Part 2

Overhaul Continued





56. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion, rear drive pinion tapered roller bearing and rear differential drive oil slinger.

HINT: Assemble the spacer and oil seal after adjusting the gear con tact pattern.





b. Using SST, install the drive pinion companion flange.
c. Coat the threads of the nut with hypoid gear oil LSD.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





d. Using SST to hold the drive pinion companion flange, tighten the nut.
Torque: 370 Nm (3,770 kgf-cm, 273 ft. lbs.) or less
SST 09330-00021

NOTICE:
^ As there is no spacer, tighten a little at a time, being careful not to overtighten it.
^ Apply hypoid gear oil LSD to the nut.





e. Using a torque wrench, measure the preload. Preload (at starting):
New bearing: 1.05 to 1.64 Nm (10.7 to 16.7 kgf-cm, 9.3 to 14.5 inch lbs.)
Reused bearing: 0.56 to 0.85 Nm (5.7 to 8.7 kgf-cm, 4.9 to 7.5 inch lbs.)





57. INSTALL DIFFERENTIAL CASE ASSY
a. Place the 2 bearing outer races on their corresponding bearings.

HINT: Make sure the right and left races are not interchanged.





58. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT
a. Install the 2 adjusting nuts into the carrier, making sure the nuts are threaded properly.





59. INSPECT AND ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Align the matchmarks on the cap and carrier.
b. Install the right and left bearing caps with the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)

HINT: If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.





c. Tighten the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)
d. Using the SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 inch).
SST 09960-10010 (09962-01000, 09963-00700)





e. While turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side.
SST 09504-00011
f. Using SST, torque the adjusting nut 1 to 1.5 notches from the 0 preload position.





g. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)

HINT: The backlash is adjusted by turning the left and right adjusting nuts for an equal amounts. For example, loosen the nut on the right side by one notch.





h. Torque the bearing cap bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)





60. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf-cm, 3.5 to 5.2 in. lbs.)
If necessary, disassemble and inspect the differential.





61. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.





c. Inspect the tooth contact pattern.





If the teeth are not engaged properly, use the chart to select an appropriate washer for correction.





Plate Washer thickness





62. REMOVE REAR DRIVE PINION NUT
a. Using SST to hold the drive pinion companion flange, remove the nut.
SST 09330-00021





63. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





64. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the drive pinion tapered roller bearing from the drive pinion.
SST 09556-22010





65. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer onto the drive pinion.





66. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the drive pinion, rear drive pinion taper roller bearing and rear differential drive oil slinger.





67. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Apply MP grease to the oil seal lip.
b. Using SST and a hammer, install a new carrier oil seal.
SST 09554-30011
Oil seal drive in depth: 1.0 - 0.45 mm (0.039 + 0.018 inch)





68. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, install the drive pinion companion flange onto the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





b. Coat the threads of a new nut with hypoid gear oil LSD.
c. Using SST to hold the flange, tighten the nut.
Torque: 370 Nm (3,770 kgf-cm, 273 ft. lbs.) or less
SST 09330-00021





69. INSPECT DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.05 to 1.64 Nm (10.7 to 16.7 kgf-cm, 9.3 to 14.5 inch lbs.)
Reused bearing: 0.56 to 0.85 Nm (5.7 to 8.7 kgf-cm, 5.0 to 7.5 inch lbs.)
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut to 13 Nm (130 kgf-cm, 9 ft lbs.) of torque at a time until the specified preload is reached.
Torque: 370 Nm (3,770 kgf-cm, 27 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.





70. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf-cm, 3.5 to 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.





71. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.





72. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the runout of the drive pinion companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
If the runouts are not within the specifications, replace the companion flange.





73. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and hammer, stake the drive pinion nut.





74. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Install 2 new adjust locks onto the bearing caps.
Torque: 13 Nm (129 kgf-cm, 9 ft. lbs.)
b. After tightening the bolts, bend the nut locks.





75. INSTALL REAR DIFFERENTIAL LOCK SHIFT FORK
a. Apply MP grease onto the outer circuit of the shaft.
b. Install the fork shaft to align the hole of the shift fork with that of the shift fork shaft.





c. Remove any FIPG material and be careful not to drop the oil shaft retainer.
d. Apply FIPG to the carrier, as shown in the illustration.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the shaft retainer within 10 minutes of applying FIPG.





e. Clean the threads of the bolts and retainer bolts holes with toluene or trichorethyene
f. Apply adhesive to 2 or 3 threads of each mount bolt end.
Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE: 242 or equivalent
g. Tighten the shaft retainer with the 2 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)





h. Using a 5 mm pin punch and hammer, install the slotted spring pin onto the shift fork.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)





i. Push the differential lock sleeve in deeply and hold it in position.





j. Install the ball, spring and spring seat.
k. Clean the threads of 2 plugs and plug holes with toluene or trichlorethylene.
Adhesive: Part No.08833-00080, THREE BOND 1344, LOCTITE: 242 or equivalent
l. Using a 6 mm hexagon wrench, install and tighten the screw plugs.





76. INSTALL TRANSFER INDICATOR SWITCH NO.1
a. Install the indicator switch with a new gasket.
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)





77. INSPECT REAR DIFFERENTIAL LOCK SLEEVE
a. Measure the distance between the sleeve and tip of the differential case when the differential is FREE and LOCKED respectively.
Standard distance:
LOCKED: 17.44 to 18.86 mm (0.6866 to 0.7425 inch)
FREE: 32.40 to 33.90 mm (1.2756 to 1.3346 inch)





78. INSTALL DIFFERENTIAL LOCK SHIFT ACTUATOR
a. Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole.





b. Ensure that the matchmarks on the pinion of the actuator are in the range between 0 and 5 degrees clockwise above the center line of the actuator.

NOTICE:
^ If the matchmarks are not within this range, rotate the pinion.
^ Don't supply the battery positive voltage directly between terminals.
^ If the matchmarks come to the limit of rotation, don't apply the electric current.

c. Install a new O-ring onto the actuator.
d. Apply a light coat of gear oil to the O-ring.
e. Apply MP grease to the gear part.





f. Ensure that the outermost rack tooth of the shift fork fits the matchmarks on the pinion of the actuator.
g. Install the actuator so that the long hole on the actuator side fits into the knock pin on the carrier side.

HINT: Don't damage the O-ring of the actuator.

h. Align the actuator with the long hole and rotate the actuator counterclockwise when the knock pin is set to the right-hand side.
i. Install and tighten the bolts.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)





79. INSTALL DIFFERENTIAL CARRIER ASSY REAR
a. Remove any dust and oil from the differential carrier assembly and the contact surface of the axle housing.
b. Install the new rear differential carrier gasket and the differential carrier assembly with the 11 nuts and washers.





c. Connect the differential lock actuator connector.
d. Connect the rear differential lock actuator breather hose to the differential actuator assembly.
80. INSTALL REAR AXLE SHAFT W/BACKING PLATE
81. INSTALL REAR AXLE SHAFT W/BACKING PLATE

HINT: Install the RH side by following the same procedures as the LH side.

82. INSTALL PARKING BRAKE CABLE ASSY NO.3
83. INSTALL PARKING BRAKE CABLE ASSY NO.2

HINT: Install the RH side by following the same procedures as the LH side.

84. INSTALL SPEED SENSOR REAR LH
85. INSTALL SPEED SENSOR REAR RH

HINT: Install the RH side by following the same procedures as the LH side.

86. INSTALL PROPELLER SHAFT ASSY (2WD DRIVE TYPE, REGULAR CAB)
87. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (2WD DRIVE TYPE, EXCEPT REGULAR CAB)
88. INSTALL PROPELLER SHAFT ASSY (4WD DRIVE TYPE, REGULAR CAB)
89. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE, EXCEPT REGULAR CAB)
90. INSTALL REAR BRAKE SHOE
SST 09718-00010
91. INSTALL FRONT BRAKE SHOE
SST 09718-00010, 09921-00010
92. CHECK REAR DRUM BRAKE INSTALLATION
93. INSTALL REAR BRAKE DRUM SUB-ASSY
94. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
95. FILL RESERVOIR WITH BRAKE FLUID (W/VSC)
96. FILL RESERVOIR WITH BRAKE FLUID (W/O VSC)
97. BLEED MASTER CYLINDER (W/O VSC)
SST 09023-00101
98. BLEED BRAKE LINE (W/VSC)
99. BLEED BRAKE LINE (W/O VSC)
100. CHECK FLUID LEVEL IN RESERVOIR (W/ VSC)
101. CHECK FLUID LEVEL IN RESERVOIR (W/O VSC)
102. CHECK FOR BRAKE FLUID LEAKAGE
103. ADD DIFFERENTIAL OIL
104. INSPECT DIFFERENTIAL OIL
105. INSPECT FOR DIFFERENTIAL OIL LEAKAGE
106. INSTALL REAR WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 inch lbs.)
107. INSPECT PARKING BRAKE PEDAL TRAVEL (AUTOMATIC TRANSAXLE)
108. INSPECT PARKING BRAKE LEVER TRAVEL (MANUAL TRANSAXLE)
109. ADJUST PARKING BRAKE PEDAL TRAVEL (AUTOMATIC TRANSAXLE)
110. ADJUST PARKING BRAKE LEVER TRAVEL (MANUAL TRANSAXLE)
111. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
112. CHECK ABS SENSOR SIGNAL (W/ VSC)
113. CHECK ABS SENSOR SIGNAL (W/O VSC)