REAR AXLE BEAM INSTALLATION


  1. INSTALL REAR AXLE CARRIER BUSHING LH


    1. A01CCU5E01

      Align the cutout of a new rear axle carrier bushing LH and the matchmark on the rear axle beam assembly and then temporarily install the rear axle carrier bushing LH to the rear axle beam assembly. (Perform this step when reusing the rear axle beam assembly.)

      Note


      • Do not apply grease to the rear axle carrier bushing LH or rear axle beam assembly.

      • Install the rear axle carrier bushing LH in the same direction as the removed bushing.

    2. A01CG3KE01

      Temporarily install a new rear axle carrier bushing LH to the position as shown in the illustration. (Perform this step when installing a new rear axle beam assembly.)

      Standard (A)
      47.5 mm (1.87 in.)
      Standard (B)
      3°35' to 9°35' (3.6° to 9.6°)

      Note


      • Do not apply grease to the rear axle carrier bushing LH or rear axle beam assembly.

      • Install the rear axle carrier bushing LH in the same direction as the removed bushing.

    3. A01CC93E01

      Using SST, install the rear axle carrier bushing LH to the rear axle beam assembly.

      SST
      09710-28031   ( 09711-02010, 09711-02020, 09711-02030, 09711-02040, 94622-51200 )

      Note


      • Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

      • Apply a small amount of grease to the threads and tip of SST (2 washers) before use.

      • Be careful not to damage the rubber part of the rear axle carrier bushing when installing it.

      • Do not deform the rear axle carrier bushing rib.

      • Do not apply grease to the rear axle carrier bushing LH or rear axle beam assembly.

  2. INSTALL REAR AXLE CARRIER BUSHING RH

    Tech Tips

    Perform the same procedure as the LH side.

  3. TEMPORARILY TIGHTEN REAR AXLE BEAM ASSEMBLY


    1. A01CAWNE01

      Using wooden blocks and a jack as shown in the illustration, jack up the rear axle beam assembly to allow it to be installed.

      Note

      Make sure to secure the rear axle beam assembly to prevent it from dropping.

    2. A01CDV5E01

      Temporarily install the rear axle beam assembly to the body with the 2 bolts and 2 nuts.

      Note


      • Insert the bolts with the threaded ends facing the outside of the vehicle.

      • Since stopper nuts are used, tighten the bolts.

      Tech Tips

      Fully tighten the nuts and bolts after stabilizing the suspension.

    3. A01CBH5E01

      Temporarily install the rear axle beam assembly to the rear shock absorber assembly with the 2 bolts and 2 nuts.

      Note


      • Insert the bolts with the threaded ends facing the outside of the vehicle.

      • Since stopper nuts are used, tighten the bolts.

      Tech Tips

      Fully tighten the nuts and bolts after stabilizing the suspension.

  4. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH


    1. A01CF5Z

      Temporarily install the parking brake assembly LH with the No. 3 parking brake cable assembly to the vehicle.

    2. Install the rear axle hub, bearing assembly LH and parking brake assembly LH to the rear axle beam assembly with the 4 bolts.

      Torque:
      90 N*m  { 918 kgf*cm, 66 ft.*lbf }

      Note

      Make sure that there is no dirt or foreign matter in the bolt threads or on mating surfaces.

  5. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  6. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. A01CCA0

      Install the No. 2 parking brake cable assembly to the body through the body hole.

    2. A01CDE6

      Install the No. 1 parking brake cable clamp to the No. 2 parking brake cable assembly.

    3. Connect the No. 2 parking brake cable assembly to the parking brake equalizer.

      A01CC5P

    4. Install the No. 2 parking brake cable assembly to the body with the 4 bolts.

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

  7. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. Connect the No. 3 parking brake cable assembly to the parking brake equalizer.

      A01CBA3

    2. Install the No. 3 parking brake cable assembly to the body with the 4 bolts.

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

  8. INSTALL REAR NO. 4 BRAKE TUBE


    1. A01CCYVE01

      Connect the rear No. 4 brake tube to the rear brake tube flexible hose.

      Note


      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt and dust to enter the brake line.

    2. Install the rear brake tube flexible hose with a new clip.

      Note

      Install the clip as far as it will go.

    3. Install the rear No. 4 brake tube to the rear axle beam assembly with the bolt and nut.

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

    4. Using a union nut wrench (10 mm), fully tighten the rear No. 4 brake tube to the rear brake tube flexible hose while holding the rear brake tube flexible hose with a wrench.

      Torque:
      without a union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt and dust to enter the brake line.

      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

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

  9. INSTALL REAR NO. 3 BRAKE TUBE


    1. A01CCBZE01

      Connect the rear No. 3 brake tube to the rear brake tube flexible hose.

      Note


      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt and dust to enter the brake line.

    2. Install the rear brake tube flexible hose with a new clip.

      Note

      Install the clip as far as it will go.

    3. Install the rear No. 3 brake tube to the rear axle beam assembly with the bolt and nut.

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

    4. Using a union nut wrench (10 mm), fully tighten the rear No. 4 brake tube to the rear brake tube flexible hose while holding the rear brake tube flexible hose with a wrench.

      Torque:
      without a union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt and dust to enter the brake line.

      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

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

  10. INSTALL REAR DISC


    1. Install the 2 rear discs Click here.

  11. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG


    1. Install the 2 parking brake shoe adjusting hole plugs to the 2 rear discs.

  12. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH


    1. A01CDH9

      Install the rear disc brake caliper assembly with rear flexible hose LH with the 2 bolts.

    2. A01CFD1E01

      Connect the rear No. 4 brake tube to the rear flexible hose LH.

      Note


      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt and dust to enter the brake line.

    3. Install the rear flexible hose LH to the backing plate with a new clip.

      Note

      Install the clip as far as it will go.

    4. Using a union nut wrench (10 mm), fully tighten the rear No. 4 brake tube to the rear flexible hose LH while holding the rear flexible hose LH with a wrench.

      Torque:
      without a union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • Do not kink or damage the brake line.

      • Do not allow any foreign matter such as dirt and dust to enter the brake line.

      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

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

  13. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  14. INSTALL REAR LOWER COIL SPRING INSULATOR LH


    1. A01CE2PE01

      Align the 2 protrusions to the guide holes and install the rear lower coil spring insulator.

      Note

      Make sure to insert the 2 protrusions fully into the guide holes.

  15. INSTALL REAR LOWER COIL SPRING INSULATOR RH

    Tech Tips

    Perform the same procedure as the LH side.

  16. INSTALL REAR COIL SPRING LH


    1. A01CATRE01

      Align the matchmarks on the rear coil spring with the SST hooks and install SST to the rear coil spring as shown in the illustration.

      SST
      09727-30021

      Tech Tips

      When installing a new coil spring, adjust the SST installation position by using the matchmarks on the original spring as a reference.

    2. Using SST, compress the rear coil spring.

      SST
      09727-30021

      Note

      Do not use an impact wrench. It will damage SST.

    3. A01CG3ZE01

      Align the stopper part of the rear upper coil spring insulator with the rear coil spring tip, and install the rear upper coil spring insulator to the rear coil spring.

    4. Confirm that the rear upper coil spring insulator and the rear lower coil spring insulator are installed securely before installing the rear coil spring.

      A01CG4PE01
      Clearance (A)
      10 mm (0.393 in.) or less

      Tech Tips

      If it is difficult to align the rear upper coil spring insulator, a minimal amount of lithium soap base glycol grease may be applied to the insulator.

    5. A01CEK3E01

      Align the stopper part of the rear lower coil spring insulator with the rear coil spring tip, and temporarily install the rear coil spring with SST to the vehicle.

    6. Release SST and install the rear coil spring to the vehicle.

      SST
      09727-30021

      Note


      • Do not use an impact wrench. It will damage SST.

      • Make sure that the rear upper coil spring insulator and rear lower coil spring insulator are correctly aligned and do not fall out of position when installing the spring.

    7. Remove SST from the rear coil spring.

      SST
      09727-30021

  17. INSTALL REAR COIL SPRING RH

    Tech Tips

    Perform the same procedure as the LH side.

  18. INSTALL REAR SPEED SENSOR WIRE (for LH Side)


    1. A01CFJS

      Install the rear speed sensor wire LH to the rear axle beam assembly with the bolt and 2 clamps.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Do not twist the rear speed sensor wire.

    2. A01CDNCE02

      Connect the rear speed sensor wire to the rear axle hub and bearing assembly LH.

      Note

      Do not twist the rear speed sensor wire.

  19. INSTALL REAR SPEED SENSOR WIRE (for RH Side)

    Tech Tips

    Perform the same procedure as the LH side.

  20. ADJUST PARKING BRAKE

    Tech Tips

    Refer to the instructions for adjust parking brake Click here.

  21. BLEED BRAKE SYSTEM

    Tech Tips

    Refer to the instructions for bleed brake line Click here.

  22. INSTALL TAIL EXHAUST PIPE ASSEMBLY

    for 2AZ-FE: Click here

    for 2GR-FE: Click here

  23. INSPECT FOR EXHAUST GAS LEAK

  24. STABILIZE SUSPENSION


    1. Install the rear wheels.

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

    2. Lower the vehicle.

    3. Bounce the vehicle up and down several times to stabilize the suspension.

    4. Remove the rear wheels.

    5. A01CAU5E01

      Jack up the spring cup of the rear axle beam assembly, placing a wooden block underneath to avoid damage. Apply load to the suspension so that the rear shock absorber assembly is positioned as shown in the illustration.

      Length A
      214 mm (8.43 in.)

      If the rear shock absorber assembly cannot be positioned as shown in the illustration even when the rear axle beam assembly is jacked up, apply additional load to the vehicle such as by having a person sit in the rear seat.

      CAUTION:

      Do not jack up the rear axle beam assembly too high as the vehicle may fall.

      Note


      • When using a jack, make sure that the wooden block does not contact the protrusions of the rear lower coil spring insulator.

      • Make sure to jack up both sides of the rear axle beam assembly evenly to prevent it from twisting.

  25. FULLY TIGHTEN REAR AXLE BEAM ASSEMBLY


    1. A01CDV5E01

      Fully tighten the 2 bolts on the rear axle beam assembly.

      Torque:
      135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

      Note


      • Since stopper nuts are used, tighten the bolts.

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

  26. FULLY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH


    1. A01CE1N

      Fully tighten the bolt on the rear shock absorber assembly (lower side).

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }

      Note


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

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

  27. FULLY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as the LH side.

  28. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY


    1. A01CC6R

      Install the rear height control sensor sub-assembly with the 4 bolts.

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

    2. Connect the connector.

  29. INSTALL REAR WHEELS

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

  30. INSPECT REAR WHEEL ALIGNMENT


    1. Inspect the rear wheel alignment Click here.

  31. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  32. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    Disconnect the cable from the negative (-) battery terminal for more than 2 seconds.

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  34. HEIGHT CONTROL SENSOR SIGNAL INITIALIZATION


    1. Initialize the height control sensor signal Click here.

  35. ADJUST HEADLIGHT AIMING

    for ALPHARD Click here

    for VELLFIRE Click here

  36. CHECK FOR SPEED SENSOR SIGNAL


    1. Check for the speed sensor signal Click here.