REAR AXLE SECTION RAX CONTENTS TRANSMISSION & DRIVELINE RAX-1 REMOVAL AND INSTALLATION... 8 PRECAUTION... 2 PREPARATION... 3 SYMPTOM DIAGNOSIS...

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1 TRSSS & DRV ST RX RR X RX TTS RUT... 2 RUTS... 2 recautions for Drive Shaft...2 RRT... 3 RRT... 3 Special Service Tools...3 ommercial Service Tools...3 SYT DSS... 5 S, VRT D RSSS (V) TRUST... 5 V Troubleshooting hart...5 RD T... 6 RR W U D US... 6 nspection nspection...7 RV D STT... 8 RR W U D US... 8 xploded View... 8 Removal and nstallation... 8 nspection xploded View...11 Removal and nstallation...12 W SD...13 W SD : Disassembly and ssembly...13 DRV SD...15 DRV SD : Disassembly and ssembly...16 nspection...18 SRV DT D STS (SDS)...19 SRV DT D STS (SDS)...19 Wheel earing...19 Drive Shaft...19 RX-1

2 < RUT > RUT RUTS recautions for Drive Shaft RUTS D: bserve the following precautions when disassembling and assembling drive shaft. - ever disassemble joint sub-assembly because it is non-overhaul parts. - erform work in a location which is as dust-free as possible. - lean the parts, before disassembling and assembling. - revent the entry of foreign objects during disassembly of the service location. - Reassemble disassembled parts carefully in the correct order. f work is interrupted, a clean cover must be placed over parts. - Use paper waste. abric shop cloths must not be used because of the danger of lint adhering to parts. - lean disassembled parts (except for rubber parts) with kerosene which shall be removed by blowing with air or wiping with paper waste. RX-2

3 < RRT > RRT RRT Special Service Tools RRT The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. D: Tool number (ent-oore o.) Tool name Description V ( ) oot band crimping tool nstalling boot band RX ZZ1229D V (-34296) rotector a: 36 mm (1.42 in) dia. nstalling drive shaft (VQ37VR) D1183 V (-33904) rotector a: 40 mm (1.57 in) dia. nstalling drive shaft (V56VD) ommercial Service Tools D1183 D: Tool name Description ower tool oosening bolts and nuts 0190 all joint remover Removing ball joint for suspension arm T146 RX-3

4 < RRT > RRT Tool name Drive shaft puller Description Remove drive shaft joint sub assembly D0152ZZ Replacer Remove sensor rotor ZZ0700D uller Remove sensor rotor ZZ0119D Drift a: pprox. 85 mm (3.35 in) dia. b: mm ( in) dia. c: 108 mm (4.25 in) or more nstalling sensor rotor S-T117 RX-4

5 S, VRT D RSSS (V) TRUST < SYT DSS > SYT DSS S, VRT D RSSS (V) TRUST V Troubleshooting hart D: Use chart below to find the cause of the symptom. f necessary, repair or replace these parts. Reference page RX-18 RX-8 V in D section. V in D section. V in RX and RSU sections. Refer to RR X in this chart. V in WT section. V in WT section. Refer to DRV ST in this chart. V in R section. V in ST section. RX ossible cause and SUSTD RTS xcessive joint angle oint sliding resistance mbalance mproper installation, looseness arts interference RR ST DRT RR X D RR SUSS RR X TR RD W DRV ST R STR DRV ST oise Shake oise Symptom RR X Shake Vibration Shimmy udder oor quality ride or handling : pplicable RX-5

6 RR W U D US < RD T > RD T RR W U D US nspection D: UT ST ake sure the mounting conditions (looseness, back lash) of each component and component conditions (wear, damage) are normal. W R ST ove wheel hub and bearing assembly in the axial direction by hand. ake sure there is no looseness of wheel bearing. xial end play : Refer to RX-19, "Wheel earing". Rotate wheel hub and bearing assembly and make sure that is no unusual noise or other irregular conditions. f there is any of irregular conditions, replace wheel hub and bearing assembly. RX-6

7 < RD T > nspection D: heck drive shaft mounting point and joint for looseness and other damage. heck boot for cracks and other damage. Replace entire drive shaft assembly when noise or vibration occurs from drive shaft. RX RX-7

8 RR W U D US < RV D STT > RV D STT RR W U D US xploded View D: D all seat 2. ushing 3. xle housing 4. otter pin 5. ack plate 6. nchor block 7. Wheel hub and bearing assembly 8. Disc rotor 9. lug 10. Spring washer 11. Wheel hub lock nut 12. djusting cap. Tightening must be done following the installation procedure. Refer to RX-8, "Removal and nstallation". Refer to -4, "omponents" for symbols in the figure. Removal and nstallation D: RV Wheel ub and earing ssembly 1. Remove tire from vehicle with power tool. Refer to WT-68, "Removal and nstallation". 2. Remove caliper assembly. ang caliper assembly in a place where it will not interfere with work. Refer to R-56, "R R SSY (1 ST TY) : Removal and nstallation" (1 piston type), R- 60, "R R SSY (2 ST TY) : Removal and nstallation" (2 piston type). ever depress brake pedal while brake caliper is removed. 3. Remove disc rotor. f disc rotor cannot be removed, remove as follows. arking brake completely in the released position. ut matching marks on the wheel hub and bearing assembly and the disc rotor before removing the disc rotor. ever drop disc rotor. a. ix the disc rotor with wheel nuts and remove the adjusting hole plug. RX-8

9 < RV D STT > RR W U D US b. Using suitable tool, rotate adjuster (1) in the direction () to retract and loosen brake shoe. 4. Remove parking brake shoe and parking brake cable from back plate. Refer to -8, "Removal and nstallation" and -6, "Removal and nstallation". 5. Set suitable jack under axle housing. heck that jack supporting status is stable. 6. Remove shock absorber from axle housing with power tool. Refer to RSU-8, "Removal and nstallation". 7. Remove toe control link from axle housing. (Without 4WS) Refer to RSU-19, "Removal and nstallation". 8. Remove 4WS rear actuator assembly from axle housing. (With 4WS) Refer to ST-187, "Removal and nstallation". 9. Remove rear lower link from axle housing side. Refer to RSU-17, "Removal and nstallation". 10. Remove front lower link from axle housing side. Refer to RSU-15, "Removal and nstallation". 11. Remove height sensor from suspension arm (left side). (With S) Refer to X-128, "Removal and nstallation". 12. Remove stabilizer connecting rod from suspension arm. Refer to RSU-21, "Removal and nstallation". 13. Remove cotter pin and adjusting cap, then loosen wheel hub lock nut with a power tool. 14. ut matching mark () on drive shaft and wheel hub and bearing assembly. Use paint or similar substance for matching marks. ever scratch the surface. 15. atch wheel hub lock nut with a piece of wood. ammer the wood to disengage wheel hub and bearing assembly from drive shaft. Take out the wheel hub lock nut and spring washer. ever place drive shaft joint at an extreme angle. lso be careful not to overextend slide joint. ever allow drive shaft to hang down without support for counterpart such as joint sub-assembly, and other parts. T: Use a suitable puller, if the wheel hub and bearing assembly and drive shaft cannot be separated even after performing the above procedure. 16. Remove wheel hub lock nut and spring washer. 17. Remove drive shaft from axle housing. 18. Remove cotter pin, then loosen suspension arm mounting nut of axle housing. 19. Separate suspension arm from axle housing, using ball joint remover, and then remove axle housing from the vehicle. ever damage ball joint boot. Temporarily tighten nuts to prevent damage to threads and to prevent the ball joint remover from coming off. ever place drive shaft joint at an extreme angle. lso be careful not to overextend slide joint. ever allow drive shaft to hang down without support for counterpart such as joint sub-assembly, and other parts. 20. Remove axle housing. 21. Remove wheel hub and bearing assembly. 22. Remove anchor block and back plate. STT ote the following, and install in the reverse order of removal. lean the matching surface of wheel hub lock nut and wheel hub and bearing assembly. ever apply lubricating oil to these matching surface. RX ZZ D0121ZZ RX

10 RR W U D US < RV D STT > lean the matching surface of drive shaft and wheel hub and bearing assembly. nd then apply paste [service parts (440037S000)] to surface () of joint sub-assembly of drive shaft. pply paste to cover entire flat surface of joint sub-assembly of drive shaft. mount paste g ( oz) When installing drive shaft, change the drive shaft and wheel hub and bearing assembly matching marks put at the removal step by 180 degree. Use the following torque range for tightening the wheel hub lock nut. D0122ZZ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel hub lock nut. e sure to use torque wrench to tighten the wheel hub lock nut. ever use a power tool. T: Wheel hub lock nut tightening torque does not over torque for avoiding axle noise, and does not less than torque for avoiding looseness. erform the final tightening of each of parts under unladen conditions, which were removed when removing wheel hub and bearing assembly and axle housing. When installing the spring washer, face the identification paint mark to the wheel hub and bearing assembly side. When installing the adjusting cap, check that there must be no play. ever reuse cotter pin, wheel hub lock nut, spring washer, and bushing. nspection : m (10 11 kg-m, ft-lb) ST TR RV Wheel ub and earing ssembly heck the wheel hub and bearing assembly for wear, cracks, and damage. Replace if necessary. xle ousing heck the axle housing for wear, cracks, and damage. Replace if necessary. D: all oint nspection heck for boot breakage, axial looseness, and torque of suspension arm ball joint. Refer to RSU-13, "nspection and djustment". ST TR STT 1. djust parking brake operation (stroke). Refer to -3, "nspection and djustment". 2. heck wheel alignment. Refer to RSU-6, "nspection". 3. djust neutral position of steering angle sensor. Refer to R-68, "Work rocedure". 4. djust levelizer adjustment of height sensor. (With S) Refer to X-64, "VZR DUSTT : Special Repair Requirement". RX-10

11 < RV D STT > xploded View D: VQ37VR RX D0176ZZ 1. Dust shield 2. Sensor rotor 3. ousing 4. Stopper ring 5. all cage/steel ball/inner race assembly 6. Stopper ring 7. oot band 8. oot 9. Shaft 10. ircular clip 11. oint sub-assembly : Wheel side 1: SS genuine grease or an equivalent. 2: pply paste [service parts (440037S000)]. Refer to -4, "omponents" for symbols not described on the above. V56VD D0190ZZ 1. Dust shield 2. Sensor rotor 3. ousing 4. Stopper ring 5. all cage/steel ball/inner race assembly 6. Stopper ring 7. oot band 8. oot 9. Shaft RX-11

12 < RV D STT > Removal and nstallation 10. ircular clip 11. oint sub-assembly : Wheel side 1: SS genuine grease or an equivalent. 2: pply paste [service parts (440037S000)]. Refer to -4, "omponents" for symbols not described on the above. D: RV 1. Remove tire from vehicle with power tool. Refer to WT-68, "Removal and nstallation". 2. Remove center muffler. Refer to X-6, "VQ37VR : Removal and nstallation" (VQ37VR) or X-7, "V56VD : Removal and nstallation" (V56VD). 3. Remove rear propeller shaft. Refer to D-101, "Removal and nstallation" (2WD) or D-108, "Removal and nstallation" (WD). 4. Remove stabilizer bar. Refer to RSU-21, "Removal and nstallation". 5. Remove wheel sensor. Refer to R-138, "RR W SSR : Removal and nstallation". 6. Separate drive shaft from rear final drive assembly. ever damage sensor rotor. T: Release the circular clip lock. 7. Remove rear final drive assembly. Refer to D-171, "Removal and nstallation" (VQ37VR) or D-210, "Removal and nstallation" (V56VD). 8. Remove cotter pin and adjusting cap, then loosen wheel hub lock nut with power tool. 9. ut matching mark () on drive shaft and wheel hub and bearing assembly. Use paint or similar substance for matching marks. ever scratch the surface. 10. atch wheel hub lock nut with a piece of wood. ammer the wood to disengage wheel hub and bearing assembly from drive shaft. T: Using a suitable puller if the wheel hub and bearing assembly and drive shaft cannot be separated even after performing the D0121ZZ above procedure. 11. Remove wheel hub lock nut and spring washer. 12. Remove drive shaft from axle housing. STT Wheel Side ote the following, and install in the reverse order of removal. lean the matching surface of wheel hub lock nut and wheel hub and bearing assembly. ever apply lubricating oil to these matching surface. RX-12

13 < RV D STT > lean the matching surface of drive shaft and wheel hub and bearing assembly. nd then apply paste [service parts (440037S000)] to surface () of joint sub-assembly of drive shaft. pply paste to cover entire flat surface of joint sub-assembly of drive shaft. mount paste g ( oz) When installing drive shaft, change the drive shaft and wheel hub and bearing assembly matching marks put at the removal step by 180 degree. Use the following torque range for tightening the wheel hub lock nut. : m (10 11 kg-m, ft-lb) D0122ZZ RX Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel hub lock nut. e sure to use torque wrench to tighten the wheel hub lock nut. ever use a power tool. T: Wheel hub lock nut tightening torque does not over torque for avoiding axle noise, and does not less than torque for avoiding looseness. erform the final tightening of each of parts under unladen conditions, which were removed when removing wheel hub and bearing assembly and axle housing. When installing the spring washer, face the identification paint mark to the wheel hub and bearing assembly side. When installing the adjusting cap, check that there must be no play. ever reuse cotter pin, wheel hub lock nut, and spring washer. inal Drive Side Replace rear final drive side oil seal. Refer to D-170, "Removal and nstallation" (VQ37VR) or D-209, "Removal and nstallation" (V56VD). lace the protector () [SST:V (-34296)] (VQ37VR) or [SST:V (-33904)] (V56VD) onto final drive to prevent damage to the oil seal while inserting drive shaft. Slide drive shaft sliding joint and tap with a hammer to install securely. heck that circular clip is completely engaged. W SD W SD : Disassembly and ssembly DSSSY 1. ix shaft with a vise. rotect shaft when fixing with a vise using aluminum or copper plates. 2. Remove dust shield from joint sub-assembly. 3. Remove boot bands and then remove boot from joint sub-assembly. D0023ZZ D: RX-13

14 < RV D STT > 4. Screw the drive shaft puller () (commercial service tool) 30 mm (1.18 in) or more into the thread of joint sub-assembly, and remove joint sub-assembly from shaft. f joint sub-assembly cannot be removed after five or more unsuccessful attempts, replace shaft and joint sub assembly as a set. lign sliding hammer and drive shaft and remove them by pulling directory. 5. Remove circular clip from shaft. 6. Remove boot from shaft. SSY 1. lean old grease on joint sub-assembly with paper waste. 2. ill serration slot joint sub-assembly (1) with SS genuine grease or equivalent until the serration slot and ball groove become full to the brim. fter applying grease, use a shop cloth to wipe off old grease that has oozed out. D0151ZZ D0008ZZ 3. nstall boot and boot bands to shaft. Wrap serration on shaft with tape () to protect the boot from damage. ever reuse boot and boot band. 4. Remove the tape wrapped around the serrated on shaft. 5. osition circular clip on groove at the shaft edge. ever reuse circular clip. T: Drive joint inserter is recommended when installing circular clip. 6. lign both center axles of the shaft edge and joint sub-assembly. Then assemble shaft with circular clip joint sub-assembly. 7. nstall joint sub-assembly to shaft using plastic hammer. onfirm that joint sub-assembly is correctly engaged while rotating drive shaft. 8. pply the balance of the specified amount of grease into the boot inside from large diameter side of boot. D0009ZZ rease amount : Refer to RX-19, "Drive Shaft". R0049D 9. nstall the boot securely into grooves (indicated by * marks) shown in the figure. RX-14

15 < RV D STT > VQ37VR V56VD f grease adheres to the boot mounting surface (indicated by * mark) on the shaft or housing, boot may come off. Remove all grease from the surfaces. 10. To prevent the deformation of the boot, adjust the boot installation length () to the specified value shown below by inserting the suitable tool into inside of the boot from the large diameter side of boot and discharging the inside air. : Refer to RX-19, "Drive Shaft". f the boot installation length is outside the standard, it may cause breakage of the boot. e careful not to touch the inside of the boot with the tip of tool. 11. Secure the ends of the boot with boot bands using the boot band crimping tool () [SST: V ( )]. ever reuse boot band. D0222ZZ D0136ZZ RX D1187 Secure boot band so that dimension () meets the specification as shown in the figure. : mm ( in) 12. Secure joint sub-assembly and shaft, and then make sure that they are in the correct position when rotating boot. nstall them with boot band when boot installation positions become incorrect. ever reuse boot band. 13. nstall dust shield to joint sub-assembly. ever reuse dust shield. DRV SD DS0047D RX-15

16 < RV D STT > DRV SD : Disassembly and ssembly D: DSSSY 1. ix shaft with a vise. rotect shaft when fixing with a vise using aluminum or copper plates. 2. Remove circular clip fom housing. (V56VD) 3. Remove dust shield from housing. 4. Remove sensor rotor from housing, using a replacer (commercial service tool) and a puller (commercial service tool). 5. Remove boot bands, and then remove boot from housing. 6. ut matching marks on housing and shaft. Use paint or similar substance for matching marks. ever scratch the surface. 7. Remove stopper ring with suitable tool, and pull out housing. 8. ut matching marks on ball cage/steel ball/inner race assembly and shaft. Use paint or similar substance for matching marks. ever scratch the surface. D0177ZZ 9. Remove snap ring, then remove ball cage/steel ball/inner race assembly from shaft. 10. Remove boot from shaft. SSY 1. Remove old grease on housing with paper waste. 2. nstall sensor rotor (1) to housing, using a drift () (commercial service tool). ever reuse sensor rotor. 3. nstall boot and boot bands to shaft. Wrap serration shaft with tape () to protect the boot from damage. ever reuse boot and boot band. 4. Remove the tape wrapped around the serrated on shaft. S514 D0184ZZ RX-16

17 < RV D STT > 5. nstall ball cage/steel ball/inner race assembly (1), align it with the matching marks on shaft (2) put during the removal. 6. Secure ball cage/steel ball/inner race assembly onto shaft with snap ring (3). ever reuse snap ring. 7. pply the appropriate amount of grease onto housing and sliding surface. rease amount : Refer to RX-19, "Drive Shaft". 8. nstall housing. 9. nstall stopper ring to housing. ever reuse stopper ring. 10. fter installed, pull shaft to check engagement between housing and stopper ring. 11. nstall boot securely into grooves (indicated by * marks) shown in the figure. VQ37VR D0004ZZ RX D0224ZZ V56VD f grease adheres to the boot mounting surfaces (indicated by * marks) on shaft or housing, boot may be removed. Remove all grease from the surfaces. 12. To prevent the deformation of the boot, adjust the boot installation length () to the value shown below by inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging inside air. : Refer to RX-19, "Drive Shaft". f the boot installation length is outside the standard, it may cause breakage of the boot. e careful not to touch the inside of the boot with the tip of tool. 13. nstall boot bands securely as shown in the figure. ever reuse boot band. 14. heck that location stays in the correct position when housing and shaft are secured and boot is rotated. nstall again when location does not stay in the correct position. ever reuse boot band. 15. nstall circular clip to housing. (V56VD) ever reuse circular clip. D0230ZZ D1188 RX-17

18 < RV D STT > 16. nstall dust shield to housing. ever reuse dust shield. nspection D: ST TR RV ove joint up/down, left/right, and in the axial direction. heck for any rough movement or significant looseness. heck boot for cracks or other damage, and also for grease leakage. f a malfunction is found, disassemble drive shaft, and then replace with new one. heck sensor rotor for cracks or other damage. ST TR SSY heck sensor rotor for cracks or other damage. S108 RX-18

19 SRV DT D STS (SDS) < SRV DT D STS (SDS) SRV DT D STS (SDS) SRV DT D STS (SDS) Wheel earing D: xial end play tem Standard 0.05 mm (0.002 in) or less Drive Shaft D: RX rease quantity oots installed length Standard tem Wheel side inal drive side VQ37VR g ( oz) g ( oz) V56VD g ( oz) g ( oz) VQ37VR mm (5.93 in) mm (7.78 in) V56VD mm (5.36 in) mm (7.73 in) RX-19

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