Axle Replacement Procedure

1. Disconnect battery negative cable.

2. Release parking brake lever.

3. Remove parking brake lever cover. To remove the front rivet, push the pin in the center of rivet into cover.

4. Disconnect lead wire of parking brake switch at coupler.

5. Remove parking brake cable locking nut.





6. Remove parking brake lever bolts and then remove parking brake lever assembly from equalizer.

7. Remove equalizer from parking brake cable.

NOTE:
Don't disassemble parking brake lever switch. It must be removed and installed as a complete switch assembly.





8. Raise and suitably support vehicle. Refer to section OA of service manual.

9. Remove both rear wheels.
10. Remove the four (4) bolts from the left and four (4) bolts from the right parking brake cable protectors on trailing rod frame and crossmember.
11. Remove parking brake cables from opening in floor.





12. Drain oil from rear axle and differential assembly.





13. Disconnect propeller shaft from differential flange and secure out of the way with a wire.

NOTE:
If propeller shaft is removed from the transmission tailshaft housing, transmission fluid may leak out.





14. Remove rear wheel speed sensor cover bolts and disconnect speed sensor connector from differential.

15. Disconnect rear wheel speed sensor harness from the rear axle.





16. Position hydraulic jack under the vehicle and support rear axle housing.





17. Disconnect brake pipe from flexible hose and remove E-ring.





18. Disconnect rear axle breather hose.





19. Detach ball joint bracket from differential carrier.





20. Loosen rear mount nut of trailing rod but don't remove bolt.





21. Remove both lower shock mounting bolts and nuts.





22. Lower the floor jack until tension of suspension coil springs is relieved and springs are a little loose.

WARNING:
Rear coil springs are under pressure. Lower hydraulic jack under rear axle slowly until coil spring tension becomes relieved. If rear coil springs become unseated while under pressure, serious bodily injury may result.

23. Remove trailing arm through bolts.
24. Slowly lower axle housing and remove rear coil springs.
25. Remove old axle and hydraulic jack from vehicle.
26. Install new axle on hydraulic jack and position axle under vehicle.

27. Raise axle assembly and install coil springs in their proper position.

NOTE:
When seating coil springs, mate spring end with stepped part of rear axle spring seat as shown.





28. Install trading arm through bolts and nuts. Refer to figure for proper installation direction of bolts.

NOTE:
Nuts should not be tightened at this time.





29. Install both lower shocks through bolts and nuts, referring to figure for proper installation direction of bolts.

30. Lower hydraulic jack.

31. Torque both trailing arm and shock through bolts and nuts to specifications.

Torque specs. for trailing arm bolts and nuts

N-m Kg-m lb.ft.

80-100 N-m 8.0-10.0 Kg-m 58.0-72 lb.ft.

Torque specs. for shock bolts and nuts

N-m Kg-m lb.ft.

70-100 N-m 7.0-10.0 Kg-m 51.0-72.0 lb.ft.





32. Install speed sensor wiring harness to rear axle, speed sensor connector, and cover. Torque the cover bolts to 15 N-m (1.5 Kg-m, 11 lb.ft.).
33. Connect rear axle breather hose to rear axle housing and secure with one clamp.





34. Install ball joint bracket onto differential carrier and tighten bolts to specified torque.

N-m Kg-m lb.ft.

40-60 N-m 4.0-6.0 Kg-m 29.0-43.0 lb.ft.





35. Remove jack from under rear axle.
36. Connect brake fluid hose and install E-clip to brake hose bracket.





37. Connect brake pipe and flexible hose and tighten nut to specified torque.

N-m Kg-m lb.ft.

14-18 N-m 1.4-1.8 Kg-m 10.5-13.0 lb.ft.





38. Mount the drive shaft and torque nuts to specification.

N-m Kg-m lb.ft.

50-60 N-m 5.0-6.0 Kg-m 36.5-43.0 lb.ft.





39. Check that the drain plug is torqued to specification.

N-m Kg-m lb.ft.

35-50 N-m 3.5-5.0 Kg-m 25.5-36.0 lb.ft.

40. Remove filler/level plug and refill with approximately 2.2 liters (4.6 pints) of GL-5 gear oil. Refer to the Temperature Chart for the recommended oil weight.

N-m Kg-m lb.ft.

35-50 N-m 3.5-5.0 Kg-m 25.5-36.0 lb.ft.

41. Install park brake cable through floor openings.

42. Install left and right park brake cable protectors on trailing rod, frame and crossmember with four (4) bolts on each side.

43. Bleed rear brakes. Refer to Section 5 of the Sidekick Service Manual.

NOTE:
Ensure after brake bleeding the brake fluid reservoir is filled with Dot 3 brake fluid.

44. Install both rear wheels and torque to specs.

N-m Kg-m lb.ft.

80-110 N-m 8.0-11.0 Kg-m 58.0-79.5 lb.ft.

45. Lower vehicle.
46. Install park brake cable to equalizer and connect equalizer to connecting rod. Secure with spacer and lock nut.

47. Adjust park brake lever by loosening or tightening the lock nut until parking brake is applied with between 7 to 9 notches on the parking brake lever with about 20 Kg (44 lbs.) force.
48. Install park brake lever cover to vehicle.

49. Check transmission fluid level and fill to specification if necessary.
50. Clean the top of the front upper radiator core support nose panel in front of the hood lock of any grease or dirt. Install Campaign Identification Label "SD."

Additional "SD" identification labels may be obtained by contacting the Technical Hotline.