Part 2 of 2
OVERHAULHINT: COMPONENTS: See Diagrams; Exploded Views.
55. INSTALL REAR DIFFERENTIAL PINION SHAFT [41342/98-44]
a. Install the pinion shaft on the differential case.
56. ADJUST DIFFERENTIAL PINION GEAR BACKLASH
a. Install the 2 side gear shafts in the differential case.
b. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 inch)
NOTICE: Differential gears should be able to rotate.
If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.
c. Remove the 2 side gear shafts.
57. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN [41343/98-44]
a. Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Using a chisel and a hammer, stake the differential case.
58. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.
b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT: Align the matchmarks on the ring gear and the differential case.
e. Tighten 2 new bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.
NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.
59. INSTALL REAR DIFFERENTIAL CASE BOLT [41302A/98-44]
a. After the ring gear has cooled sufficiently, install new 8 ring gear set bolts to which thread lock has been applied.
Thread lock: Part No. 08833-00100, THREE BOND 1360K or equivalent.
NOTICE: New ring gear set bolts should be used in every case.
b. Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
c. Tighten the bolts further by 60 - 90°.
NOTICE: Tighten the bolts in diagonally opposite pairs.
60. INSTALL REAR DIFFERENTIAL CASE BEARING [41301A/98-44]
a. Using SST and a press, install the 2 differential case bearings.
SST 09950-60010 (09951-00560), 09950-70010 (09951-07100)
Fig. 36 Installing Side Bearing Outer Race & Adjusting Washer:
b. Using SST and press install the adjusting plate washer and outer race.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
HINT:
- The adjusting washer is used for adjusting the tooth contact pattern. 42 types of washer with different thicknesses are available.
- First fit a washer with the same thickness as the washer, which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.
- When removing an adjusting washer, be sure to replace it with a new one.
61. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY [41301/98-44]
a. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
NOTICE: Do not damage the side bearing.
b. Using SST and a hammer, install the 2 carrier retainers.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
c. Tighten the 16 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)
62. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
63. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY [41105/98-44]
a. Remove the 16 bolts.
b. Using SST, remove the 2 carrier retainers and washers.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09955-04061, 09954-04010, 09953-04011, 09957-04010), 09950-60010 (09951-00480)
c. Take the differential case out of the carrier with lifting ring gear side as show in the illustration.
NOTICE: Do not damage the side bearing.
64. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING [41201A/98-44]
a. Using SST and a press, install the rear bearing.
SST 09502-24010 (09250-10011), 09950-70010 (09951-07100)
b. Using SST and a press, install the rear bearing outer race and adjusting washer.
SST 09502-24010 (09250-10011), 09950-70010 (09951-07100)
65. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, install the front bearing outer race.
SST 0995-60020 (09951-00710), 09950-70010 (09951-07100)
b. Install the drive pinion in the differential carrier.
c. Using SST and a press, install the front bearing on the drive pinion.
SST 09316-60011 (09316-00011), 09608-04031,
HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern.
Fig. 14 Pinion Flange Installation:
d. Using SST and a press, install the companion flange.
SST 09223-06011, 09325-00010
66. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Adjust the drive pinion preload by tightening the companion flange nut.
Torque: 490 Nm (5,000 kgf-cm, 361 ft. lbs.) or less
HINT: Using SST to hold the flange, tighten the nut.
SST 09950-30012 (09955-03040), 09229-55010, 09331-00020)
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
b. Using SST and a torque wrench, measure the preload.
SST 09220-55010
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (15 - 18 kgf-cm, 13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
HINT: For vehicles which have run 8,000 km (5,000 miles) or less, if the preload value measured before disassembly is greater than the specification for a reused bearing, return the preload to the same as before disassembly.
67. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY [41301/98-44]
a. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
68. INSTALL REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY [41105/98-44]
a. Using SST and a hammer, install the 2 carrier retainers.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
b. Tighten the 16 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)
69. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
NOTICE: The difference between the maximum and minimum measure values must be less than 0.05 mm (0.0020 inch).
HINT: The measured values should be used as reference when selecting washers, so take a note of the values.
If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.
Adjusting washer thickness
70. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
Fig. 17 Proper Contact Pattern:
c. Inspect the tooth contact pattern.
If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.
NOTICE: Make sure to always use a new one when replacing adjusting washer.
HINT: Refer to the table on the next page for selection of the adjusting washer.
HINT: Adjust washers in 42 (different thickness in 0.01 mm (0.004 inch)) units are available.
71. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 0922-55010
Total preload (at starting):
Drive pinion preload plus 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
If the measured preload is less than the specification, replace the washer of the ring gear's tooth surface side with a thicker one.
If the preload is greater than the specification, replace the washer of the ring gear's tooth surface side with a thinner one.
HINT: Changing the snap ring thickness by 0.02 mm (0.0008 inch) will change the total preload by approximately 0.1 Nm (1 kgf-cm, 0.9 inch lbs.)
72. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY [41105/98-44](See step 35)
SST 09950-00011 (09951-04020, 09952-04010, 09953-04030, 0995-04061, 09950-04010, 09957-04010, 0995-04011), 09950-60010 (09951-00480)
73. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY [41301/98-44](See step 36)
74. REMOVE REAR DRIVE PINION NUT [41204B/98-44](See step 37)
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
75. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR [41204/98-44](See step 38)
SST 09950-30012 (09951-03010, 09953-03010, 09953-03010, 09956-03060, 09956-03040)
76. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER [41214/98-44](See step 41)
77. REMOVE DIFFERENTIAL DRIVE PINION (See step 42)
78. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING [41201B/98-44](See step 44)
79. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER [41231/98-44]
a. Install a new spacer on the drive pinion.
80. INSTALL DIFFERENTIAL DRIVE PINION (See step 65)
SST 09316-60011 (09316-00011), 09600-04031
81. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
82. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR [41252/98-44]
a. Using SST and a press, install a new dust deflector.
SST 09316-60011 (09316-00011)
83. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL [41201C/98-44]
a. Apply MP grease to a new oil seal lip.
b. Using SST, install the oil seal until its end is flush with the surface of the differential carrier.
SST 09316-60011 (09316-00011, 09316-00041), 09502-12010
Fig. 14 Pinion Flange Installation:
84. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR [41204/98-44]
a. Using SST and a press, install the companion flange.
SST 09953-30012, 09223-56010, 09325-40010
NOTICE: Be careful not to damage the oil seal.
85. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY [41301/98-44](See step 61)
Fig. 26 Removing Side Bearing Outer Race & Plate Washer:
86. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL [41334B/98-44]
a. Using SST and a press, install 2 new oil seals to the carrier retainers.
SST 0960-32010, 0995-70010 (09951-07150)
b. Coat the MP grease to the oil seal lip.
87. INSTALL REAR DIFFERENTIAL CARRIER RETAINER RING [41105A/98-44]
a. Coat 2 new O-rings with hypoid gear oil.
b. Install the 2 O-rings to the carrier retainers.
88. INSTALL REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY [41105/98-44]
a. Using SST and a hammer, install the carrier retainer.
SST 09950-60020 (09951-00810), 09950-70010 (09951-7100)
NOTICE: Do not damage the differential case.
b. Install the 16 bolts and carrier retainer.
Torque: 22 Nm (225 kgf cm 16 ft. lbs.)
89. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Coat the threads and flange of a new nut with hypoid gear oil for LSD.
b. Using SST, tighten the nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
c. Using SST and a torque wrench, measure the preload.
SST 09220-55010
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (15 - 18 kgf-cm, 13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
If the preload is greater than the specification, replace the spacer.
If the preload is less than the specification, retighten the nut with a force of 13 Nm (130 kgf cm, 9 ft. lbs.) at a time until the specified preload is reached.
Torque: 490 Nm (5,000 kgf-cm, 361 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.
90. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION (See step 28)
91. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER [41336/98-44]
a. Using SST and a hammer, install a new dust cover.
SST 09550-55011 (09550-05061), 09950-70010 (09951-07100), 09502-24010
92. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY [41309A/98-44]
a. Using needle nose pliers, install 2 new snap rings to the side gear shafts.
b. Coat the MP grease to the snap rings.
c. Using a brass bar and a hammer, install the 2 side gear shafts.
HINT: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
NOTICE: Be careful not to damage the oil seal.
93. INSPECT TOTAL PRELOAD (See step 30)
SST 09220-55010
94. INSTALL REAR DRIVE PINION NUT [41204B/98-44]
a. Using a chisel and a hammer, caulking the nut.
95. REMOVE DIFFERENTIAL CARRIER ASSY REAR [41110/98-44]
a. Remove the differential carrier from the overhaul stand, etc.
96. INSTALL REAR DIFFERENTIAL CARRIER COVER [41181H/98-44]
a. Clean the contact surfaces of the carrier and cover of any residual FIPG material using cleaner.
b. Coat FIPG to the carrier or cover.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
c. Install the carrier cover to the carrier with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
HINT: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is for an hour or more. Also, for 12 hours or more, avoid rapid acceleration/deceleration.
d. Install the breather plug.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
97. INSTALL DIFFERENTIAL CARRIER ASSY REAR [41110/98-44]
a. Install the 2 upper mount stoppers on the rear differential carrier assembly.
HINT: Use the upper mount stopper, which was removed.
b. Support the rear differential carrier assembly with a jack and temporally install the lower mount stoppers and 2 new front side set bolts.
NOTICE: Do not let the rear differential carrier assembly interfere with the drive shaft.
c. Using a hexagon wrench (12 mm), install the 3 rear side set hexagon bolts.
Torque: 142 Nm (1,450 kgf-cm, 105 ft. lbs.)
d. Torque the 2 front side set bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
e. Lower the jack.
98. INSTALL REAR DIFFERENTIAL DRAIN PLUG [41110D/98-44]
a. Using a hexagon wrench (10 mm), install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.)
99. ADD DIFFERENTIAL OIL
a. Fill the rear differential carrier assembly with hypoid gear oil.
Oil grade: Hypoid gear oil API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W or 80W-90
Capacity: 1.35 ± 0.05 liters (1.43 ± 0.05 US qts, 1.19 ± 0.06 Imp. qts)
100. INSPECT DIFFERENTIAL OIL
101. INSTALL REAR DIFFERENTIAL FILLER PLUG [41110H/98-44]
a. Using a hexagon wrench (10 mm), install the filler plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.)
102. INSTALL REAR DRIVE SHAFT ASSY LH [42340B/98-45]
a. Align the matchmarks, and connect the drive shaft to the side gear shaft.
NOTICE: Be careful not to damage the boots and end cover.
b. Using a hexagon wrench (8 mm), install the 3 washers and 6 hexagon bolts, while applying the brakes.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
103. INSTALL REAR DRIVE SHAFT ASSY RH [42330/98-45]
HINT: Install the RH side by the same procedures with LH side.
104. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 LH [48740F/98-64]
a. Connect the rear suspension arm assembly No. 2 LH to the axle carrier with the cam bolt, cam plate and nut.
NOTICE: Do not torque the nut.
105. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2RH [48730F/98-64]
HINT: Install the LH side by the same procedures with RH side.
106. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 LH [48720A/98-64]
a. Connect the rear suspension arm assembly No. 1 LH to the axle carrier with the bolt and nut.
NOTICE: Do not torque the nut.
107. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 1 RH [48710A/98-64]
HINT: Install the RH side by the same procedures with LH side.
108. INSTALL REAR SUSPENSION MEMBER BRACE RH [52295/98-65]
a. Install the rear suspension member brace with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
HINT: Install the LH side by the same procedures with RH side.
109. INSTALL FRONT FLOOR HEAT INSULATOR NO. 1 [58151/98-80]
a. Install the front floor heat insulator No. 1 with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
110. INSTALL PARKING BRAKE CABLE HEAT INSULATOR [46439/98-55]
a. Install the parking brake cable heat insulator with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
111. INSTALL REAR WHEEL
a. Install the rear wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
112. STABILIZE SUSPENSION
113. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 LH [48740F/98-64]
a. Align the matchmarks, and fully tighten the nut.
Torque: 110 Nm (1,120 kgf-cm, 81 ft. lbs.)
114. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 RH [48730F/98-64]
HINT: Install the RH side by the same procedures with LH side.
115. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 LH [48720A/98-64]
a. Fully tighten the nut.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
116. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 RH [48710A/98-64]
HINT: Install the RH side by the same procedures with LH side.
117. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY [37100/98-43]
118. INSTALL EXHAUST PIPE ASSY
119. INSTALL BODY RR END MOUNTING BRACKET SUB-ASSY [51709E/98-65]
a. Install the body RR end mounting bracket sub-assembly with the 8 bolts and 3 nuts.
Torque:
Bolt (A): 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
Bolt (B): 69 Nm (704 kgf-cm, 51 ft. lbs.)
Nut: 54 Nm (551 kgf-cm, 40 ft. lbs.)
120. INSTALL RR END BODY MOUNTING SET PLATE [52299A/98-65]
a. Install the RR end body mounting set plate with the 4 bolts.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
121. INSTALL RR END BODY MOUNTING SET PLATE [52299A/98-65]
a. Install the RR end body mounting set plate with the 4 bolts.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
122. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH [52297/98-65]
a. Install the RR suspension member brace rear lower RH with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
123. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH [52298/98-65]
HINT: Install the LH side by the same procedures with RH side.
124. INSTALL FRONT FLOOR BRACE CENTER [57533A/98-65]
a. Install the front floor brace CTR with the 4 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
125. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
126. CHECK EXHAUST GAS LEAK