DIFFERENTIAL SIDE GEAR SHAFT INSTALLATION


  1. INSTALL DUST COVER


    1. LH side


      1. A01NCXNE04
        Text in Illustration
        *1 Steel Plate

        Using SST, steel plate and a press, install a new dust cover.

        SST
        09527-21011

        Note

        Do not damage the dust cover.

    2. RH side


      1. Using SST, steel plate and a press, install a new dust cover.

        SST
        09527-20011

        Note

        Do not damage the dust cover.

  2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY


    1. Install a new snap ring.

    2. A01NFHOE01
      Text in Illustration
      *1 LH Side
      *2 RH Side

      Using SST, install the side gear shaft.

      SST
      09520-24010   ( 09520-04010, 09520-32040 )

      Note


      • Set the snap ring with the opening side facing downward.

      • Do not tap in the side gear shaft at an angle. If the snap ring is installed at an angle, replace it with a new one and tap in the shaft again.

      • Do not damage the oil seal.

    3. A01NGXS

      Using a vernier caliper, measure the distance between the right and left side gear shafts, as shown in the illustration.

      Standard distance
      272.9 mm (107.44 in.) or less

  3. INSTALL REAR DRIVE SHAFT ASSEMBLY


    1. A01NG7QE02
      Text in Illustration
      *1 Jack
      *2 Wooden Block

      Using a jack and wooden block, jack up the rear No. 2 suspension arm assembly to replicate standard vehicle height conditions.

      Note

      Do not jack up the rear No. 2 suspension arm assembly too high as the vehicle may fall.

    2. A01NDTTE02
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the rear drive shaft assembly and rear axle hub and bearing assembly, and then insert the rear drive shaft assembly to the rear axle hub and bearing assembly.

    3. Align the matchmarks.

    4. A01NH75E01
      Text in Illustration
      *1 Matchmark

      Install the rear drive shaft assembly with the 4 nuts and washers.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

  4. INSTALL REAR AXLE SHAFT NUT


    1. Clean the threaded parts on the rear drive shaft assembly and a new 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 matter.

    2. A01NHSO

      Temporarily install the rear disc with the 5 hub nuts.

    3. While applying the parking brakes, temporarily install the new rear axle shaft nut.

      Torque:
      294 N*m  { 2998 kgf*cm, 217 ft.*lbf }

      Note

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

    4. Remove the 5 hub nuts and the rear disc.

  5. INSTALL REAR SUSPENSION ARM COVER (w/o Air Suspension)


    1. A01NFBI

      Insert the 2 guides of the rear suspension arm cover to the rear No. 2 suspension arm assembly.

    2. Install the rear suspension arm cover to the rear No. 2 suspension arm assembly with the 2 bolts as shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Make sure that the 2 guides of rear suspension arm cover are inserted.

  6. INSTALL REAR SUSPENSION ARM COVER (w/ Air Suspension)


    1. A01NGSG

      Insert the 2 guides of the rear suspension arm cover to the rear No. 2 suspension arm assembly.

    2. Install the rear suspension arm cover to the rear No. 2 suspension arm assembly with the 2 bolts as shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Make sure that the 2 guides of rear suspension arm cover are inserted.

    3. Check that the rear pneumatic cylinder cover is not deformed or collapsed inward.

  7. INSTALL REAR SPEED SENSOR


    1. A01NH71

      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


      • Prevent foreign matter from attaching to the sensor tip.

      • Do not file the rear speed sensor installation hole or surface because the gap between the magnet rotor and rear speed sensor is important.

      • Do not twist or apply excessive force to the front speed sensor during installation to prevent it from being damaged.

      • Install the rear speed sensor without twisting it.

  8. INSTALL TAIL EXHAUST PIPE ASSEMBLY (for RH Side)


    1. A01NGY9

      Using a vernier caliper, measure the free length of the compression springs.

      Minimum length
      41.5 mm (1.64 in.)

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

    2. Fully insert a new gasket to the center exhaust pipe assembly.

    3. A01NE1VE17
      Text in Illustration
      *1 Center Exhaust Pipe Assembly
      *2 Gasket
      *3 Wooden Block

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

      Note


      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Connect the tail exhaust pipe assembly to the 2 exhaust pipe supports.

    5. A01NH05

      Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

  9. INSTALL REAR WHEEL

  10. ADD HYBRID TRANSAXLE FLUID


    1. A01NDEME01

      Add transaxle fluid until the transaxle fluid level is between 0 and 5 mm (0 and 0.197 in.) from the bottom lip of the transaxle filler plug opening.

      Note


      • Stop the vehicle on a flat road.

      • Recheck the transaxle fluid level after driving when exchanging transaxle fluid.

      • Insufficient or excessive amounts of transaxle fluid may be the cause of some trouble.

      Capacity
      1.8 liters (1.9 US qts, 1.6 Imp. qts)

  11. INSPECT AND ADJUST HYBRID TRANSAXLE FLUID


    1. A01NDEME01

      Check that the transaxle fluid level is between 0 and 5 mm (0 and 0.197 in.) from the lowest position of the inner surface of the transaxle filler plug opening.

      Note


      • Stop the vehicle on a flat road.

      • Recheck the transaxle fluid level after driving when exchanging transaxle fluid.

      • Insufficient or excessive amounts of transaxle fluid may be the cause of some trouble.

      Capacity
      1.8 liters (1.9 US qts, 1.6 Imp. qts)

    2. Check for leaks if the quantity of transaxle fluid is low.

    3. Using a hexagon socket wrench 10 mm, install the filler plug and a new gasket.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  12. INSPECT FOR EXHAUST GAS LEAK (for RH Side)

  13. CHECK FOR SPEED SENSOR SIGNAL


    1. Check for the speed sensor signal Click here.