Axle Shaft: Service and Repair

2WD





4WD


Removal
^ Before removing the rear axle, disconnect the ABS wheel sensor from the assembly. Then move it away from the axle. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative.
^ Wheel bearing does not require maintenance (4WD models).
^ If growling noise is emitted from wheel bearing during operation, replace wheel bearing assembly.
^ If the wheel bearing assembly is removed, it must be replaced. The old assembly must not be re-used.
1. Disconnect parking brake cable and brake tube.





2. Remove nuts securing wheel bearing cage with baffle plate.





3. Draw out axle shaft with Tool.
When drawing out axle shaft, be careful not to damage oil seal.
4. Remove case shim and case seal (2WD models).
5. Remove O-ring (4WD models).
6. Remove oil seal.
Do not reuse oil seal once it is removed.
Always install new one.





7. Remove ABS sensor rotor (4WD models).





8. Unbend lock washer with a screwdriver.





9. Remove bearing lock nut with Tool.





10. Remove wheel bearing together with bearing cage and baffle plate from axle shaft.





11. Remove grease seal in bearing cage with suitable bar.
12. Remove wheel bearing outer race with a brass drift (2WD models).





13. Remove wheel bearing assembly (4WD models).

Inspection
AXLE SHAFT
^ Check axle shaft for straightness, cracks, damage, wear and distortion. Replace if necessary.

WHEEL BEARING
^ Make sure wheel bearing rolls freely and is free from noise, cracks, pitting and wear.

AXLE CASE
^ Check axle case for yield, deformation and cracks. Replace if necessary.

Installation
-2WD MODELS-





1. Install wheel bearing outer race with a brass drill.
2. Install a new grease seal in bearing cage.
After installing new grease seal, coat sealing lip with multi purpose grease.





3. Install bearing spacer with chamfer side facing axle shaft flange.





4. Install wheel bearing inner race with a brass drift..
5. Coat each bearing cone with multi-purpose grease.
Specified amount of grease: 8 - 12 g (0.28 - 0.42 oz)





6. Install plain washer and a new wheel bearing lock washer.
7. Tighten wheel bearing lock nut.
Fit wheel bearing lock washer lip in wheel bearing lock nut groove correctly by tightening lock nut. Be sure to bend it up.





8. Install a new oil seal with suitable tool. After installing new oil seal, coat sealing lip with multi-purpose grease.





9. Apply recess of axle case end with multi-purpose grease.
10. Apply gear oil to the spline of axle shaft. Coat seal surface of axle shaft with multi-purpose grease (as shown).
11. Adjust axial end play.





a. Select end shims.
Standard thickness including seal: 1.5 mm (0.059 inch)
Axle case end shim: Refer to Application and ID.
Do not insert end shims between case seal and bearing cage.





b. Insert axle shaft with Tool as a guide.
When inserting axle shaft, be careful not to damage oil seal.
c. Measure end play of axle shaft.
Axial end play:
Servicing only one side of axle shaft
0.02 - 0.15 mm (0.0008 - 0.0059 inch)
Servicing both side axle shafts
On first axle shaft (right or left) adjust axial end play
0.30 - 0.90 mm (0.0118 - 0.0354 inch)
After servicing second axle strafe.
total end play
0.02 - 0.15 mm (0.0008 - 0.0059 inch)





d. If axial end play is not within the specified limit, reselect axle case end shims.
While adjusting axial end play, be careful not to damage oil seal.

-4WD MODELS-





1. Press new wheel bearing until it bottoms end face of bearing cage.
Maximum load P: 78 kN (8 ton, 8.8 US ton, 7.9 Imp ton)
Always press outer race of wheel bearing during installation.





2. Press new grease seal until it bottoms end face of bearing cage.
After installing new grease seal, coat sealing lip with multi purpose grease.





3. Press axle shaft into inner race of wheel bearing.
Maximum load P: 47.1 kN (4.8 ton, 5.3 US ton, 4.72 Imp ton)
Be careful not to damage or deform grease seal.





4. Install plain washer and a new wheel bearing lock washer.
5. Tighten wheel bearing lock nut to specified torque.
147 - 196 Nm (15 - 20 kg-m, 108 - 145 ft. lbs.)
Fit wheel bearing lock washer lip in wheel bearing lock nut groove correctly by tightening lock nut. Be sure to bend it up.





6. Check wheel bearing preload.
a. Turn bearing cage (with respect to axle shaft) two or three times. It must turn smoothly.
b. Attach spring gauge to bearing cage bolt (as shown) and pull it at a speed of 10 rpm to measure preload.
Spring gauge indication: 6.9 - 48.1 N (0.7 - 4.9 kg, 1.5 - 10.8 lbs.)





7. Install new oil seal to rear axle housing using a suitable tool. After installing new oil seal, coat sealing lip with multi-purpose grease.
8. Install new O-ring to rear axle housing.





9. Press ABS sensor rotor onto axle shaft until it contacts wheel bearing lock nut.





10. Position axle shafts in rear axle housing with Tool as a guide.
Be careful not to damage oil seal.





11. Check axial end play.
a. Check that wheel bearings operate smoothly.
b. Check axial end play.
Axial end play: 0 mm (0 inch)