REAR DIFFERENTIAL CARRIER ASSEMBLY INSTALLATION

TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH

1. 

   Temporarily install the rear No. 1 suspension arm assembly LH 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.

2. 

   Set the rear No. 1 suspension arm LH in the position shown in the illustration.

   Length A
   20 mm (0.787 in.)

3. Fully tighten the bolt.

   80 N*m

   815 kgf*cm

   59 ft.*lbf

   Note:

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

INSTALL REAR SUSPENSION MEMBER

1. 

   Support the rear suspension member with a jack using a wooden block.

   Tip:
   

   • Use a properly sized wooden block to keep the jack and suspension member level.

   • Support the rear suspension member until retightening of the suspension member is complete.

2. 

   Raise the rear suspension member with a jack.

3. Temporarily install the rear suspension member, the 2 rear upper suspension member stoppers and rear lower suspension member stopper retainers with the 4 nuts and the 2 bolts.

4. 

   Fully tighten the 2 nuts.

   115 N*m

   1170 kgf*cm

   85 ft.*lbf

INSTALL REAR DRIVE SHAFT SNAP RING LH

1. Install a new rear drive shaft snap ring.

INSTALL REAR DRIVE SHAFT ASSEMBLY LH

1. 

   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.

INSTALL REAR AXLE CARRIER SUB-ASSEMBLY LH

1. 

   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. 

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

   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.

   Tip:

   Insert the bolts from the rear side.

TEMPORARILY INSTALL REAR STRUT ROD ASSEMBLY (for LH Side)

1. 

   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.

INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH

1. 

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

   Note:

   Do not rotate the drive shaft.

2. 

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

   75 N*m

   764 kgf*cm

   55 ft.*lbf

   Note:

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

INSTALL REAR DISC (for LH Side)

1. 

   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.

INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH

1. 

   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. 

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

   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.

   Tip:

   Insert the bolts from the rear side.

TEMPORARILY INSTALL REAR AXLE SHAFT NUT LH

1. 

   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.

   294 N*m

   2996 kgf*cm

   216 ft.*lbf

   Note:

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

INSTALL REAR SPEED SENSOR LH

1. 

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

   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.

STABILIZE SUSPENSION

1. 

   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.

   Tip:
   

   • 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.

FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH

1. 

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

   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.

FULLY TIGHTEN REAR STRUT ROD ASSEMBLY (for LH Side)

1. 

   Fully tighten the bolt.

   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. 

   Fully tighten the bolt.

   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.

INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

1. 

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

   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.

SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH

1. 

   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.

REMOVE REAR DISC (for LH Side)

1. 

   Put matchmarks on the rear disc and the axle hub.

2. 

   Release the parking brake and remove the rear disc.

   Tip:

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

INSPECT REAR AXLE HUB BEARING LOOSENESS (for LH Side)

1. 

   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.

   Tip:

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

INSPECT REAR AXLE HUB RUNOUT (for LH Side)

1. 

   Using a dial indicator, check for runout on the surface of the rear axle hub and bearing assembly outside the rear axle hub bolt.

   Maximum runout
   0.08 mm (0.0031 in.)

   Note:

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

   Tip:

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

INSTALL REAR DISC (for LH Side)

1. 

   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.

INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH (for LH Side)

1. 

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

   78 N*m

   795 kgf*cm

   57 ft.*lbf

INSTALL REAR AXLE SHAFT NUT LH (for LH Side)

1. 

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

INSTALL CENTER EXHAUST PIPE ASSEMBLY

1. 

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

   Minimum

   41.5 mm (1.63 in.)

   Tip:

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

2. 

   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. 

   Install the 2 compression springs and 2 bolts.

   48 N*m

   489 kgf*cm

   35 ft.*lbf

INSTALL TAIL EXHAUST PIPE ASSEMBLY

1. 

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

   Minimum

   40.5 mm (1.59 in.)

   Tip:

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

2. 

   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. 

   Install the 2 compression springs and 2 bolts.

   48 N*m

   489 kgf*cm

   35 ft.*lbf

TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

1. 

   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. 

   Remove SST from the transaxle.

3. Insert the yoke into the transaxle.

4. 

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

5. 

   Tighten the 4 bolts.

   74 N*m

   750 kgf*cm

   54 ft.*lbf

FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

1. 

   Remove the piece of cloth from the joint.

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

   26 N*m

   265 kgf*cm

   19 ft.*lbf

3. 

   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.

   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).

      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).

      09370-50010

      No. 2 joint angle
      (C) - (D) = 1.8° to 3.5°

      Tip:

      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.

      26 N*m

      265 kgf*cm

      19 ft.*lbf

INSPECT DIFFERENTIAL OIL

1. Stop the vehicle on a level place.

2. Remove the differential filler plug and gasket.

3. 

   Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the inner surface of the differential filler plug opening.

   Note:
   

   • Excessively large or small amounts of oil may cause trouble.

   • After replacing oil, drive the vehicle and check the oil level.

   Tip:

   If necessary, fill the rear differential carrier 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
   0.9 +/- 0.05 liters (0.95 +/- 0.05 US qts, 0.79 +/- 0.04 lmp. qts)

4. Check for oil leakage when the oil level is low.

5. Install the differential filler plug and a new gasket.

   49 N*m

   500 kgf*cm

   36 ft.*lbf

INSPECT AND ADJUST TRANSFER OIL

1. 

   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.

   49 N*m

   500 kgf*cm

   36 ft.*lbf

INSPECT FOR EXHAUST GAS LEAK

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