DIFFERENTIAL GEAR OILRFD-9
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
RFD
N
O P
DIFFERENTIAL GEAR OIL
Changing Differential Gear OilINFOID:0000000001327495
DRAINING
1. Stop engine.
2. Remove drain plug (1) and drain gear oil.
3. Set a gasket on drain plug (1) and install it to final drive assem- bly and tighten to the specified torque. Refer to RFD-17, "
Disas-
sembly and Assembly".
CAUTION:
Never reuse gasket.
FILLING
1. Remove filler plug (1). Fill with new gear oil until oil level reaches the specified level near filler plug mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug (1), then install it to final drive assembly. Refer to RFD-17, "
Disas-
sembly and Assembly".
CAUTION:
Never reuse gasket.
Checking Differential Gear OilINFOID:0000000001327496
OIL LEAKAGE AND OIL LEVEL
Make sure that oil is not leaking from final drive assembly or around it.
Remove filler plug (1) and check oil level from filler plug mounting hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
Set a gasket on filler plug (1) and install it on final drive assembly.
Refer to RFD-17, "
Disassembly and Assembly".
CAUTION:
Never reuse gasket.
PDIA0748J
Oil grade and Viscosity:
Refer to MA-9, "
Fluids and Lubricants".
Oil capacity:
Approx. 1.4 (3 US pt, 2-1/2 Imp pt)
PDIA0749J
PDIA0749J
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
FRONT OIL SEALRFD-13
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
RFD
N
O P
5. Tighten to drive pinion lock nut, while adjust total preload torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
If the preload torque exceeds the specified value, replace
collapsible spacer and tighte n it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
6. Make a stamping for identificati on of front oil seal replacement
frequency. Refer to "IDENTIFICATION STAMP OF REPLACE-
MENT FREQUENCY OF FRONT OIL SEAL".
CAUTION:
Be sure to make a stamping after replacing front oil seal.
7. Install propeller shaft. Refer to PR-9, "
Removal and Installation".
8. Install side flange with the following procedure.
a. Attach the protector to side oil seal.
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the pro-
tector.
c. Put a suitable drift on the center of side flange, then drive it until sound changes.
NOTE:
When installation is completed, driving sound of the side flange turns into a sound which seems to affect
the whole final drive.
d. Confirm that the dimension of the side flange installation (Mea- surement A) in the figure comes into the following.
9. Install drive shaft. Refer to RAX-10
.
10. Install rear wheel sensor. Refer to BRC-52
.
11. Install center muffler. Refer to EX-3
.
12. Refill gear oil to the final drive and check oil level. Refer to RFD-
9, "Changing Differential Gear Oil".
13. Check the final drive for oil leakage. Refer to RFD-9, "
Checking
Differential Gear Oil".
Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque:
147 - 323 N·m (15 - 32 kg-m, 109 - 238 ft-lb)
Total preload torque: Total preload torque should equal the measurement tak-
en during removal plus an ad ditional 0.1 - 0.4 N·m (0.01 -
0.04 kg-m, 1 - 3 in-lb).
Tool number : KV38107900 (J-39352)
PDIA0981E
SDIA0822E
Measurement A: 326 - 328 mm (12.83 - 12.91 in)
SDIA1039E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
SIDE OIL SEALRFD-15
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
RFD
N
O P
2. Install side oil seal until it becomes flush with the case end, using the drift.
CAUTION:
Never reuse oil seal.
When installing, never incline oil seal.
3. Install side flange with the following procedure.
a. Attach the protector to side oil seal.
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the pro-
tector.
c. Put a suitable drift on the center of side flange, then drive it until sound changes.
NOTE:
When installation is completed, driving sound of the side flange turns into a sound which seems to affect
the whole final drive.
d. Confirm that the dimension of the side flange installation (Mea- surement A) in the figure comes into the following.
4. Install drive shaft. Refer to RAX-10
.
5. Install rear wheel sensor. Refer to BRC-52
.
6. Install center muffler. Refer to EX-3, "
Component".
7. When oil leaks while removing, check oil level after the installa- tion. Refer to RFD-9
.
Tool number : KV38100200 (J-26233)
SDIA1585E
Tool number : KV38107900 (J-39352)
SDIA0822E
Measurement A: 326 - 328 mm (12.83 - 12.91 in)
SDIA1039E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
REAR FINAL DRIVE ASSEMBLYRFD-17
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
RFD
N
O P
8. Remove the mounting bolts and nuts connecting to the suspen- sion member, and remove rear final drive assembly with a power
tool.
CAUTION:
Secure rear final drive assembly to a suitable jack while
removing it.
INSTALLATION
Note the following, and installation is in the reverse order of removal.
Refer to "COMPONENTS" about each tightening torque.
When installing breather hoses (1), refer to the figure.CAUTION:
Make sure there are no pinched or restricted areas on the
breather hose caused by bending or winding when installing
it.
- For installation, the vehicle side end shall be inserted to suspen- sion member (2). Install metal connector (3) side of this hose to
rear cover by inserting it with aiming painted marking to the front of
vehicle.
When oil leaks while removing final drive assembly, check oil level
after the installation. Refer to RFD-9, "
Checking Differential Gear
Oil".
Disassembly and AssemblyINFOID:0000000001327500
COMPONENTS
SDIA1969J
SDIA1970J
PDIA0754E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
RFD-22
< SERVICE INFORMATION >
REAR FINAL DRIVE ASSEMBLY
Never change the total amount of washers as it will change the bearing preload.
Companion Flange Runout
1. Fit a test indicator to the inner side of companion flange (socket
diameter).
2. Rotate companion flange to check for runout.
3. If the runout value is outside t he runout limit, follow the proce-
dure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90 ° step, and search for the position
where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and
malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.
4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.
CAUTION:
Be careful not to damage the mating surface.
Never insert flat-bladed screwdriver, this way damage the
mating surface.
5. Using two 45 mm (1.77 in) spacers, mount carrier on the attach- ment.Runout limit: 0.08 mm (0.0031 in)
PDIA0490E
Tool number A: KV10111100 (J-37228)
PDIA0756J
Tool number A: KV38100800 (J-25604-01)
PDIA0757J
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
REAR FINAL DRIVE ASSEMBLYRFD-33
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
RFD
N
O P
8. Using the drift, install front oil seal as shown in figure.
CAUTION:
Never reuse oil seal.
When installing, never incline oil seal.
Apply multi-purpose grease onto oil seal lips, and gear oilonto the circumference of oil seal.
9. Install companion flange (1). NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange (1).
10. Apply anti-corrosion oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION:
Never reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
If the preload torque exceeds the specified value, replace collapsible spacer and tighte n it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
After adjustment, rotate dri ve pinion back and forth 2 to 3
times to check for unusual no ise, rotation malfunction,
and other malfunctions.
12. Install differential case assembly. Refer to "Differential Assem- bly".
CAUTION:
Never install rear cover yet.
13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Companion Flange Runout".
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to "Total Preload Torque".
15. Install rear cover. Refer to "Differential Assembly". Tool number A: ST30720000 (J-25405)
PDIA0764J
PDIA0750J
Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque:
147 - 323 N·m (15 - 32 kg-m, 109 - 238 ft-lb)
Drive pinion bearing preload: 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)
PDIA0765J
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
RFD-36
< SERVICE INFORMATION >
REAR FINAL DRIVE ASSEMBLY
13. Insert selected left and right side bearing adjusting washers inplace between side bearings and gear carrier.
14. Align matching marks on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to "COMPONENTS".
16. Using the drift, drive side oil s eals until it becomes flush with the
case end.
CAUTION:
Never reuse oil seal.
When installing, n ever incline oil seal.
Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
17. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "Drive
Gear Runout", "Tooth Contact", "Backlash", "Total Preload Torque".
Recheck above items. Readjust the above description, if necessary.
18. Apply sealant to mating surface of rear cover. Use Genuine Silicone RTV or equivalent. Refer to GI-44
.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
19. Install rear cover on gear carrier and tighten mounting bolts with the specified torque. Refer to "COMPONENTS".
20. Install side flange with the following procedure.
SPD558
SDIA1795E
Tool number : KV38100200 (J-26233)
SPD560
PDIA0961E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
RSU-2
< SERVICE INFORMATION >
PRECAUTIONS
SERVICE INFORMATION
PRECAUTIONS
CautionsINFOID:0000000001327548
• When installing rubber bushings, final tightening must be carried out under unladen conditions with tires on
level ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
Unladen conditions means that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and
mats are in designated positions.
After servicing suspension parts, be sure to check wheel alignment.
Caulking nuts are not reusable. Always use new ones w hen installing. Since new caulking nuts are pre-oiled,
tighten as they are.
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C