Differential Axle Housing: Service and Repair
REMOVAL1. Drain differential gear oil.
Carry out steps 2. to 6. and 14. to 16. on both right and left wheels.
Note that left wheel and its related parts are used in illustrations in this section.
2. Remove rear brake drum. Refer to Brakes and Traction Control.
3. Disconnect brake pipe from wheel cylinder. With right side wheel cylinder, disconnect 2 brake pipes.
4. Remove rear wheel bearing retainer nuts from rear axle housing.
5. Check to ensure that there is clearance between rear wheel bearing retainer and parking brake shoe lever. If no clearance is found, loosen cable locking nut further to obtain clearance.
6. Using special tools (B) & (C) indicated below, draw out axle shaft.
NOTE: Use care not to pull brake back plate along with shaft.
Special Tool:
(C): 09943-35511
(B): 09942-15510 or equivalents.
7. Disconnect brake pipe from flexible hose and remove ring.
8. Remove brake pipe clamps and pipes from axle housing and disconnect breather hose from axle housing.
9. Disconnect propeller shaft and remove propeller shaft from transmission.
10. For jobs hereafter, support rear axle housing by using floor jack under axle housing.
11. Detach ball joint bracket from differential carrier.
12. Remove rear wheel speed sensor cover and disconnect sensor coupler.
13. Remove differential carrier assembly.
14. Loosen rear mount nut of trailing rod but don't remove bolt.
15. Remove shock absorber lower mount bolt.
16. Lower floor jack until tension of suspension coil spring becomes a little loose and remove rear mount bolt of trailing rod.
17. Lower rear axle housing gradually.
18. Remove axle housing.
INSTALLATION
Install removed parts in reverse order of removal, noting the following.
1. Place rear axle housing on floor jack. Then install trailing rod rear mounting bolts (right & left) in proper direction as shown. At this time, mount nuts but don't tighten them.
2. Install coil spring (right & left) on spring seat of axle housing and raise axle housing.
NOTE: When seating coil spring, mate spring end with stepped part of rear axle spring seat as shown.
3. Install lower part of shock absorber to right and left sides of axle housing and install bolts in proper direction as shown in figure. At this time, mount nuts but don't tighten them.
4. Clean mating surfaces of axle housing and differential carrier and apply sealant to housing side.
"A": Sealant 99000-31110 or equivalent.
5. Install differential carrier assembly to axle housing and tighten carrier nuts to specified torque.
Tightening Torque (a): 55 Nm (40.0 ft. lbs.)
6. Install rear upper arm ball joint bracket onto differential carrier and tighten bolts to specified torque. If it is difficult to install bracket bolts, raising or lowering floor jack supporting axle housing will help.
Tightening Torque (b): 50 Nm (36.5 ft. lbs.)
7. Connect sensor coupler and install sensor cover.
8. Install propeller shaft and torque nuts to specification.
Tightening Torque (c): 55 Nm (40.0 ft. lbs.)
9. Remove floor jack from axle housing and connect breather hose onto axle housing and clamp it securely.
10. Connect brake pipes onto axle housing and clamp them securely.
11. Connect brake flexible hose to bracket on axle housing and secure it with E-ring.
12. Connect brake pipe to brake flexible hose and tighten brake pipe flare nut to specified torque.
Tightening Torque (d): 16 Nm (11.5 ft. lbs.)
13. Clean mating surface of axle housing (right & left) with brake back plate and apply sealant as shown.
"A": Sealant 99000-31110 or equivalent.
14. Apply grease to axle shaft inner oil seal lip as shown.
"A": Grease 99000-25010 or equivalent.
15. Apply sealant to mating surface of bearing retainer with brake back plate.
NOTE: Make sure to remove old sealant before applying it anew.
"B": Sealant 99000-31110 or equivalent.
16. Install rear axle shaft to rear axle housing and tighten bearing retainer nuts to specified torque.
NOTE: When installing rear axle shaft, be careful not to cause damage to oil seal lip in axle housing.
Tightening Torque (a): 23 Nm (17.0 ft. lbs.)
17. Connect brake pipes to wheel cylinders (right & left) and tighten brake pipe flare nuts to specified torque.
Tightening Torque (f): 16 Nm (11.5 ft. lbs.)
18. Install brake drum (right & left). Refer to Brakes and Traction Control.
19. Refill differential gear housing with new specified gear oil.
20. Fill reservoir with brake fluid and bleed brake system. Refer to Brakes and Traction Control.
21. Install wheel and tighten wheel nuts to specified torque.
Tightening Torque (g): 95 Nm (69.0 ft. lbs.)
22. Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable. Refer to Brakes and Traction Control.
23. Tighten parking brake lever cover screws.
24. Lower hoist.
25. Tighten right and left trailing rod nuts and shock absorber nuts to specified torque.
NOTE: When tightening these nuts, be sure that vehicle is off hoist and in non loaded condition.
Tightening Torque:
(h): 90 Nm (65.0 ft. lbs.)
(i): 85 Nm (61.5 ft. lbs.)
26. Check to ensure that brake drum is free from dragging and proper braking is obtained.
27. Perform brake test (foot brake and parking brake).
28. Check each installed part for oil leakage.