DIFFERENTIAL CARRIER ASSEMBLY (w/ Differential Lock) INSTALLATION


  1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. Clean the contact surfaces of the differential carrier and axle housing.

      Note

      Be careful not to damage the installation surface.

    2. Install the differential carrier and a new gasket with the 10 nuts and washers.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Be careful to install the gasket without tearing it.

  2. CONNECT REAR DIFFERENTIAL LOCK ACTUATOR BREATHER TUBE


    1. Connect the rear differential lock actuator breather tube.

    2. Connect the 2 connectors.

  3. INSTALL REAR AXLE SHAFT WITH BACKING PLATE LH

    Click here

  4. INSTALL REAR AXLE SHAFT WITH BACKING PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  5. INSTALL REAR PROPELLER SHAFT ASSEMBLY

    Click here

  6. ADD DIFFERENTIAL OIL


    1. A01J4UTE51
      Text in Illustration
      *a 0 to 5 mm (0 to 0.196 in.)

      Add differential oil so that the oil level is within 5 mm (0 to 0.196 in.) from the bottom lip of the differential filler plug hole.

      Note


      • After changing the oil, drive the vehicle, and then check the oil level again.

      • Too much or too little oil will lead to differential problems.

      If necessary, fill the differential carrier with hypoid gear oil.

      Oil type
      Hypoid gear oil API GL-5
      Recommended Viscosity
      Temperature Viscosity
      Above -18°C (0°F) SAE 90
      Below -18°C (0°F) SAE 80W-90 or SAE 80W
      Standard Differential Oil Capacity
      Item Specified Condition
      Front Differential 1.40 to 1.50 liters (1.48 to 1.58 US qts., 1.23 to 1.32 Imp. qts.)
      Rear differential w/ Differential Lock 2.85 to 2.95 liters (3.01 to 3.12 US qts., 2.51 to 2.59 Imp. qts.)
      w/o Differential Lock 3.30 to 3.40 liters (3.49 to 3.59 US qts., 2.91 to 2.99 Imp. qts.)

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

    3. for front differential:


      1. A01J6I1E01
        Text in Illustration
        *1 10 mm Straight Hexagon Wrench
        *2 10 mm Union Nut Wrench
        *3 Socket Adaptor

        Using SST and the 10 mm straight hexagon wrench, 10 mm union nut wrench and socket adaptor, install a new gasket and the differential filler plug.

        SST
        09961-00950
        Torque:
        39 N*m  { 400 kgf*cm, 29 ft.*lbf }

        Note


        • Make sure all the tools are connected in a straight line.

        • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

          Formula
          T' = T x L3 / (L1 + L2 + L3)
          - T' = Spec. value of torque wrench
          - T = Value of specified tightening torque
          - L1 = Length of union nut wrench
          - L2 = Length of SST
          - L3 = Length of torque wrench

    4. for rear differential:


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

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

  7. BLEED AIR FROM BRAKE LINE

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  8. ADJUST PARKING BRAKE

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  9. INSTALL REAR WHEEL

    Torque:
    105 N*m  { 1,071 kgf*cm, 77 ft.*lbf }

  10. CHECK ABS SPEED SENSOR SIGNAL

    Click here