y
*d Complete
&
cardiagn.com
'
DI-00949
CAUTION:
• Perform installation while checking the SST and the rear differen-
tial mount cushion NO. 1 are not tilted.
• If the rear differential mount cushion NO. 1 is tilted, the operation
becomes less efficient. When setting the rear differential mount
cushion NO. 1 in the rear suspension member, make sure there
are no gaps between the SST and the rear differential mount cush-
ion NO. 1.
NOTE:
• Align the alignment marks on the rear differential mount cush-
ion NO. 1 and the rear suspension member, and install it while
AD checking how it is off-centered.
• The allowable range of the rear differential mount cushion NO.
1 installation angle should be within 3°.
AD–77
• Insert the rear differential mount cushion until *4 (SST) con-

tacts the rear suspension member.
cardiagn.com
q q
3. Installation of stabilizer bar RR (Refer to RP - 27)

4. Installation of exhaust tail pipe ASSY (Refer to IE - 44)
5. Installation of rear differential carrier ASSY (Refer to AD - 70)
AD
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AD

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Drive train

Front axle hub bolt

N*m {kgf*cm, ft*lbf} : Tightening torque

Front axle hub bolt LH

N*m {kgf*cm, ft*lbf} : Tightening torque

8. Installation of front disc brake caliper ASSY LH (brembo type)

Front axle hub

95 {969,70.1} x4 7.5 {77,5.5}

Front axle hub &

N*m {kgf*cm,ft*lbf} : Tightening torque Front disc

Front disc brake caliper ASSY LH

N*m {kgf*cm,ft*lbf} : Tightening torque

4. Disconnection of speed sensor FR LH

5. Removal of front axle hub & bearing ASSY LH

AD 4. Installation of speed sensor FR LH

4. Inspection of front axle hub & bearing ASSY axial play

5. Inspection of front axle hub & bearing ASSY runout

155 {1581,114.3} Steering knuckle LH

Disc brake dust cover FR LH

Tie-rod end SUB-ASSY LH

Front suspension lower arm ASSY LH

3. Disconnection of tie-rod end SUB-ASSY LH

• Install the tie-rod ball joint puller so as to make A parallel to B with

Application area of lubricant Drive

5. Removal of steering knuckle LH

Rear axle hub bolt

Rear disc brake caliper ASSY LH

Rear axle hub bolt LH

Non-reusable parts Rear disc

Rear disc brake caliper ASSY LH

Rear axle hub bolt LH

N*m {kgf*cm, ft*lbf} : Tightening torque

Rear axle hub

Speed sensor RR LH 7.5 {77,5.5}

Rear axle hub & bearing ASSY LH

N*m {kgf*cm,ft*lbf} : Tightening torque

Rear axle shaft nut LH

Speed sensor RR LH 7.5 {77,5.5}

Rear disc brake caliper ASSY LH

Rear axle hub and bearing ASSY LH

AD N*m {kgf*cm, ft*lbf} : Tightening torque

No oil on the threaded portion

2. Disconnection of speed sensor RR LH

3. Removal of rear axle shaft nut LH

4. Removal of rear drive shaft ASSY (Refer to DP - 5)

9. Installation of speed sensor RR LH

5. Inspection of rear axle hub & bearing ASSY runout

6. Installation of rear disc (Refer to RB - 16)

Rear axle carrier

Upper control arm ASSY RR LH

Parking brake plate SUB-ASSY LH

Parking brake cable

Rear axle carrier LH

Rear suspension arm ASSY No. 1 bush LH

Rear stabilizer link SUB-ASSY

Rear suspension arm ASSY No. 1 LH

Rear suspension arm

N*m (kgf*cm, ft*lbf) : Tightening torque Non-reusable parts

3. Disconnection of rear stabilizer link SUB-ASSY (installed on LH side) (Refer to RP - 6)

5. Disconnection of upper control arm ASSY RR LH

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm,ft*lbf} : Tightening torque Front disc

Nm {kgfcm,ft*lbf} : Tightening torque

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm,ft*lbf} : Tightening torque

AD Nm {kgfcm, ft*lbf} : Tightening torque

Nm (kgfcm, ft*lbf) : Tightening torque Non-reusable parts