DIFFERENTIAL MOUNT CUSHION INSTALLATION


  1. INSTALL REAR NO. 1 DIFFERENTIAL MOUNT CUSHION


    1. Using SST, install a new rear No. 1 differential mount cushion.

      SST
      09570-24011
      (A)
      2.2 +/- 0.5 mm (0.09 +/- 0.02 in.)
      (B)
      0° +/- 3°
      A017C0DE01

      Note

      Do not set SST in the wrong direction.

      Tech Tips

      Perform this operation only when the No. 1 rear differential mount cushion is replaced.

  2. INSTALL REAR NO. 2 DIFFERENTIAL MOUNT CUSHION


    1. Using SST, install a new rear No. 2 differential mount cushion.

      SST
      09570-24011
      09316-12010
      (A)
      4.7 +/- 0.5 mm (0.19 +/- 0.02 in.)
      (B)
      0° +/- 3°
      A017FXBE02

      Note

      Do not set SST in the wrong direction.

      Tech Tips

      Perform this operation only when the No. 2 rear differential mount cushion is replaced.

  3. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A017F0C

      Jack up the rear differential carrier assembly and rear suspension member sub-assembly with a jack.

    2. Connect the No. 1 rear differential support to the rear suspension member sub-assembly with the 2 bolts and 2 lock nuts.

      Torque:
      137 N*m  { 1400 kgf*cm, 101 ft.*lbf }
    3. A017FNK

      Install the rear differential carrier assembly to the rear suspension member sub-assembly with the 3 bolts.

      Torque:
      95 N*m  { 970 kgf*cm, 70 ft.*lbf }

  4. INSTALL REAR SUSPENSION MEMBER


    1. A017DX4E01

      Using SST and a socket wrench (19 mm), fully tighten the nut (LH side).

      Torque:
      without SST
      181 N*m  { 1850 kgf*cm, 133 ft.*lbf }
      with SST
      134 N*m  { 1366 kgf*cm, 98 ft.*lbf }
      SST
      09961-00950

      Note


      • Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).

      • This torque value is effective when SST is parallel to the torque wrench.

    2. A017EKCE01

      Using SST and a socket wrench (19 mm), fully tighten the nut (RH side).

      Torque:
      without SST
      181 N*m  { 1850 kgf*cm, 133 ft.*lbf }
      with SST
      134 N*m  { 1366 kgf*cm, 98 ft.*lbf }
      SST
      09961-00950

      Note


      • Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).

      • This torque value is effective when SST is parallel to the torque wrench.

  5. INSTALL REAR DRIVE SHAFT SNAP RING LH


    1. Install a new rear drive shaft snap ring.

  6. INSTALL REAR DRIVE SHAFT SNAP RING RH

    Tech Tips

    Perform the same procedure as the LH side.

  7. INSTALL REAR DRIVE SHAFT ASSEMBLY LH


    1. A017FY2

      Align the shaft splines and install the rear drive shaft assembly with a brass bar and hammer.

      Note


      • Set the snap ring with the opening facing downward.

      • Be careful not to damage the oil seal, boot, or dust cover.

      • Install the drive shaft assembly while keeping it level.

  8. INSTALL REAR DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  9. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

    A017BH0E01

    1. Temporarily install the rear No. 1 suspension arm assembly RH to the rear suspension member sub-assembly with the bolt and the nut.

      Note


      • Ensure that the identification mark faces the rear side of the vehicle.

      • Since a stopper nut is used, temporarily tighten the bolt.

  10. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

    Tech Tips

    Perform the same procedure as the LH side.

  11. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  12. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY LH


    1. A017B48

      Temporarily install the the rear axle carrier sub-assembly with the 2 bolts and the 2 nuts.

      Note


      • Be careful not to damage the outboard joint boot.

      • Be careful not to damage the speed sensor rotor.

      • Prevent foreign matter from adhering to the speed sensor rotor.

    2. A017F92

      Install the rear axle carrier sub-assembly with the 2 bolts and the 2 nuts.

      Torque:
      290 N*m  { 2956 kgf*cm, 213 ft.*lbf }

      Note


      • Be careful not to damage the outboard joint boot.

      • Be careful not to damage the speed sensor rotor.

      • Prevent foreign matter from adhering to the speed sensor rotor.

      • Do not rotate the drive shaft with the rear axle hub and bearing assembly removed.

      Tech Tips

      Insert the bolts from the rear side.

  13. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  14. TEMPORARILY INSTALL REAR STRUT ROD ASSEMBLY (for LH Side)


    1. A017C6RE01

      Check that the identification mark of the rear strut rod assembly is positioned on the inner side of the vehicle.

    2. Temporarily install the rear strut rod assembly with the 2 bolts and the 2 nuts.

      Note

      Since stopper nuts are used, temporarily tighten the bolts.

  15. TEMPORARILY INSTALL REAR STRUT ROD ASSEMBLY (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  16. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH


    1. A017CXUE01

      Align the matchmarks on the drive shaft and rear axle hub.

      Note

      Do not rotate the drive shaft.

    2. A017GBA

      Install the parking brake assembly and the rear axle hub and bearing assembly with the 4 bolts.

      Torque:
      75 N*m  { 764 kgf*cm, 55 ft.*lbf }

      Note

      Do not twist the No. 3 parking brake cable assembly when installing it.

  17. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  18. INSTALL REAR DISC (for LH Side)


    1. A017FKWE01

      Align matchmarks and install the rear disc.

      Note

      When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

  19. INSTALL REAR DISC (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  20. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH


    1. A017DLS

      Install the rear disc brake caliper assembly with the 2 bolts.

      Torque:
      78 N*m  { 795 kgf*cm, 57 ft.*lbf }

  21. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  22. TEMPORARILY INSTALL REAR AXLE SHAFT NUT LH


    1. A017CAN

      Clean the threaded parts on the rear drive shaft assembly and rear axle shaft nut using a non-residue solvent.

      Note


      • Be sure to perform this work for a new rear drive shaft assembly.

      • Keep the threaded parts free of oil and foreign objects.

    2. While applying the brakes, temporarily install a new rear axle shaft nut.

      Torque:
      294 N*m  { 2996 kgf*cm, 216 ft.*lbf }

      Note

      Stake the nut after inspecting for looseness and runout in the following steps.

  23. TEMPORARILY INSTALL REAR AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as the LH side.

  24. INSTALL REAR SPEED SENSOR LH


    1. A017FNS

      Install the rear speed sensor to the rear axle carrier sub-assembly with the bolt .

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • Keep the rear speed sensor tip and sensor installation hole free from foreign matter.

      • To prevent interference with the bearing rotor, do not rotate the rear speed sensor body when inserting the rear speed sensor body or after inserting the rear speed sensor body.

      • Do not twist the rear speed sensor wire when installing.

  25. INSTALL REAR SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as the LH side.

  26. STABILIZE SUSPENSION


    1. A017FTBE01

      Jack up the rear axle carrier sub-assembly, placing a wooden block underneath to avoid damage. Apply load to the suspension so that the rear drive shaft assembly is positioned horizontally.

      CAUTION:

      Do not jack up the rear axle carrier sub-assembly too high as the vehicle may fall.

      Note

      Do not bend the brake dust cover.

      Tech Tips


      • If the rear drive shaft assembly cannot be positioned horizontally as shown in the illustration even when the rear axle carrier sub-assembly is jacked up, apply additional load to the vehicle such as by having a person sit in the rear seat.

      • Use the same procedure for the RH side and LH side.

  27. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH


    1. A017EJ8

      Fully tighten the rear No. 1 suspension arm assembly with the bolt and nut.

      Torque:
      112 N*m  { 1141 kgf*cm, 82 ft.*lbf }

      Note


      • Since a stopper nut is used, fully tighten the bolt.

      • The final torque must be applied under standard vehicle height conditions.

  28. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  29. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

    A017DVHE01

    1. Align the matchmarks on the adjust cams and rear suspension member sub-assembly.

    2. Fully tighten the nut.

      Torque:
      100 N*m  { 1019 kgf*cm, 74 ft.*lbf }

      Note

      The final torque must be applied under standard vehicle height conditions.

      Tech Tips

      When fully tightening the nut, keep the rear suspension toe adjust cam sub-assembly from rotating.

    3. Fully tighten the bolt.

      Torque:
      112 N*m  { 1141 kgf*cm, 82 ft.*lbf }

      Note


      • Since a stopper nut is used, fully tighten the bolt.

      • The final torque must be applied under standard vehicle height conditions.

  30. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  31. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY (for LH Side)


    1. A017C5T

      Fully tighten the bolt.

      Torque:
      80 N*m  { 815 kgf*cm, 59 ft.*lbf }

      Note


      • Since a stopper nut is used, fully tighten the bolt.

      • The final torque must be applied under standard vehicle height conditions.

    2. A017CN3

      Fully tighten the bolt.

      Torque:
      80 N*m  { 815 kgf*cm, 59 ft.*lbf }

      Note


      • Since a stopper nut is used, fully tighten the bolt.

      • The final torque must be applied under standard vehicle height conditions.

  32. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  33. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. A017DVV

      Install the No. 3 parking brake cable assembly with the bolt and the nut.

      Torque:
      Bolt
      39 N*m  { 397 kgf*cm, 29 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note

      Do not twist the No. 3 parking brake cable assembly when installing it.

  34. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY

    Tech Tips

    Perform the same procedure as the No. 3 parking brake cable assembly.

  35. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH


    1. A017DLS

      Remove the 2 bolts and separate the rear disc brake caliper assembly.

      Note

      Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose.

  36. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  37. REMOVE REAR DISC (for LH Side)


    1. A017FKWE01

      Put matchmarks on the rear disc and the axle hub.

    2. A017DGC

      Release the parking brake and remove the rear disc.

      Tech Tips

      If the disc cannot be removed easily, turn and press firmly the shoe adjuster until the wheel comes free.

  38. REMOVE REAR DISC (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  39. INSPECT REAR AXLE HUB BEARING LOOSENESS (for LH Side)


    1. A017EJZ

      Using a dial indicator, check for looseness near the center of the rear axle hub and bearing assembly.

      Maximum looseness
      0 mm (0 in.)

      Note

      Ensure that the dial indicator is set perpendicular to the measurement surface.

      Tech Tips

      If the looseness exceeds the maximum, replace the rear axle hub and bearing assembly.

  40. INSPECT REAR AXLE HUB BEARING LOOSENESS (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  41. INSPECT REAR AXLE HUB RUNOUT (for LH Side)


    1. A017FKWE01

      Align matchmarks and install the rear disc.

      Note

      When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

  42. INSPECT REAR AXLE HUB RUNOUT (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  43. INSTALL REAR DISC (for LH Side)


    1. A017FKWE01

      Align matchmarks and install the rear disc.

      Note

      When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

  44. INSTALL REAR DISC (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  45. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH


    1. A017DLS

      Install the rear disc brake caliper assembly with the 2 bolts.

      Torque:
      78 N*m  { 795 kgf*cm, 57 ft.*lbf }

  46. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  47. INSTALL REAR AXLE SHAFT NUT LH


    1. A017D4R

      Using a chisel and a hammer, stake the rear axle shaft nut.

  48. INSTALL REAR AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as the LH side.

  49. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. A017FC7E01

      Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, 4 washers and 4 nuts.

    2. A017G8QE01

      Remove SST from the transaxle.

    3. Insert the yoke into the transaxle.

    4. A017G71

      Install the 4 adjusting shims and propeller shaft with center bearing, and temporarily tighten the 4 bolts.

    5. A017FC7E01

      Tighten the 4 bolts.

      Torque:
      74 N*m  { 750 kgf*cm, 54 ft.*lbf }

  50. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. A017B7D

      Remove the piece of cloth from the joint.

    2. Using a hexagon wrench (6 mm), tighten the 6 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    3. A017BGHE01

      With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft as shown in the illustration.

      (A)
      58.0 +/- 0.5 mm (2.283 +/- 0.02 in.)

    4. Under the same condition as above, adjust the front and rear dimensions between the edge surface of the center support bearing and the edge surface of the cushion respectively as shown, and then tighten the bolts.

      A017FFHE01
      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }
      (B)
      12.5 +/- 1.0 mm (0.492 +/- 0.039 in.)

    5. Check that the center line of the bracket is at the right angle in the shaft axial direction.

    6. If any vibration or noise occurs, perform joint angle check as follows and replace the adjusting shim with a proper one.


      1. Turn the propeller shaft several times by hand to stabilize the center support bearings.

      2. Using a jack, raise and lower the differential to stabilize the differential mounting cushion.

      3. Remove the transfer dynamic damper.

      4. Using SST, measure the transfer installation angle (A) and front propeller shaft installation angle (B).

        SST
        09370-50010
        No. 1 joint angle
        (A) - (B) = -1.3° to -3.3°

      5. Using SST, measure the rear propeller shaft installation angle (C) and rear differential shaft installation angle (D).

        SST
        09370-50010
        No. 2 joint angle
        (C) - (D) = 1.8° to 3.5°
        A017CTPE01

        Tech Tips

        If the measured angle is not within the specification, adjust it with the center support bearing adjusting shim.

        Center support bearing adjusting shim thickness
        Thickness mm (in.) Thickness mm (in.)
        3.2 (0.126) 11.0 (0.433)
        4.5 (0.177) 13.5 (0.531)
        6.5 (0.256) 15.5 (0.610)
        9.0 (0.354) 17.5 (0.689)

      6. Install the transfer dynamic damper.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  51. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. A017BDT

      Using vernier calipers, measure the free length of the compression spring.

      Minimum 41.5 mm (1.63 in.)

      Tech Tips

      If the length is less than the minimum, replace the compression spring.

    2. A017F8GE01

      Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.

      Note


      • Tap in the gasket in the correct direction.

      • Do not reuse the removed gasket.

      • Do not push in the gasket while installing the center exhaust pipe assembly.

    3. Connect the 3 exhaust pipe supports, and install the center exhaust pipe assembly.

    4. A017EM8

      Install the 2 compression springs and 2 bolts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  52. INSTALL TAIL EXHAUST PIPE ASSEMBLY


    1. A017BDT

      Using vernier calipers, measure the free length of the compression spring.

      Minimum 40.5 mm (1.59 in.)

      Tech Tips

      If the length is less than the minimum, replace the compression spring.

    2. A017F8GE01

      Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the center exhaust pipe assembly.

      Note


      • Tap in the gasket in the correct direction.

      • Do not reuse the removed gasket.

      • Do not push in the gasket while installing the tail exhaust pipe assembly.

    3. Connect the exhaust pipe support, and install the tail exhaust pipe assembly.

    4. A017DZ8

      Install the 2 compression springs and 2 bolts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  53. INSPECT AND ADJUST TRANSFER OIL


    1. A017BX2E03

      Remove the No. 1 transfer case plug and gasket.

    2. Check the oil level is within 0 to 5 mm (0 to 0.20 in.) below the lowest end of the hole for the No. 1 transfer case plug.

      Note


      • When changing oil, recheck the oil level after driving.

      • Excessively large or small quantity of oil may cause some trouble.

    3. When the oil level is too low, check for oil leakage.

    4. Tighten the No. 1 transfer case plug with a new gasket.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  54. INSTALL REAR WHEELS

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  55. INSPECT REAR WHEEL ALIGNMENT

    Click here

  56. CHECK FOR REAR SPEED SENSOR SIGNAL

    Click here

  57. INSPECT FOR EXHAUST GAS LEAK

    If exhaust gas is leaking, repair the leak. Replace damaged or worn parts as necessary.