Differentials 3B-1

Driveline, Axle
Differentials
Table of Contents
Rear final drive (φ194 mm { 7.64 in })...........................3B-2
removal.......................................................................3B-2
disassembly.................................................................3B-5
inspection..................................................................3B-11
reassembly................................................................3B-14
installation.................................................................3B-29
Differential oil...............................................................3B-36
inspection..................................................................3B-36
replacement...............................................................3B-37
Supplementary Information...........................................3B-38
3B-2 Differentials

Rear final drive (φ194 mm { 7.64 in })

removal Caution：
・ Because the propeller shaft is adjusted to have
1. Preliminary and post procedures precise balance, always place alignment
1. Preliminary procedures marks on each of the joints before removing or
disassembling.
1) Disconnect the battery cable from the battery
negative terminal.
2. Differential oil drain
1) Remove the filler plug and gasket from the rear
axle.
2) Remove the drain plug and gasket from the rear
axle, and drain the differential oil from the rear
axle.
3. Disc wheel removal
Move the vehicle to a flat surface and pull the parking
brake lever.
1) Secure the vehicle using chock blocks.
2) Raise the vehicle.
Note：
・ Jack up the vehicle but not to an extent that
the tire leaves the ground. 2) Remove the propeller shaft from vehicle.

3) Loosen the wheel nuts. Note：

・ Remove in order starting from the rear of the
Note：
vehicle and moving forward.
・ Loosen without allowing the disc wheel to
rattle. Axle flange
・ Wheel nuts on both the left and right wheels
have right-handed threads.
Caution：
・ At this time, do not remove the wheel nuts.
・ Do not loosen the wheel nuts excessively as
doing so may result in damage to the wheel
pin.
4) Raise the vehicle.
Note：
・ Jack up the vehicle until the tire is completely
off the ground.
5) Support the vehicle using a chassis stand as
necessary.
6) Remove the disc wheel from the vehicle.
4. Propeller shaft removal
1) Draw alignment marks on each flange yoke, flange,
and parking brake drum.
 Differentials 3B-3

Transmission flange

Legend
5. Brake drum removal
1. Hold by pushing toward the brake shoe.
1) Release the parking brake lever. 2. Turn.
2) Remove the brake drum from the rear axle shaft. 3) Remove the shoe holder pin from the brake shoe.
6. Brake shoe removal Caution：
1) Remove the adjust lever spring from the adjust ・ Do not reuse the shoe holder pin.
lever and brake shoe.
4) Remove the lower spring from the brake shoe.
2) Remove the following parts from the brake shoe.
Note：
・ Adjust lever ring ・ Remove the brake shoe and lower spring by
・ Adjust lever sliding them toward the ground.
Caution：
・ Do not reuse the adjust lever ring.
Note：
・ Remove the shoe holding spring from the shoe
holder pin.
・ While holding the shoe holding spring by
pushing it toward the brake shoe, remove it
from the shoe holder pin by turning it.
Caution：
・ Do not reuse the shoe holding spring.

Legend
1. Lower spring

5) Remove the adjuster rod and upper spring from the

brake shoe.
6) Remove the upper spring from the adjuster rod.
3B-4 Differentials
7) Remove the brake shoe from the back plate.
7. Rear wheel cylinder removal
1) Disconnect the brake pipe from the wheel cylinder.
2) Remove the wheel cylinder from the back plate.
8. Rear axle shaft removal
1) Remove the rear axle shaft from the rear axle.
Note：
・ Remove together with the following parts.
・ Bearing holder
・ Back plate
2) Remove the axle case oil seal from the rear axle
case.
Caution：
・ Because the axle case oil seal is damaged
when the rear axle shaft is removed, replace
the axle case oil seal.
9. Final drive removal
1) Remove the final drive from the rear axle.
 Differentials 3B-5

disassembly 1. Component views

Rear final drive (φ194 mm {7.64 in})

Part name 13. Drive pinion

14. Differential cage
1. Flange nut
15. Adjust shim
2. Flange
16. Side bearing inner race
3. Oil seal
17. Side bearing outer race
4. Outer bearing inner race
18. Bolt
5. Outer bearing outer race
6. Differential carrier Tightening torque
7. Bearing cap
8. Bolt 1: 177 to 275 N・m { 18.0 to 28.0 kgf・m / 131 to 203
9. Inner bearing outer race lb・ft }
10. Collapsible distance piece 8: 98 N・m { 10.0 kgf・m / 72 lb・ft }
11. Inner bearing inner race
12. Adjust shim 18: 108 N・m { 11.0 kgf・m / 80 lb・ft }
3B-6 Differentials

Rear differential cage (φ194 mm {7.64 in})

Part name
1. Lock pin
2. Pinion gear
3. Side gear thrust washer
4. Side gear
5. Cross pin
6. Ring gear
7. Bolt SST: 5-8840-0003-0 - base
8. Differential cage

Tightening torque
7: 108 N・m { 11.0 kgf・m / 80 lb・ft }
2. Final drive disassembly
1) Secure the final drive to a work bench using the
special tool.
SST: 5-8840-0275-0 - holding fixture
 Differentials 3B-7

Legend 6) Remove the side bearing inner race from the

differential cage using the special tool.
1. 5-8840-0003-0
2. 5-8840-0275-0

2) Place alignment marks on the bearing cap and

differential carrier.

SST: 5-8840-0013-0 - bearing puller

SST: 5-8840-0014-0 - bearing remover leg

3) Remove the bearing cap from the differential

carrier.
4) Remove the differential cage from the differential
carrier. SST: 9-8521-1743-0 - adapter

5) Remove the side bearing outer race from the

differential cage.
Caution：
・ Organize the removed side bearings according
to left/right installation positions and bearing
race combinations by using labels, etc.
3B-8 Differentials

Legend Legend
1. 5-8840-0013-0 1. 5-8840-0133-0
2. 9-8521-1743-0
3. 5-8840-0014-0 10) Remove the drive pinion from the differential
carrier using the special tool and hammer.
7) Remove the adjust shim from the bearing.
Caution：
・ Organize the removed adjust shims according
to the left/right installation positions and
thickness by using labels, etc.
8) Pry up the staked portion of the flange nut.
9) Remove the flange from the drive pinion using the SST: 9-8521-5032-0 - spindle
special tool.

SST: 5-8840-0133-0（J-8614-11） - flange holder

Legend
1. 9-8521-5032-0

11) Remove the collapsible distance piece from the

drive pinion.
 Differentials 3B-9
12) Remove the inner bearing inner race from the drive
pinion using the special tool.

SST: 5-8840-0015-0 - bearing installer & remover

17) Remove the inner bearing outer race from the

differential carrier using a brass rod and hammer.
Note：
・ Apply a brass rod, etc., to the differential
carrier inner notch, and tap out with a hammer
to remove.

Legend
1. 5-8840-0015-0

13) Remove the adjust shim from the drive pinion.

Caution：
・ Organize the removed adjust shims according
to thickness and number using labels, etc.
14) Remove the oil seal from the differential carrier.
15) Remove the outer bearing inner race from the
differential carrier.
16) Remove the outer bearing outer race from the
differential carrier using a brass rod and hammer. 3. Differential cage disassembly
Note： 1) Measure the backlash of the side gear and pinion
・ Apply a brass rod, etc., to the differential gear using a dial gauge.
carrier inner notch, and tap out with a hammer
to remove. Standard: 0.10 to 0.20 mm { 0.004 to 0.008 in }
3B-10 Differentials

2) Remove the ring gear from the differential cage. 5) Remove the pinion gear and side gear from the
differential cage.
Caution：
・ Remove the ring gear and differential cage 6) Remove the side gear thrust washer from the side
without damaging them. gear.
・ Do not insert tools, etc., between the ring gear
and the differential cage.
3) Remove the lock pin from the differential cage
using a long drift punch.

4) Remove the cross pin from the differential cage

using a brass rod and hammer.
 Differentials 3B-11

inspection 3) Inspect the pinion bearing race and pinion bearing

oil seal inlay sections for the following.
1. Final drive inspection
・ Cracking
1) Inspect each bearing for the following. ・ Damage
・ Seizing ・ Wear
・ Spalling 4) Inspect the flange for the following.
・ Noise ・ Worn oil seal contact section
・ Worn spline section
・ Cracking of mounting section
・ Damage to the mounting section

Legend
1. Inner bearing
2. Outer bearing
3. Side bearing 5) Inspect the gear contact surfaces on the drive and
coast sides of the ring gear and drive pinion for the
2) Inspect the differential carrier rear axle mounting following.
section, differential carrier side bearing mounting
・ Chipping
section, as well as bearing cap for the following.
・ Cracking
・ Cracking ・ Spalling
・ Damage ・ Pitting
・ Wear ・ Improper tooth contact
6) Inspect the spline section of the drive pinion for the
following.
・ Cracking
・ Twisting
・ Damage
Caution：
・ Replace the ring gear and drive pinion as a
set.
3B-12 Differentials

2. Differential cage inspection 2. Pinion gear measurement

1. Visual inspection 1) Measure the outer diameter of the cross pin using a
micrometer.
1) Inspect the side gear, side gear thrust washer, pinion
gear, and cross pin for the following. 2) Measure the inner diameter of the pinion gear.
・ Wear 3) Calculate the clearance between the pinion gear and
・ Damage cross pin from the outer diameter of the cross pin
・ Other malfunctions and the inner diameter of the pinion gear.
2) Inspect the differential cage for the following. Standard: 0.06 to 0.12 mm { 0.002 to 0.005 in }
・ Wear Standard: 0.20 mm { 0.008 in }
・ Damage
・ Corrosion
・ Other malfunctions
3) Inspect the fitting section of the differential cage
and ring gear, the fitting section of the differential
cage and side gear, as well as the differential cage
cross pin holes for the following.
・ Damage
・ Wear
Note：
・ Repair minor damage and wear using an oil
stone or fine sandpaper.

3. Side gear measurement

1) Install the side gear to the drive shaft.
2) Measure the play of the side gear and drive shaft in
the spline rotational direction using a dial gauge.
Standard: 0.08 to 0.36 mm { 0.003 to 0.014 in }
Standard: 0.5 mm { 0.02 in }
 Differentials 3B-13

4. Differential cage measurement

1) Measure the outer diameter of the side gear using a
micrometer.
2) Measure the inner diameter of the differential cage
using a cylinder gauge.
3) Calculate the clearance of the side gear and
differential cage from the outer diameter of the side
gear and the inner diameter of the differential cage.
Standard: 0.03 to 0.10 mm { 0.001 to 0.004 in }
Limit: 0.15 mm { 0.006 in }

Legend
a. Side gear outer diameter
b. Differential cage inner diameter
3B-14 Differentials

reassembly 1. Component views

Rear final drive (φ194 mm {7.64 in})

Part name 13. Drive pinion

14. Differential cage
1. Flange nut
15. Adjust shim
2. Flange
16. Side bearing inner race
3. Oil seal
17. Side bearing outer race
4. Outer bearing inner race
18. Bolt
5. Outer bearing outer race
6. Differential carrier Tightening torque
7. Bearing cap
8. Bolt 1: 177 to 275 N・m { 18.0 to 28.0 kgf・m / 131 to 203
9. Inner bearing outer race lb・ft }
10. Collapsible distance piece 8: 98 N・m { 10.0 kgf・m / 72 lb・ft }
11. Inner bearing inner race
12. Adjust shim 18: 108 N・m { 11.0 kgf・m / 80 lb・ft }
 Differentials 3B-15

Rear differential cage (φ194 mm {7.64 in})

Part name Refer to "201.General Information 14B.Vehicle

Information Recommended fluids, lubricants and diesel
1. Lock pin
fuels".
2. Pinion gear
3. Side gear thrust washer 3. Differential cage reassembly
4. Side gear
1) Apply differential oil to the following parts.
5. Cross pin
6. Ring gear ・ Side gear
7. Bolt ・ Pinion gear
8. Differential cage ・ Side gear thrust washer
2) Install the side gear and side gear thrust washer to
Tightening torque
the differential cage.
7: 108 N・m { 11.0 kgf・m / 80 lb・ft }
3) Install the pinion gear to the differential cage.
2. Final drive safety information
Note：
When assembling, if nothing in particular is specified, ・ While turning both pinion gears in the same
refer to the following and apply or add differential oil. direction, engage them with the side gear and
install the pinion gears.
3B-16 Differentials

4) Install the cross pin to the differential cage. 6) Install the lock pin to the differential cage.
Note： 7) Stake the lock pin.
・ Align the lock pin holes of the cross pin and Caution：
differential cage and install.
・ Securely stake the lock pin so that it does not
come out.

5) Measure the backlash of the pinion gear using a dial

gauge.
Legend
Caution：
1. Staked section
・ If the backlash is outside the specified range, 2. Lock pin
change the thrust washer thickness and
adjust. 8) Apply LOCTITE 271 to the threaded portion of the
bolt and the ring gear threaded hole.
Standard: 0.10 to 0.20 mm { 0.004 to 0.008 in }
Backlash Note：
Thrust washer thicknesses ・ Linearly apply LOCTITE 271 or equivalent to
1.00 mm { 0.039 in } the threaded portion of the bolt from the end
toward the center.
1.05 mm { 0.041 in }
1.10 mm { 0.043 in } 9) Install the ring gear to the differential cage.
 Differentials 3B-17
Caution：
・ Do not reuse the bolt.
・ Replace the ring gear and drive pinion as a
set.

Ring gear bolt tightening order

Legend
1. 5-8840-0007-0
2. 9-8522-1141-0

2) Install the inner bearing outer race to the differential

carrier using the special tool.
Tightening torque: 108 N・m { 11.0 kgf・m / 80 lb・ft }
4. Final drive reassembly
1) Install the outer bearing outer race to the differential
carrier using the special tool.

SST: 9-8522-1274-0 - bearing installer

SST: 9-8522-1141-0 - bearing installer

SST: 5-8840-0007-0 - grip

SST: 5-8840-0007-0 - grip

3B-18 Differentials

SST: 5-8840-2087-0 - gauge plate

Tightening torque: 2.3 N・m { 0.2 kgf・m / 20 lb・in }

Legend
1. 5-8840-0007-0
2. 9-8522-1274-0

3) Apply differential oil to the inner bearing inner race

and outer bearing inner race.
4) Install the following parts to the differential carrier.
・ Inner bearing inner race
・ Outer bearing inner race
・ Special tool Legend
Caution： 1. 5-8840-2085-0
・ Thoroughly clean the special tool before using 2. 5-8840-2089-0
it. 3. 5-8840-2087-0

5) Tighten the special tool nut.

Tightening torque: 2.3 N・m { 0.2 kgf・m / 20 lb・in }
6) Clean the side bearing installation section.
7) Install the special tool to the differential carrier.

SST: 5-8840-2085-0 - pilot

SST: 5-8840-0126-0 - dial indicator

SST: 5-8840-2089-0 - stud & nut

SST: 5-8840-2088-0 - disc

 Differentials 3B-19

SST: 5-8840-0128-0 - arbor

SST: 5-8840-2087-0 - gauge plate

8) Install the bearing cap to the differential carrier. Legend
Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft } 1. 5-8840-0126-0
2. 5-8840-0128-0
3. Plunger (5-8840-0128-0)
4. 5-8840-2087-0

12) Place the end of the arbor plunger on top of the

gauge plate.
13) Gently move the arbor back and forth, and verify
the position where the dial indicator runout is
largest.
14) Set the dial indicator scale to 0 at the position where
the dial indicator runout is largest.
15) Using the same procedure, make sure the scale
reads 0.

Legend
1. 5-8840-0126-0
2. 5-8840-2088-0
3. 5-8840-0128-0
4. 5-8840-2087-0

Note：
・ The dial indicator scale display is in inches.
9) Set the dial indicator scale to 0.
10) Bring the dial indicator into contact with the arbor
plunger section, then push the dial indicator down
to the point where the needle rotates approximately
halfway in the clockwise direction, and secure.
16) Rotate the arbor and move the end of the plunger
11) Set the dial indicator scale to 0.
away from the gauge plate.
17) Record the value indicated on the dial indicator.
3B-20 Differentials
Note： If the value is negative, perform the opposite.
・ This value is the adjust shim thickness.

19) Select the appropriate adjust shim based on the

1. Example: when the dial indicator reading value read by the dial indicator and the drive pinion
numerical value is 0.085 code.
Note：
18) Record the pinion depth code on the drive pinion
head section. ・ There are 20 types of adjust shims, with
thickness ranging from 2.18 mm {0.0858 in} to
If the value is positive, the mesh depth is too large, so 2.56 mm {0.1008 in} in 0.02 mm {0.0008 in}
decrease the adjust shim thickness. increments.
If the value is negative, the mesh depth is too small, so
increase the adjust shim thickness.
0 indicates that no adjustment is required.
Ex: If the value is +2, the mesh depth is 0.02 mm {0.0008
in} too large, so decrease the adjust shim thickness by
0.02 mm {0.0008 in}.

Adjust shim selection table (mm {in}) No. 1

Dial indicator Drive pinion depth code
reading (in) 10 8 6 4 2 0
0.081
0.082
0.083
0.084
0.085
2.18
0.086
{0.0858}
2.18 2.20
0.087
{0.0858} {0.0866}
2.18 2.20 2.24
0.088
{0.0858} {0.0866} {0.0882}
2.18 2.20 2.24 2.26
0.089
{0.0858} {0.0866} {0.0882} {0.0890}
2.18 2.20 2.24 2.26 2.28
0.090
{0.0858} {0.0866} {0.0882} {0.0890} {0.0898}
 Differentials 3B-21

2.18 2.20 2.24 2.26 2.28 2.32

0.091
{0.0858} {0.0866} {0.0882} {0.0890} {0.0898} {0.0913}
2.20 2.24 2.26 2.28 2.32 2.34
0.092
{0.0866} {0.0882} {0.0890} {0.0898} {0.0913} {0.0921}
2.24 2.26 2.28 2.32 2.34 2.36
0.093
{0.0882} {0.0890} {0.0898} {0.0913} {0.0921} {0.0929}
2.26 2.28 2.32 2.34 2.36 2.38
0.094
{0.0890} {0.0898} {0.0913} {0.0921} {0.0929} {0.0937}
2.28 2.32 2.34 2.36 2.38 2.42
0.095
{0.0898} {0.0913} {0.0921} {0.0929} {0.0937} {0.0953}
2.32 2.34 2.36 2.38 2.42 2.44
0.096
{0.0913} {0.0921} {0.0929} {0.0937} {0.0953} {0.0961}
2.34 2.36 2.38 2.42 2.44 2.46
0.097
{0.0921} {0.0929} {0.0937} {0.0953} {0.0961} {0.0969}
2.36 2.38 2.42 2.44 2.46 2.48
0.098
{0.0929} {0.0937} {0.0953} {0.0961} {0.0969} {0.0976}
2.38 2.42 2.44 2.46 2.48 2.52
0.099
{0.0937} {0.0953} {0.0961} {0.0969} {0.0976} {0.0992}
2.42 2.44 2.46 2.48 2.52 2.54
0
{0.0953} {0.0961} {0.0969} {0.0976} {0.0992} {0.1000}
2.44 2.46 2.48 2.52 2.54 2.56
0.001
{0.0961} {0.0969} {0.0976} {0.0992} {0.1000} {0.1008}
2.46 2.48 2.52 2.54 2.56
0.002
{0.0969} {0.0976} {0.0992} {0.1000} {0.1008}
2.48 2.52 2.54 2.56
0.003
{0.0976} {0.0992} {0.1000} {0.1008}
2.52 2.54 2.56
0.004
{0.0992} {0.1000} {0.1008}
2.54 2.56
0.005
{0.1000} {0.1008}
2.56
0.006
{0.1008}
Adjust shim selection table (mm {in}) No. 2
Dial indicator Drive pinion depth code
reading (in) 0 -2 -4 -6 -8 -10
2.18
0.081
{0.0858}
2.18 2.20
0.082
{0.0858} {0.0866}
2.18 2.20 2.24
0.083
{0.0858} {0.0866} {0.0882}
2.18 2.20 2.24 2.26
0.084
{0.0858} {0.0866} {0.0882} {0.0890}
2.18 2.20 2.24 2.26 2.28
0.085
{0.0858} {0.0866} {0.0882} {0.0890} {0.0898}
2.18 2.20 2.24 2.26 2.28 2.32
0.086
{0.0858} {0.0866} {0.0882} {0.0890} {0.0898} {0.0913}
2.20 2.24 2.26 2.28 2.32 2.34
0.087
{0.0866} {0.0882} {0.0890} {0.0898} {0.0913} {0.0921}
2.24 2.26 2.28 2.32 2.34 2.36
0.088
{0.0882} {0.0890} {0.0898} {0.0913} {0.0921} {0.0929}
3B-22 Differentials

2.26 2.28 2.32 2.34 2.36 2.38

0.089
{0.0890} {0.0898} {0.0913} {0.0921} {0.0929} {0.0937}
2.28 2.32 2.34 2.36 2.38 2.42
0.090
{0.0898} {0.0913} {0.0921} {0.0929} {0.0937} {0.0953}
2.32 2.34 2.36 2.38 2.42 2.44
0.091
{0.0913} {0.0921} {0.0929} {0.0937} {0.0953} {0.0961}
2.34 2.36 2.38 2.42 2.44 2.46
0.092
{0.0921} {0.0929} {0.0937} {0.0953} {0.0961} {0.0969}
2.36 2.38 2.42 2.44 2.46 2.48
0.093
{0.0929} {0.0937} {0.0953} {0.0961} {0.0969} {0.0976}
2.38 2.42 2.44 2.46 2.48 2.52
0.094
{0.0937} {0.0953} {0.0961} {0.0969} {0.0976} {0.0992}
2.42 2.44 2.46 2.48 2.52 2.54
0.095
{0.0953} {0.0961} {0.0969} {0.0976} {0.0992} {0.1000}
2.44 2.46 2.48 2.52 2.54 2.56
0.096
{0.0961} {0.0969} {0.0976} {0.0992} {0.1000} {0.1008}
2.46 2.48 2.52 2.54 2.56
0.097
{0.0969} {0.0976} {0.0992} {0.1000} {0.1008}
2.48 2.52 2.54 2.56
0.098
{0.0976} {0.0992} {0.1000} {0.1008}
2.52 2.54 2.56
0.099
{0.0992} {0.1000} {0.1008}
2.54 2.56
0
{0.1000} {0.1008}
2.56
0.001
{0.1008}
0.002
0.003
0.004
0.005
0.006
Note：
・ When ordering adjust shims, check the adjust
shim thickness in the above table and identify
the part numbers on the part catalog.
20) Remove the special tool from the differential
carrier.
21) Install the adjust shim to the drive pinion. SST: 9-8522-1165-0 - pinion bearing installer
Note：
・ Face the chamfered side of the adjust shim
toward the pinion head to install.
22) Install the inner bearing inner race to the drive
pinion using the special tool and press.
Caution：
・ Increase the pressure only on the inner
bearing inner race.
 Differentials 3B-23

Legend Legend
1. 9-8522-1165-0 1. 9-8522-1275-0

23) Install the collapsible distance piece to the drive 27) Install the dust cover to the flange.
pinion.
28) Apply differential oil to the threaded portion of the
Caution： drive pinion.
・ Do not reuse the collapsible distance piece. 29) Temporarily tighten the flange to the drive pinion
24) Install the drive pinion to the differential carrier. using the special tool.

25) Apply grease to the lip section of the oil seal. Caution：
・ Do not reuse the flange nut.
Caution：
・ Do not reuse the oil seal.
26) Install the oil seal and outer bearing inner race to
the differential carrier using the special tool.

SST: 5-8840-0133-0（J-8614-11） - flange holder

SST: 9-8522-1275-0 - oil seal installer

Caution：
・ Take care not to mix up with the rear
differential carrier oil seal.
・ Do not press-fit the oil seal at an angle.
Press-fitting the oil seal at an angle is a cause of oil
leakage.
3B-24 Differentials
Legend
1. 5-8840-0133-0

30) Measure the pinion bearing preload.

Standard: 0.7 to 1.1 N・m { 0.07 to 0.11 kgf・m / 6 to 10
lb・in } Starting torque
Caution：
・ If the pinion bearing preload is outside the
specified range, adjust by further tightening or
loosening the flange nut.
Tightening torque: 177 to 275 N・m { 18.0 to 28.0 kgf・
m / 131 to 203 lb・ft }

Legend
1. 5-8840-2293-0

Standard value
a. 1.5 mm {0.06 in} or less
32) Measure the pinion bearing preload.
Standard: 0.7 to 1.1 N・m { 0.1 to 0.1 kgf・m / 6 to 10
lb・in } Starting torque
33) Install the side bearing inner race to the differential
carrier using the special tool.

31) Stake the flange nut in 2 locations using the special

tool and hammer.
Caution：
・ When staking, rotate the nut to confirm the
correct preload.
SST: 5-8840-2162-0 - side bearing installer

SST: 5-8840-2293-0 - end nut lock punch

SST: 5-8840-0007-0 - grip
 Differentials 3B-25
Note：
・ Install the special tool so that it makes contact
perpendicularly with the gear teeth of the ring
gear.

SST: 5-8840-0126-0 - dial indicator

Legend
1. 5-8840-0007-0
2. 5-8840-2162-0

34) Install the side bearing outer race to the differential

cage.
35) Install the differential cage to the differential
carrier.

Legend
1. 5-8840-0126-0

38) Change the left and right feeler gauge thicknesses

and adjust the backlash.
Standard: 0.13 to 0.18 mm { 0.005 to 0.007 in }
The dial indicator scale display is in inches.

36) Insert the 2 feeler gauges so that the backlash

between the left and right side bearing outer races
and the differential carrier is 0.
Note：
・ Securely insert the feeler gauge all the way to
the bottom of the bearing.
37) Install the special tool to the differential carrier.
3B-26 Differentials
SST: 5-8840-0014-0 - bearing remover leg

SST: 9-8521-1743-0 - adapter

39) Select an adjust shim based on the thickness of the

feeler gauge.
Note：
・ Select an adjust shim 0.05 mm {0.0020 in}
thicker than the feeler gauge.
Caution：
・ Do not reuse the adjust shim.
40) Remove the differential cage from the differential
carrier.
Legend
41) Remove the side bearing outer race from the
1. 5-8840-0013-0
differential cage.
2. 9-8521-1743-0
Caution： 3. 5-8840-0014-0
・ When removing the bearings, keep them
43) Install the adjust shim and side bearing inner race to
organized so the combinations of the left/right
the differential cage using the special tool.
installation positions and bearing race are not
mixed up.
42) Remove the side bearing inner race from the
differential cage using the special tool.

SST: 9-8522-1164-0 - side bearing installer

SST: 5-8840-0013-0 - bearing puller

SST: 5-8840-0007-0 - grip

 Differentials 3B-27

SST: 9-8521-1743-0 - adapter

Legend
1. Alignment mark

Legend
1. 5-8840-0007-0
2. 9-8522-1164-0
3. 9-8521-1743-0

44) Install the side bearing outer race to the differential

cage.
45) Install the differential cage to the differential
carrier.
46) Install the bearing cap to the differential carrier.
Note：
47) Measure the runout of the ring gear using the dial
・ Install according to the alignment marks
gauge.
applied during disassembly.
Limit: 0.05 mm or less { 0.002 in or less }
Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }
3B-28 Differentials
50) Slightly move the ring gear while holding the drive
pinion by hand, and inspect the tooth contact of the
ring gear and drive pinion.

Note：
・ Measure the runout of the ring gear at its rear
surface.
48) Clean the gear teeth of the ring gear and of the drive Caution：
pinion. ・ Refer to the following diagram to adjust the
positions of the ring gear and drive pinion if the
49) Apply red lead primer to the gear teeth of the ring
tooth contact of the ring gear and drive pinion
gear.
is found to be incorrect as a result of the
Note： inspection.
・ Apply to both surfaces of 7 to 8 gear teeth.
 Differentials 3B-29

installation 2. Rear axle shaft installation

1) Apply BESCO L-2 grease or equivalent to the axle
1. Final drive installation
case oil seal lip section.
1) Clean the mating surfaces of the rear axle and
2) Install the axle case oil seal to the rear axle case
differential carrier.
using the special tool.
2) Apply ThreeBond TB1215 to the rear axle and
differential carrier mounting surface.
Note：
・ Apply as shown in the following diagram.

SST: 5-8840-2202-0 - oil seal installer

SST: 5-8840-0007-0 - grip

Standard value
a. 3 mm {0.12 in}
3) Install the final drive to the rear axle.
Tightening torque (φ194 mm {7.64 in})
Bolt 25 N・m { 2.5 kgf・m / 18 lb・ft }
Nut 37 N・m { 3.8 kgf・m / 27 lb・ft }

φ194 mm {7.64 in}

Legend
1. 5-8840-2202-0
2. 5-8840-0007-0

3) Measure the dimension shown in the following

diagram.
3B-30 Differentials

Standard value 2) Connect the brake pipe to the wheel cylinder.

a. 34.5 to 36.1 mm {1.36 to 1.42 in} Tightening torque: 13 to 19 N・m { 1.3 to 1.9 kgf・m /
10 to 14 lb・ft }
4) Clean the mating surface of the rear axle case and
bearing holder.
5) Apply ThreeBond TB1215 or equivalent to the rear
axle case mounting surface.
6) Install the rear axle shaft to the rear axle.
Caution：
・ Do not damage the oil seal.
・ If the bearing holder installation bolt has been
removed from the brake, do not reuse the bolt.
7) Install the bearing holder fixing nut to the rear axle
shaft.
Tightening torque: 84 N・m { 8.6 kgf・m / 62 lb・ft }
3. Rear wheel cylinder installation
1) Install the wheel cylinder to the back plate.
Tightening torque: 14 to 18 N・m { 1.4 to 1.8 kgf・m /
10 to 13 lb・ft } 4. Brake shoe installation
1) Apply grease to the brake shoe fitting section and
back plate sliding section.
 Differentials 3B-31
・ Adjust lever ring
Caution：
・ Do not reuse the adjust lever ring.
9) Install the adjust lever spring to the adjust lever and
brake shoe.
10) Install the shoe holder pin to the brake shoe.
Caution：
・ Do not reuse the shoe holder pin.
11) Install the shoe holding spring to the shoe holder
pin.
Caution：
・ Do not reuse the shoe holding spring.

Legend
1. Back plate sliding section
2. Brake shoe fitting section

2) Install the brake shoe to the back plate.

Caution：
・ Do not damage the wheel cylinder dust cover.
・ Make sure the wheel cylinder piston does not
shoot out.
3) Install the lower spring to the brake shoe.
4) Apply grease to the brake shoe installation section.

5. Brake drum installation

1) Install the brake drum to the rear axle shaft.
6. Propeller shaft installation
1. Precautions when installing the rear propeller shaft
Caution：
・ Always install according to the alignment
marks that were made during removal.
・ Always install the propeller shaft body and
spline yoke so that they face the same
direction.

5) Install the upper spring to the adjuster rod.

6) Install the adjuster rod and upper spring to the brake
shoe.
7) Apply grease to the adjust lever sliding surface.
8) Install the following parts to the front brake shoe.
・ Adjust lever
3B-32 Differentials
Tightening torque
63 N・m { 6.4 kgf・m / 46
Transmission flange
lb・ft }
63 N・m { 6.4 kgf・m / 46
Axle flange
lb・ft }

Transmission flange

Legend
1. Correct assembly method
2. Incorrect assembly method

Caution：
・ If foreign materials such as grease, oil, or paint
are attached to the mounting surfaces of the
Axle flange
flange yoke or coupling driver, etc., clean the
surfaces.

7. Disc wheel installation

1) Temporarily tighten the disc wheel to the vehicle.
2. Rear propeller shaft installation
2) Lower vehicle.
1) Install the propeller shaft to vehicle.
3) Final tighten the wheel nut in the order shown in the
Note： diagram.
・ Install according to the alignment marks
Tightening torque: 120 N⋅m {12 kgf⋅m / 87 lb⋅ft}
applied during disassembly.
・ Install in order starting from the front of the
vehicle and moving rearward.
 Differentials 3B-33

Caution： Legend
・ After completing installation, make sure to 1. Filler plug
further tighten the wheel nuts to the specified 2. Drain plug
torque after the vehicle has been driven a 3. Oil surface
distance exceeding the standard value. 4. Hole lower edge
Standard: 50 to 100 km { 31 to 62 mile }
3) Install the filler plug and gasket to the rear axle.
8. Differential oil filling
Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }
1. Regarding lubricant refill amount and type
Caution：
For the differential oil refill amount, refer to the ・ Do not reuse the gasket.
following.
9. Preliminary and post procedures
Refer to "204.Driveline, Axle 17B.Maintenance
Information Primary specifications of driveline, axle". 1. Post procedures

For the differential oil type, refer to the following. 1) Connect the battery cable to the battery negative
terminal.
Refer to "201.General Information 14B.Vehicle
Information Recommended fluids, lubricants and diesel 10. Brake fluid filling
fuels". 1. Precautions for brake fluid refill and air bleeding
2. Refill procedure procedures

1) Install the drain plug and gasket to the rear axle. Caution：
・ In the following cases, refill with brake fluid
Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }
and bleed the air.
Caution：
・ The brake pipe, brake hose, etc., have been
・ Do not reuse the gasket. disconnected.
2) Replenish the differential oil in the rear axle. ・ Air is in the hydraulic system.
・ Brake fluid has been drained.
Note：
Caution：
・ Fill oil up to the lower surface of the filler plug
・ When refilling with brake fluid and bleeding the
hole.
air with the tires in contact with the ground,
move the vehicle to a level area, and set chock
blocks in place at the tires.
・ Always fill with new brake fluid.
・ Fill to prevent the mixing in of air bubbles.
・ Do not fill the brake fluid tank with brake fluid
over the MAX level.
3B-34 Differentials

・ Bleed air until air has been fully discharged Caution：

from the hydraulic system. ・ Repeat the process mentioned above until no
・ Perform air bleeding procedures while air bubbles are found in the discharged brake
maintaining sufficient brake fluid levels. fluid.
・ Use the following brake fluid brands. 4. Inspection after bleeding air
Refer to "201.General Information 14B.Vehicle 1) After air bleeding is complete, depress the brake
Information Recommended fluids, lubricants and diesel pedal and check for any abnormal conditions.
fuels".
2) Check the brake fluid level in the brake fluid tank,
Caution： and fill the brake fluid tank with brake fluid as
・ Bleed air from the brake fluid while the engine necessary.
is running. Caution：
The vacuum brake booster may be broken if air bleeding ・ When filling, do not exceed the MAX level.
is performed without starting the engine.
3) Stop the engine.
2. Preparations for brake fluid refill and air bleeding
Note：
procedures
・ After completing the air bleeding procedure for
1) Start the engine. the brake system, bleed the air from the clutch
2) Release the parking brake lever. system as necessary.

3) Remove the cap from the brake fluid tank. 11. Rear drum brake adjustment

4) Replenish the brake fluid tank with the brake fluid. 1. Rear drum brake lining gap adjustment (Except
after overhaul)
5) Perform the air bleeding procedure in the following
order. All brakes are automatic adjustment type. The lining gap
is automatically adjusted by repeatedly depressing the
・ Left rear wheel cylinder brake pedal.
・ Right rear wheel cylinder
・ DSPV 1) Repeatedly depress and release the brake pedal until
・ Left front brake caliper the click of the auto adjuster is not heard.
・ Right front brake caliper 2) When the clicking sound can no longer be heard,
3. Bleed the air. depress the brake pedal 10 times to make sure that
there is no stroke variation.
Caution：
・ Bleed air 10 times or more for the front wheel, 2. Rear drum brake lining gap adjustment (After
and 15 times or more for the rear wheel. overhaul)

1) Apply an appropriate wrench to the bleeder. 1) Release the parking brake lever by moving it to the
position where it is completely released.
2) Connect a clear tube to the bleeder.
2) Loosen the lock nut and adjust nut using a wrench.
3) Dip the opposite end of the tube into a clear
container filled with brake fluid. 3) Repeatedly depress and release the brake pedal until
the click of the auto adjuster is not heard.
Note：
Note：
・ The container should be approximately 1/3 full
of brake fluid. ・ If the clearance between the brake drum and
the lining is adjusted to 0.5 mm {0.020 in}, the
4) Depress the brake pedal repeatedly and then keep it number of times of depressing the brake pedal
depressed. can be reduced.
5) Loosen the bleeder approximately 1/2 a turn and 4) When the clicking sound can no longer be heard,
bleed the air from the brake fluid. depress the brake pedal 10 times to make sure that
6) Tighten the bleeder. there is no stroke variation.
7) Release the brake pedal. 5) Remove the cover from the back plate.
6) Measure the gap between the brake drum and brake
shoe.
 Differentials 3B-35
Standard: 0.25 to 0.40 mm { 0.0098 to 0.0157 in }
Lining clearance
Note：
・ If it is outside the standard range, inspect the
adjuster.
3B-36 Differentials

Differential oil

inspection
1. Differential oil inspection
1) Raise the vehicle.
2) Remove the filler plug and gasket from the rear
axle.
3) Insert a finger through the filler plug hole to inspect
the oil level.
Note：
・ Inspect if the oil is filled up to the lower surface
of the hole.

Legend
1. Filler plug
2. Drain plug
3. Oil surface
4. Lower surface of the hole

If the oil level is below the specified amount, refer to the

following and add differential oil.
Refer to "Differential oil replacement" in this section.
4) Install the filler plug and gasket to the rear axle.
Caution：
・ Do not reuse the gasket.
Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }
5) Lower the vehicle.
 Differentials 3B-37

replacement 3. Oil surface

4. Hole lower edge
1. Differential oil drain
3) Install the filler plug and gasket to the rear axle.
1) Raise the vehicle.
Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }
2) Remove the filler plug and gasket from the rear
axle. Caution：
3) Remove the drain plug and gasket from the rear ・ Do not reuse the gasket.
axle, and drain the differential oil from the rear 4) Lower the vehicle.
axle.
2. Differential oil filling
1. Regarding lubricant refill amount and type
For the differential oil refill amount, refer to the
following.
Refer to "204.Driveline, Axle 17B.Maintenance
Information Primary specifications of driveline, axle".
For the differential oil type, refer to the following.
Refer to "201.General Information 14B.Vehicle
Information Recommended fluids, lubricants and diesel
fuels".
2. Refill procedure
1) Install the drain plug and gasket to the rear axle.
Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }
Caution：
・ Do not reuse the gasket.
2) Replenish the differential oil in the rear axle.
Note：
・ Fill oil up to the lower surface of the filler plug
hole.

Legend
1. Filler plug
2. Drain plug
3B-38 Differentials

Supplementary Information
1. Component views

Rear final drive (φ194 mm {7.64 in})

Part name 13. Drive pinion

14. Differential cage
1. Flange nut
15. Adjust shim
2. Flange
16. Side bearing inner race
3. Oil seal
17. Side bearing outer race
4. Outer bearing inner race
18. Bolt
5. Outer bearing outer race
6. Differential carrier Tightening torque
7. Bearing cap
8. Bolt 1: 177 to 275 N・m { 18.0 to 28.0 kgf・m / 131 to 203
9. Inner bearing outer race lb・ft }
10. Collapsible distance piece 8: 98 N・m { 10.0 kgf・m / 72 lb・ft }
11. Inner bearing inner race
12. Adjust shim 18: 108 N・m { 11.0 kgf・m / 80 lb・ft }
 Differentials 3B-39

Rear differential cage (φ194 mm {7.64 in})

Part name
1. Lock pin
2. Pinion gear
3. Side gear thrust washer
4. Side gear
5. Cross pin
6. Ring gear
7. Bolt
8. Differential cage

Tightening torque
7: 108 N・m { 11.0 kgf・m / 80 lb・ft }