Differential System: Removal & Installation Lexus SC II

REPLACEMENT

HINT

1. Replacement the RH side by the same procedures with LH side.

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1. REMOVE REAR WHEEL Remove the 10 bolts and ornament. Remove the 5 nuts and rear wheel.
2. REMOVE REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), remove the filler plug and gasket.
3. REMOVE REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), remove the drain plug and gasket. Drain the differential oil.
4. REMOVE REAR SUSPENSION MEMBER BRACE RH Remove the 2 bolts and suspension member brace LH.
5. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH Place matchmarks on the adjusting cam and rear suspension arm assy No. 2 LH. Remove the cam bolt, cam plate and nut, disconnect the rear suspension arm assy No. 2 LH from the axle hub.
6. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH Remove the bolt and nut, disconnect the rear suspension arm assy No. 1 LH from the axle hub.
7. SEPARATE SPEED SENSOR REAR LH (See «AXLE SHAFTS»(ref-164294-S14512384702004072900000) )
8. SEPARATE REAR DRIVE SHAFT ASSY LH Place matchmarks on the drive shaft and side gear shaft. NOTE: Do not punch to mark the matchmarks. Use paint etc. Using a hexagon wrench (12 mm), remove the 6 hexagon bolts and 2 washers with depressing the brake pedal. Separate the drive shaft from the differential carrier.
9. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY Using SST, remove the side gear shaft. SST 09520-24010 (09520-04010, 09520-32040) Using a screwdriver, remove the snap ring.
10. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST, remove the oil seal. SST 09308-10010
11. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST and a hammer, install a new oil seal. Apply MP grease to the oil seal lip. SST 09608-32010, 09950-70010 (09951-07150)
12. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY Using needle nose pliers, install a new snap ring to the side gear shaft. Coat the MP grease to the snap ring. Using a brass bar and a hammer, install the side gear shaft. NOTE: Be careful not to damage the oil seal. HINT: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
13. INSTALL REAR DRIVE SHAFT ASSY LH (See «AXLE SHAFTS»(ref-164294-S14512384702004072900000) )
14. CONNECT SPEED SENSOR REAR LH (See «AXLE SHAFTS»(ref-164294-S14512384702004072900000) )
15. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 LH Connect the rear suspension arm assy No. 2 LH to the axle carrier with the cam bolt, cam plate and nut. NOTE: Do not torque the nut.
16. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 LH Connect the rear suspension arm assy No. 1 LH to the axle carrier with the bolt and nut. NOTE: Do not torque the nut.
17. INSTALL REAR WHEEL Install the rear wheel with the 5 nuts. Torque: 103 N.m (1,050, kgf.cm, 76 ft.lbf) Install the ornament with the 10 bolts. Torque: 20 N.m (204, kgf.cm, 15 ft.lbf)
18. INSTALL REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), install the drain plug with a new gasket. Torque: 49 N.m (500 kgf.cm, 39 ft.lbf)
19. ADD DIFFERENTIAL OIL Fill the rear differential carrier assy 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: 1.35 +/- 0.05 liters (1.43 +/- 0.05 US qts, 1.19 +/- 0.06 Imp. qts)
20. INSPECT DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-183290-S30461918542005081300000) )
21. INSTALL REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), install the filler plug with a new gasket. Torque: 49 N.m (500 kgf.cm, 39 ft.lbf)
22. STABILIZE SUSPENSION (See «REAR WHEEL ALIGNMENT»(ref-183288) )
23. INSTALL REAR SUSPENSION MEMBER BRACE RH Install the suspension member brace LH with the 2 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
24. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Align the matchmarks, and fully tighten the nut. Torque: 110 N.m (1,120 kgf.cm, 81 ft.lbf)
25. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Fully tighten the nut. Torque: 78 N.m (765 kgf.cm, 55 ft.lbf)
26. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See «REAR WHEEL ALIGNMENT»(ref-183288) )
27. SPEED SENSOR SIGNAL CHECK (See «DTC P0500: VEHICLE SPEED SENSOR "A" OR DTC P0503: VEHICLE SPEED SENSOR "A" INTERMITTENT/ERRATIC/HIGH»(ref-151781-S35982960512003010800000) )

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1. REMOVE REAR WHEEL Remove the 10 bolts and ornament. Remove the 5 nuts and rear wheel.
2. REMOVE FRONT FLOOR BRACE CENTER Remove the 4 bolts and floor brace CTR.
3. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER RH Remove the 2 bolts and RR suspension member brace rear lower RH.
4. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH Remove the 2 bolts and RR suspension member brace rear lower LH.
5. REMOVE EXHAUST PIPE (See «EXHAUST SYSTEM»(ref-183320) )
6. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 Remove the 4 bolts and front floor heat insulator No. 1.
7. REMOVE PARKING BRAKE CABLE HEAT INSULATOR Remove the 4 bolts and parking brake cable heat insulator.
8. REMOVE RR END BODY MOUNTING SET PLATE Remove the 4 bolts and RR end body mounting set plate.
9. REMOVE RR END BODY MOUNTING SET PLATE Remove the 4 bolts and RR end body mounting set plate.
10. REMOVE BODY RR END MOUNTING BRACKET SUB-ASSY Remove the 8 bolts, 3 nuts and body RR end mounting bracket sub-assy.
11. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (See «PROPELLER W/CENTER BEARING SHAFT ASSY»(ref-183293-S33771753112005081300000) ) SST 09922-10010
12. REMOVE REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), remove the filler plug and gasket.
13. REMOVE REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), remove the drain plug and gasket. Drain the differential oil.
14. REMOVE REAR SUSPENSION MEMBER BRACE RH Remove the 2 bolts and rear suspension member brace RH. HINT: Remove the LH side by the same procedures with RH side.
15. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH Remove the bolt and nut, disconnect the rear suspension arm assy No. 1 LH from the axle hub.
16. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH HINT: Separate the RH side by the same procedures with LH side.
17. SEPARATE REAR SUSPENSION ARM ASSY NO. 2 LH Place matchmarks on the adjusting cam and rear suspension arm assy No. 2 LH. Remove the cam bolt, cam plate and nut, disconnect the rear suspension arm assy No. 2 LH from the axle hub.
18. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH HINT: Separate the RH side by the same procedures with LH side.
19. SEPARATE REAR DRIVE SHAFT ASSY LH Place matchmarks on the drive shaft and side gear shaft. NOTE: Do not punch to mark the matchmarks. Use paint, etc. Using a hexagon wrench (12 mm), remove the 6 hexagon bolts and 2 washers with depressing the brake pedal. Separate the drive shafts from the differential carrier.
20. SEPARATE REAR DRIVE SHAFT ASSY RH HINT: Separate the RH side by the same procedures with LH side.
21. REMOVE DIFFERENTIAL CARRIER ASSY REAR Support the differential carrier with a jack. Using a hexagon wrench (12 mm), remove the 3 hexagon bolts Remove the 2 bolts and lower mount stoppers. Remove the differential. Remove the 2 upper mount stoppers from the differential carrier.
22. REMOVE REAR DIFFERENTIAL CARRIER COVER Remove the 8 bolts from the carrier cover. Using a brass bar and a hammer, separate the cover from carrier. If necessary, remove the breather plug from the differential carrier cover. Remove the bolt and oil deflector form rear differential carrier cover.
23. FIX DIFFERENTIAL CARRIER ASSY REAR Set the differential carrier to the overhaul stand, etc., as shown in the illustration.
24. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Using a dial indicator, measure the ring gear runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.
25. INSPECT DIFFERENTIAL RING GEAR BACKLASH Using a dial indicator, measure the backlash of the ring gear at 3 points at least and check that the average value is within the specification. Backlash: 0.08-0.13 mm (0.0031-0.0051 in.) NOTE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 In.). If the backlash is not within the specification, adjust the backlash (See step 69 .
26. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
27. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case. Maximum: 0.15 mm (0.0059 in.) NOTE: Differential gears should be able to rotate. If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.
28. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) away from the end of the shaft. Maximum runout: 0.08 mm (0.0031 in.) If the runout is greater than the maximum, replace the drive pinion and ring gear.
29. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Using SST and a torque wrench, measure the preload using the backlash of the drive pinion and ring gear. SST 09229-55010 Preload (at starting) 0.5-0.8 N.m (5-8 kgf.cm, 4.3-6.9 in.lbf)
30. INSPECT TOTAL PRELOAD Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. SST 09229-55010 Total preload (at starting): Drive pinion preload plus 0.5-0.8 N.m (5-8 kgf.cm, 4.3-6.9 in.lbf) If necessary, disassemble and inspect the differential.
31. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY Using SST, remove the 2 side gear shafts. SST 09520-24010 NOTE: Be careful not to damage the oil seal.
32. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING Using a screwdriver, remove the 2 snap rings from the side gear shafts.
33. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER Using a screwdriver and a hammer remove the dust cover.
34. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST, remove the 2 oil seals. SST 09308-00010
35. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY Remove the 16 bolts. Using SST, remove the 2 carrier retainers and washers. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
36. REMOVE REAR DEFERENTIAL CASE SUB-ASSY NOTE: Do not damage the case bearing.
37. REMOVE REAR DRIVE PINION NUT Using a chisel and a hammer, loosen the staked part of the nut. Using SST to hold the flange, remove the nut. SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
38. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03060)
39. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, remove the dust deflector. SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)
40. Remove Rear Differential Carrier Oil Seal Using SST, remove the oil seal from the differential carrier. SST 09308-10010
41. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Using a magnet hand, remove the differential drive pinion oil slinger.
42. REMOVE DIFFERENTIAL DRIVE PINION Using a press, remove the drive pinion with the rear bearing from the differential carrier. NOTE: Be careful not to drop the drive pinion.
43. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Remove the spacer from the drive pinion.
44. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Remove the front bearing from the differential carrier. Using a brass bar and a hammer remove the front bearing outer race.
45. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, remove the rear bearing from the drive pinion. SST 09950-00020 Using a brass bar and a hammer remove the rear bearing outer race. Remove the plate washer.
46. REMOVE DIFFERENTIAL RING GEAR Place matchmarks on the ring gear and differential case. Remove the 10 ring gear set bolts. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
47. REMOVE REAR DIFFERENTIAL CARRIER RETAINER O-RING Using a screwdriver, remove the 2 O-rings from the differential carrier retainers. NOTE: Be careful not to damage the carrier retainer.
48. INSPECT RUNOUT OF REAR DEFERENTIAL CASE SUB-ASSY Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case. NOTE: Do not damage the case bearing. Using SST and a hammer, install 2 carrier retainers. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) Tighten the 16 bolts. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) Using a dial indicator, measure the differential case runout. Maximum runout: 0.05 mm (0.0020 in.)
49. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY Remove the 16 bolts. Using SST, remove the 2 carrier retainers and washers. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09955-04061, 09954-04010, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
50. REMOVE REAR DEFERENTIAL CASE SUB-ASSY NOTE: Do not damage the side bearing.
51. REMOVE REAR DIFFERENTIAL CASE BEARING Using SST, remove the 2 differential case bearings from the differential case. SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011) Using SST and a press, remove the 2 outer races and adjusting plate washers. SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
52. REMOVE REAR DIFFERENTIAL PINION SHAFT PIN Using a chisel and a hammer, release the stake the out side of the differential case pin hole. Using a pin punch (5 mm) and a hammer, remove the straight pin.
53. REMOVE REAR DIFFERENTIAL SIDE GEAR Remove the pinion shaft from the differential case. Remove the 2 pinion gears and thrust washers from the differential case. Remove the 2 side gears and thrust washers from the differential case.
54. INSTALL REAR DIFFERENTIAL PINION Install the 2 proper thrust washer on the side gears. Install the 2 side gears to the differential case. Install the 2 pinion gears and 2 pinion thrust washers on the differential case. HINT: Using the chart below, select thrust washers which will ensure that the backlash is within the specification. Thrust washer thickness
55. INSTALL REAR DIFFERENTIAL PINION SHAFT Install the pinion shaft on the differential case.
56. ADJUST DIFFERENTIAL PINION GEAR BACKLASH Install the 2 side gear shafts in the differential case. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case. Maximum: 0.15 mm (0.0059 in.) NOTE: Differential gears should be able to rotate. If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses. Remove the 2 side gear shafts.
57. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft. Using a chisel and a hammer, stake the differential case.
58. INSTALL DIFFERENTIAL RING GEAR Clean the contact surfaces of the differential case and the threads of the ring gear and differential case. Heat the ring gear in boiling water. Carefully remove the ring gear from the boiling water. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the ring gear and the differential case. Tighten 2 new bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned. NOTE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.
59. INSTALL REAR DIFFERENTIAL CASE BOLT After the ring gear has cooled sufficiently, install new 8 ring gear set bolts to which thread lock has been applied. Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent. NOTE: New ring gear set bolts should be used in every case. Torque the 10 set bolts uniformly and a little at a time. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) Tighten the bolts further by 60-90 +/-. NOTE: Tighten the bolts in diagonally opposite pairs.
60. INSTALL REAR DIFFERENTIAL CASE BEARING Using SST and a press, install the 2 differential case bearings. SST 09950-60010 (09951-00560), 09950-70010 (09951-07100) Using SST and press install the adjusting plate washer and outer race. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) HINT: The adjusting washer is used for adjusting the tooth contact pattern. 42 types of washer with different thicknesses are available. First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary. When removing an adjusting washer, be sure to replace it with a new one.
61. INSTALL REAR DEFERENTIAL CASE SUB-ASSY Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case. NOTE: Do not damage the side bearing. Using SST and a hammer, install the 2 carrier retainers. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) Tighten the 16 bolts. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf)
62. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Using a dial indicator, measure the ring gear runout. Maximum runout: 0.05 mm (0.0020 in.)
63. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY Remove the 16 bolts. Using SST, remove the 2 carrier retainers and washers. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09955-04061, 09954-04010, 09958-04011, 09957-04010), 09950-60010 (09951-00480) Take the differential case out of the carrier with lifting ring gear side as show in the illustration. NOTE: Do not damage the side bearing.
64. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, install the rear bearing. SST 09502-24010 (09250-10011), 09950-70010 (09951-07100) Using SST and a press, install the rear bearing outer race and adjusting washer. SST 09502-24010 (09250-10011), 09950-70010 (09951-07100)
65. INSTALL DIFFERENTIAL DRIVE PINION Using SST and a press, install the front bearing outer race. SST 09950-60020 (09951-00710), 09950-70010 (09951-07100) Install the drive pinion in the differential carrier. Using SST and a press, install the front bearing on the drive pinion. SST 09316-60011 (09316-00011), 09608-04031, HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern. Using SST and a press, install the companion flange. SST 09223-6011, 09325-40010
66. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD Adjust the drive pinion preload by tightening the companion flange nut. Torque: 490 N.m (5,000 kgf.cm, 361 ft.lbf) or less HINT: Using SST to hold the flange, tighten the nut. SST 09950-30012 (09955-03040), 09229-55010, 09330-00021 NOTE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. Using SST and a torque wrench, measure the preload. SST 09229-55010 Preload (at starting): New bearing: 1.5-1.8 N.m (15-18 kgf.cm, 13.0-15.6 in.lbf) Reused bearing: 0.5-0.8 N.m (5-8 kgf.cm, 4.3-6.9 in.lbf) HINT: For vehicles which have run 8,000 km (5,000 miles) or less, if the preload value measured before disassembly is greater than the specification for a reused bearing, return the preload to the same as before disassembly.
67. INSTALL REAR DEFERENTIAL CASE SUB-ASSY Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
68. INSTALL REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY Using SST and a hammer, install the 2 carrier retainers. SST 09950-60020 (09951-00890), 09950-70010 (09951-07150) Tighten the 16 bolts. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf)
69. ADJUST DIFFERENTIAL RING GEAR BACKLASH Using a dial indicator, measure the backlash of the ring gear at 3 positions at least. Backlash: 0.08-0.13 mm (0.0031-0.0051 in.) NOTE: The difference between the maximum and minimum measure values must be less than 0.05 mm (0.0020 in.). HINT: The measured values should be used as reference when selecting washers, so take a note of the values. If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.
70. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead. Hold the companion flange firmly and rotate the ring gear in both directions. Inspect the tooth contact pattern. If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it. NOTE: Make sure to always use a new one when replacing adjusting washer. HINT: Refer to the chart for selection of the adjusting washer. HINT: Adjust washers in 42 (different thickness in 0.01 mm (0.004 in.)) units are available.
71. INSPECT TOTAL PRELOAD Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. SST 09229-55010 Total preload (at starting): Drive pinion preload plus 0.5-0.8 N.m (5-8 kgf.cm, 4.3-6.9 in.lbf) If the measured preload is less than the specification, replace the washer of the ring gear's tooth surface side with a thicker one. If the preload is greater than the specification, replace the washer of the ring gear's tooth surface side with a thinner one. HINT: Changing the snap ring thickness by 0.02 mm (0.0008 in.) will change the total preload by approx. 0.1 N.m (1 kgf.cm, 0.9 in.lbf).
72. REMOVE REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY (See step 35 SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09955-04061, 09954-04010, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
73. REMOVE REAR DEFERENTIAL CASE SUB-ASSY (See step 36
74. REMOVE REAR DRIVE PINION NUT (See step 37 SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
75. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (See step 38 SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)
76. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER (See step 41
77. REMOVE DIFFERENTIAL DRIVE PINION (See step 42
78. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (See step 44
79. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Install a new spacer on the drive pinion.
80. INSTALL DIFFERENTIAL DRIVE PINION (See step 65 SST 09316-60011 (09316-00011), 09608-04031
81. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
82. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, install a new dust deflector. SST 09316-60011 (09316-00011)
83. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Apply MP grease to a new oil seal lip. Using SST, install the oil seal until its end is flush with the surface of the differential carrier. SST 09316-60011 (09316-00011, 09316-00041), 09502-12010
84. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR Using SST and a press, install the companion flange. SST 09950-30012, 09223-56010, 09325-40010 NOTE: Be careful not to damage the oil seal.
85. INSTALL REAR DEFERENTIAL CASE SUB-ASSY (See step 61)
86. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST and a press, install 2 new oil seals to the carrier retainers. SST 09608-32010, 09950-70010 (09951-07150) Coat the MP grease to the oil seal lip.
87. INSTALL REAR DIFFERENTIAL CARRIER RETAINER O-RING Coat 2 new O-rings with hypoid gear oil. Install the 2 O-rings to the carrier retainers.
88. INSTALL REAR DIFFERENTIAL CARRIER RETAINER SUB-ASSY Using SST and a hammer, install the carrier retainer. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) NOTE: Do not damage the differential case. Install the 16 bolts and carrier retainer. Torque: 22 N.m (225 kgf.cm 16 ft.lbf)
89. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD Coat the threads and flange of a new nut with hypoid gear oil for LSD. Using SST, tighten the nut. SST 09229-55010, 09330-00021, 09950-30012 (09955-03040) Using SST and a torque wrench, measure the preload. SST 09229-55010 Preload (at starting): New bearing: 1.5-1.8 N.m (15-18 kgf.cm, 13.0-15.6 in.lbf) Reused bearing: 0.5-0.8 N.m (5-8 kgf.cm, 4.3-6.9 in.lbf) If the preload is greater than the specification, replace the spacer. If the preload is less than the specification, retighten the nut with a force of 13 N.m (130 kgf.cm, 9 ft.lbf) at a time until the specified preload is reached. Torque: 490 N.m (5,000 kgf.cm, 361 ft.lbf) or less If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.
90. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION (See step 28
91. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER Using SST and a hammer, install a new dust cover. SST 09550-55011 (09550-05061), 09950-70010 (09951-07100), 09502-24010
92. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY Using needle nose pliers, install 2 new snap rings to the side gear shafts. Coat the MP grease to the snap rings. Using a brass bar and a hammer, install the 2 side gear shafts. HINT: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in. NOTE: Be careful not to damage the oil seal.
93. INSPECT TOTAL PRELOAD (See step 30 SST 09229-55010
94. INSTALL REAR DRIVE PINION NUT Using a chisel and a hammer, calking the nut.
95. REMOVE DIFFERENTIAL CARRIER ASSY REAR Remove the differential carrier from the overhaul stand, etc.
96. INSTALL REAR DIFFERENTIAL CARRIER COVER Clean the contact surfaces of the carrier and cover of any residual FIPG material using cleaner. Coat FIPG to the carrier or cover. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent Install the carrier cover to the carrier with the 8 bolts. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) HINT: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is for an hour or more. Also, for 12 hours or more, avoid rapid acceleration/deceleration. Install the breather plug. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
97. INSTALL DIFFERENTIAL CARRIER ASSY REAR Install the 2 upper mount stoppers on the rear differential carrier assembly. HINT: Use the upper mount stopper which was removed. Support the rear differential carrier assembly with a jack and temporally install the lower mount stoppers and 2 new front side set bolts. NOTE: Do not let the rear differential carrier assembly interfere with the drive shaft. Using a hexagon wrench (12 mm), install the 3 rear side set hexagon bolts. Torque: 142 N.m (1,450 kgf.cm, 105 ft.lbf) Torque the 2 front side set bolts. Torque: 123 N.m (1,250 kgf.cm, 90 ft.lbf) Lower the jack.
98. INSTALL REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), install the drain plug with a new gasket. Torque: 49 N.m (500 kgf.cm, 39 ft.lbf)
99. ADD DIFFERENTIAL OIL Fill the rear differential carrier assy 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: 1.35 +/- 0.05 liters (1.43 +/- 0.05 US qts, 1.19 +/- 0.06 Imp. qts)
100. INSPECT DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-183290-S30461918542005081300000) )
101. INSTALL REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), install the filler plug with a new gasket. Torque: 49 N.m (500 kgf.cm, 39 ft.lbf)
102. INSTALL REAR DRIVE SHAFT ASSY LH Align the matchmarks, and connect the drive shaft to the side gear shaft. NOTE: Be careful not to damage the boots and end cover. Using a hexagon wrench (8 mm), install the 3 washers and 6 hexagon bolts, while applying the brakes. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf)
103. INSTALL REAR DRIVE SHAFT ASSY RH HINT: Install the RH side using the same procedures as LH side.
104. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 LH Connect the rear suspension arm assy No. 2 LH to the axle carrier with the cam bolt, cam plate and nut. NOTE: Do not torque the nut.
105. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Install the LH side by the same procedures with RH side.
106. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Connect the rear suspension arm assy No. 1 LH to the axle carrier with the bolt and nut. NOTE: Do not torque the nut.
107. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Install the RH side by the same procedures with LH side.
108. INSTALL REAR SUSPENSION MEMBER BRACE RH Install the rear suspension member brace with the 2 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) HINT: Install the LH side by the same procedures with RH side.
109. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 Install the front floor heat insulator No. 1 with the 4 bolts. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
110. INSTALL PARKING BRAKE CABLE HEAT INSULATOR Install the parking brake cable heat insulator with the 4 bolts. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
111. INSTALL REAR WHEEL Install the rear wheel with the 5 nuts. Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) Install the ornament with the 10 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
112. STABILIZE SUSPENSION (See «REAR -- SC430»(ref-165245) )
113. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Align the matchmarks, and fully tighten the nut. Torque: 110 N.m (1,120 kgf.cm, 81 ft.lbf)
114. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Install the RH side by the same procedures with LH side.
115. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Fully tighten the nut. Torque: 75 N.m (765 kgf.cm, 55 ft.lbf)
116. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Install the RH side by the same procedures with LH side.
117. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (See «PROPELLER W/CENTER BEARING SHAFT ASSY»(ref-183293-S33771753112005081300000) )
118. INSTALL EXHAUST PIPE ASSY (See «EXHAUST SYSTEM»(ref-183320) )
119. INSTALL BODY RR END MOUNTING BRACKET SUB-ASSY Install the body RR end mounting bracket sub-assy with the 8 bolts and 3 nuts. Torque: Bolt (A): 103 N.m (1,050 kgf.cm, 76 ft.lbf) Bolt (8): 69 N.m (704 kgf.cm, 51 ft.lbf) Nut: 54 N.m (551 kgf.cm, 40 ft.lbf)
120. INSTALL RR END BODY MOUNTING SET PLATE Install the RR end body mounting set plate with the 4 bolts. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf)
121. INSTALL RR END BODY MOUNTING SET PLATE Install the RR end body mounting set plate with the 4 bolts. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf)
122. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH Install the RR suspension member brace rear lower RH with the 2 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
123. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH HINT: Install the LH side by the same procedures with RH side.
124. INSTALL FRONT FLOOR BRACE CENTER Install the front floor brace CTR with the 4 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
125. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See «REAR WHEEL ALIGNMENT»(ref-183288) )
126. CHECK EXHAUST GAS LEAK (See «EXHAUST SYSTEM»(ref-183320) )