DIFFERENTIAL CARRIER ASSEMBLY REMOVAL


  1. REMOVE REAR WHEELS

  2. DRAIN DIFFERENTIAL OIL


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and drain the oil.

  3. DRAIN BRAKE FLUID

  4. REMOVE REAR BRAKE DRUM SUB-ASSEMBLIES


    1. Release the parking brake lever, and remove the brake drum.

      A003HEME01
      Text in Illustration
      *A for 295 mm Drum *B for 254 mm Drum

      Tech Tips

      If the brake drum cannot be removed easily, perform the following steps.

    2. Remove the hole plug and insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster.

    3. Using another screwdriver, contract the brake shoe adjuster by turning the adjusting wheel.

  5. REMOVE REAR AXLE BRAKE DRUM GASKETS

  6. REMOVE AUTOMATIC ADJUST LEVER LH


    1. for 254 mm drum:


      1. A003CMW

        Remove the automatic adjust lever and the tension spring.

  7. REMOVE AUTOMATIC ADJUST LEVER RH

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  8. SEPARATE PARKING BRAKE SHOE STRUT SET LH


    1. for 254 mm drum:


      1. A003B1LE01

        Using SST, remove the upper side tension spring from the brake shoe.

        SST
        09703-30011

    2. for 295 mm drum:


      1. A003CWOE01

        Using SST, remove the upper side tension spring from the brake shoe.

        SST
        09703-30011

  9. SEPARATE PARKING BRAKE SHOE STRUT SET RH

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  10. REMOVE FRONT BRAKE SHOES


    1. for 254 mm drum:


      1. A003D9P

        Using a needle-nose pliers, remove the anchor side tension spring.

      2. A003E58E01

        Using SST, remove the cup, shoe hold-down sprig and pin.

        SST
        09718-00011
      3. A003F1JE02
        Text in Illustration
        *A LH Side
        *B RH Side

        Remove the parking brake shoe lower strut.

      4. Separate the brake shoe return spring, and remove the front brake shoe.

    2. for 295 mm drum:


      1. A003CTHE01

        Using SST, remove the cup, shoe hold-down sprig and pin.

        SST
        09718-00011

      2. Separate the brake shoe return spring, and remove the front brake shoe.

  11. REMOVE REAR BRAKE SHOES


    1. for 254 mm drum:


      1. A003D7FE01

        Using SST, remove the cup, shoe hold-down sprig and pin.

        SST
        09718-00011
      2. A003EMZ

        Disconnect the parking brake cable No. 3 and remove the rear brake shoe.

    2. for 295 mm drum:


      1. A003GYTE01

        Using SST, remove the cup, shoe hold-down sprig and pin.

        SST
        09718-00011

      2. Remove the tension spring.

      3. A003AYI

        Disconnect the parking brake cable No. 3 and remove the rear brake shoe.

  12. REMOVE PARKING BRAKE SHOE STRUT SET LH


    1. for 254 mm drum:


      1. A003IDME02
        Text in Illustration
        *1 Brake Shoe Lever
        *2 Brake Shoe Strut Set
        *3 Rear Brake Shoe
        *4 Rear Cushion Lever
        *5 C-washer

        Using a screwdriver, remove the C-washer, brake shoe lever, rear cushion lever and brake shoe strut set from the brake shoe.

      2. Remove the adjusting bolt and tension spring from the brake shoe strut set.

    2. for 295 mm drum:


      1. A003GO0E01
        Text in Illustration
        *1 Rear Brake Shoe
        *2 Brake Shoe Strut Set
        *3 Brake Shoe Lever
        *4 Automatic Adjust Lever
        *5 C-washer
        *6 E-ring

        Remove the brake shoe strut set.

      2. Using a screwdriver, remove the E-ring and automatic adjust lever.

      3. Using a screwdriver, remove the C-washer and brake shoe lever from the brake shoe.

  13. REMOVE PARKING BRAKE SHOE STRUT SET RH

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  14. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO. 3


    1. A003BY7

      Remove the 2 bolts and separate the parking brake cable assembly No.3 from the backing plate.

    2. Remove the 5 bolts, nut and parking brake cable assembly No.3.

      A003I6L

    3. Remove the parking brake cable assembly No.3 from the parking brake equalizer.

  15. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO. 2

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  16. REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY LH


    1. A003EFL

      Using a union nut wrench, disconnect the brake tube, use a container to catch brake fluid.

    2. Remove the 2 bolts and wheel cylinder.

  17. REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY RH

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  18. SEPARATE REAR SPEED SENSOR LH (w/ ABS)


    1. Disconnect the sensor connector.

      A003FR9

    2. Detach the 4 clamps.

    3. Remove the bolt and rear speed sensor LH.

      Note

      Prevent foreign matter from attaching to the sensor tip.

    4. Remove the O-ring from the rear speed sensor.

  19. SEPARATE REAR SPEED SENSOR RH (w/ ABS)

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  20. REMOVE REAR AXLE SHAFT WITH BACKING PLATE LH


    1. A003DLHJ01

      Remove the 4 nuts and rear axle shaft with backing plate.

      Note


      • Be careful not to damage the rear axle shaft oil seal.

      • Be careful not to damage the skid control rotor rear.

  21. REMOVE REAR AXLE SHAFT WITH BACKING PLATE RH

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  22. REMOVE BEARING RETAINER O-RINGS


    1. Remove the bearing retainer O-ring from the rear axle housing assembly.

  23. REMOVE REAR AXLE SHAFT LH OIL SEAL


    1. A003FQUE01

      Using SST, remove the rear axle shaft oil seal from the rear axle housing assembly.

      SST
      09308-00010

  24. REMOVE REAR AXLE SHAFT RH OIL SEAL

    Tech Tips

    Removal procedure of the RH side is the same as that of the LH side.

  25. REMOVE PROPELLER SHAFT ASSEMBLY (for Super Long Wheelbase)


    1. A003AD9E01

      Put matchmarks on both flanges.

    2. Remove the 4 nuts, bolts and washers.

      Tech Tips

      If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller with center bearing shaft assembly from the differential companion flange.

    3. A003C3U

      Remove the 2 bolts and center support bearing assembly No.1.

    4. Remove the propeller with center bearing shaft assembly.

    5. A003BT1E01

      Insert SST in the transmission to prevent oil leakage.

      Note

      Do not damage the oil seal.


      1. Use the following SST for the automatic transmission.

        SST
        09325-40010

      2. Use the following SST for the manual transmission.

        SST
        09325-20010

  26. REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    1. A003AD9E01

      Put matchmarks on both flanges.

    2. Remove the 4 nuts, bolts and washers.

      Tech Tips

      If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.

    3. Remove the propeller shaft assembly.

    4. A003BT1E01

      Insert SST in the transmission to prevent oil leakage.

      Note

      Do not damage the oil seal.


      1. Use the following SST for the automatic transmission

        SST
        09325-40010

      2. Use the following SST for the manual transmission

        SST
        09325-20010

  27. DISCONNECT LOAD SENSING BRACKET


    1. A003F0W

      Remove the 2 nuts and load sensing bracket.

  28. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. Support the differential carrier assembly with a jack.

      Note

      Do not drop the differential carrier assembly

    2. A003CMHE01

      Remove the 10 nuts, washers and differential carrier assembly.

      Note


      • Do not damage the installation surface when removing the differential carrier assembly.

      • The remaining oil may leak out when removing the differential carrier assembly.

  29. REMOVE REAR DIFFERENTIAL CARRIER GASKET