Differential Axle Housing: Service and Repair
RemovalNOTE: Note that left wheel and its related parts are used in the following illustrations.
1. Drain differential gear oil. Carry out Steps (2) to (7) and (15) to (18) on both right and left wheels.
2. Remove rear brake drum.
3. Disconnect brake pipe (2) from wheel cylinder. With right side wheel cylinder, disconnect 2 brake pipes.
4. For vehicle with ABS, disconnect wheel speed sensor coupler (2) and remove wheel speed sensor with its harness (4).
5. Remove rear wheel bearing retainer nuts (1) from rear axle housing.
6. Check to ensure that there is clearance (3) between rear wheel bearing retainer (1) and parking brake shoe lever (2). If no clearance is found, loosen cable locking nut further to obtain clearance.
7. Using special tools, draw out axle shafts. For vehicle equipped with ABS, remove wheel speed sensor from axle housing before drawing out axle shaft.
NOTE: Use care not to pull brake back plate along with shaft.
Special tool
(B): 09942-15510
(C): 09943-35512
8. Remove LSPV stay (1) from axle housing (if equipped with LSPV).
9. Remove brake back plate from rear axle housing.
10. Disconnect brake pipe (3) from flexible hose (1) and remove E-ring (front side) (2).
11. Remove brake pipe clamps and pipes from axle housing and disconnect breather hose (1) from axle housing (2).
12. Disconnect propeller shaft (1) and remove propeller shaft (1) from differential carrier (2).
13. For jobs hereafter, support rear axle housing (1) by using floor jack (2).
14. Remove differential carrier assembly (1).
15. Loosen rear mount nut of upper rod but don't remove bolt.
16. Loosen rear mount nut (2) of lower rod (1) but don't remove bolt.
17. Remove rear axle side lateral rod mount bolt.
18. Remove shock absorber lower mount bolt (1).
19. Lower floor jack until tension of suspension coil spring becomes a little loose and remove rear mount bolt of upper, lower and lateral rod.
20. Lower rear axle housing (1) gradually.
21. Remove axle housing (1).
Installation
Install removed parts in reverse order of removal, noting the followings.
1. Place rear axle housing on floor jack. Then install upper/lower rod rear mounting bolts (right and left) in proper direction as shown in the figure. At this time, mount nuts but don't tighten them.
2. Install coil spring (right and left) (3) on spring seat (2) of axle housing (1) and raise axle housing (1).
NOTE: When seating coil spring (3), mate spring end with stepped part (4) of rear axle spring seat (2) as shown in the figure.
3. Install lateral rod to rear axle housing.
4. Install lower part of shock absorber to right and left sides of axle housing and install bolts in proper direction as shown in the figure. At this time, mount nuts but don't tighten them.
5. Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side.
"A": Sealant 99000-31110
6. Install differential carrier assembly to axle housing and tighten carrier nuts to specified torque.
Tightening torque
Differential carrier nut (a): 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
7. For vehicle with ABS, connect wheel speed sensor coupler and install harness clamp.
8. Install propeller shaft and tighten nuts to specified torque.
Tightening torque
Propeller shaft nut (a): 50 Nm (5.0 kg-m, 36.5 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. Install LSPV stay to axle housing, tighten LSPV stay bolt to specified torque.
13. Adjust LSPV.
Tightening torque
LSPV stay bolt (a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
14. Connect brake pipe to brake flexible hose and tighten brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (b): 16 Nm (1.6 kg-m, 11.5 ft. lbs.)
15. Clean mating surface of axle housing (1) (right and left) and brake back plate, then apply sealant "A" as shown in the figure.
"A": Sealant 99000-31110
16. Apply grease "A" to axle shaft inner oil seal lip as shown in the figure.
"A": Grease 99000-25010
17. Apply sealant "B" to mating surface of bearing retainer (1) with brake back plate.
NOTE: Make sure to remove old sealant before applying it a new.
"B": Sealant 99000-31110
18. 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
Bearing retainer nut (a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
19. For vehicle with ABS, tighten wheel speed sensor bolt to specified torque.
Tightening torque
Wheel speed sensor bolt (a): 21 Nm (2.1 kg-m, 15.5 ft. lbs.)
20. Connect brake pipes to wheel cylinders (right and left) and tighten brake pipe flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 Nm (1.6 kg-m, 11.5 ft. lbs.)
21. Install brake drum (right and left).
22. Refill differential gear housing with new specified gear oil.
23. Fill reservoir with brake fluid and bleed brake system.
24. Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nut (a): 100 Nm (10.0 kg-m, 72.5 ft. lbs.)
25. Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs.) load three to ten times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable.
26. Tighten parking brake lever cover screws.
27. Lower hoist.
28. Tighten right and left lower/upper rod nuts, lateral rod mount bolt and shock absorber lower nuts to specified torque.
NOTE: When tightening these nuts, be sure that vehicle is off hoist and in non-loaded condition.
29. Check to ensure that brake drum is free from dragging and proper braking is obtained.
30. Perform brake test (foot brake and parking brake).
31. Check each installed part for oil leakage.