Symptom Suspect Area See page. 3. Shock absorber (Worn out) 3. Shock absorber (Worn out)

Transcription

1 TROUBLESHOOTING PROBLEM SYMPTOMS TABLE TROUBLESHOOTING Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page SA1 SA0OP02 Wander/pulls Bottoming Sways/pitches Front wheel shimmy Abnormal tire wear Noise in rear differential Oil leak from rear differential 1. Tires (Worn or improperly inflated) 2. Wheel alignment (Incorrect) 3. Steering linkage (Loosen or worn) 4. Hub bearings (Loosen or worn) 5. Steering gear (Out of adjustment or broken) 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn out) 1. Tires (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 3. Shock absorber (Worn out) 1. Tires (Worn or improperly inflated) 2. Wheels (Out of balance) 3. Shock absorber (Worn out) 4. Wheel alignment (Incorrect) 5. Ball joints (Worn) 6. Hub bearings (Loosen or worn) 7. Steering linkage (Loosen or worn) 8. Steering gear (Out of adjustment or broken) 1. Tires (Improperly inflated) 2. Wheel alignment (Incorrect) 3. Suspension parts (Worn out) 4. Shock absorber (Worn out) 1. Oil level (Low or wrong grade) 2. Excessive backlash between pinion and ring gear 3. Ring, pinion or side gears (Worn or chipped) 4. Pinion shaft bearing (Worn) 5. Side bearing (Worn) 6. Differential bearing (Loosen or worn) 1. Oil level (Too high or wrong grade) 2. Drive pinion oil seal (Worn or damaged) 3. Side gear oil seal (Worn or damaged) 4. Companion flange (Loose or damaged) 5. Side gear shaft (Damaged) SA2 SA3 SA8 SA11 SA41 SA19 SA89 SA19 SA89 SA2 SA37 SA107 SA19 SA89 SA2 SA2 SA19 SA3 SA28 SA32 SA11 SA2 SA3 SA8 SA19 SA89 SA59 SA62 SA62 SA62 SA62 SA62 SA59 SA62 SA62 SA62 SA

2 SA2 TIRE AND WHEEL TIRE AND WHEEL INSPECTION SA0OQ01 1. INSPECT TIRE (a) Check the tires for wear and for the proper inflation pressure. Cold tire inflation pressure: 2JZGE R03031 Tire size Front Rear kpa (kgf/cm 2, psi) kpa (kgf/cm 2, psi) 225/50R16 92V 230 (2.3, 33) 245/45R16 94V 230 (2.3, 33) 2JZGTE Tire size Front kpa (kgf/cm 2, psi) Rear kpa (kgf/cm 2, psi) 235/45ZR (2.3, 33) 255/40ZR (2.3, 33) (b) Check the tire runout. Tire runout: 1.4 mm (0.055 in.) or less 2. INSPECT WHEEL BALANCE (a) Check and adjust the Offthecar balance. (b) If necessary, check and adjust the Onthecar balance. Imbalance after adjustment: 5.0 g (0.011 lb) or less R07928 R CHECK WHEEL BEARING LOOSENESS (a) Check the axle bearing backlash. Maximum: 0.05 mm ( in.) (b) Check the axle hub deviation. Maximum: 0.05 mm ( in.) 4. CHECK FRONT SUSPENSION FOR LOOSENESS 5. CHECK STEERING LINKAGE FOR LOOSENESS 6. CHECK BALL JOINT FOR LOOSENESS 7. CHECK SHOCK ABSORBER WORKS PROPERLY Check for oil leak. Check mounting bushings for wear. Check front and rear of the vehicle for bounce. 1692

3 FRONT WHEEL ALIGNMENT SA3 Front FRONT WHEEL ALIGNMENT INSPECTION 1. MEASURE FRONT AND REAR VEHICLE HEIGHT SA0OR01 2JZGE Front* 1 Rear* 2 Tire size 225/50R16 92V 245/45R16 94V Height 186 mm (7.32 in.) 246 mm (9.68 in.) Rear R06911 R06912 F JZGTE Front* 1 Rear* 2 235/45ZR17 255/40ZR mm (7.40 in.) 254 mm (10.00 in.) * 1 : Front measuring point Measure from the ground to the center of the lower suspension arm front mounting bolt. * 2 : Rear measuring point Measure from the ground to the center of the lower suspension arm No.2 mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification. If the vehicle height is not within the specification, try adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER CASTER KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Z03382 Camber Caster Leftright error Leftright error 2JZGE 0 20 ± 45 (0.33 ± 0.75 ) 30 (0.5 ) or less 3 20 ± 45 (3.33 ± 0.75 ) 30 (0.5 ) or less 2JZGTE 0 30 ± 45 (0.5 ± 0.75 ) 30 (0.5 ) or less 3 30 ± 45 (3.5 ± 0.75 ) 30 (0.5 ) or less Steering axis inclination <Reference> 9 35 ± 45 (9.58 ± 0.75 ) 9 45 ± 45 (9.75 ± 0.75 ) If the steering axis inclination is not within the specification, after camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 1693

4 SA4 FRONT WHEEL ALIGNMENT A D Front B 4. INSPECT TOEIN Toein A + B: 0 ± 12 (0 ± 0.2 ) (Total) C D: 0 ± 2 mm (0 ± 0.08 in.) If toein is not within specification, adjust by the tie rod end. C SA ADJUST CAMBER AND CASTER (a) Remove the engine under cover. (b) Remove the nut, 2 bolts and lower arm bracket stay. R06928 R06930 (c) Loosen the front and/or rear adjusting cam nuts. (d) Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). Try to adjust the camber and caster to the center value. (e) Torque the front and/or rear adjusting cam nuts. Torque: 226 N m (2,300 kgf cm, 166 ft lbf) (f) Install the lower arm bracket stay. Torque: Bolt: 44 N m (450 kgf cm, 32 ft lbf) Nut: 59 N m (600 kgf cm, 43 ft lbf) (g) Install the engine under cover. 6. ADJUST TOEIN (a) Remove the boot clamps. (b) Loosen the tie rod end lock nuts. R

5 FRONT WHEEL ALIGNMENT SA5 R06915 (c) Turn the left and right rack ends an equal amount to adjust the toein. Make sure that the lengths of the left and right rack ends are the same. Try to adjust the toein to the center value. Rack end length difference: 1.5 mm (0.059 in.) or less (d) Tighten the tie rod end lock nut. Torque: 56 N m (570 kgf cm, 41 ft lbf) (e) Place the boot on the seat and clip it. Make sure that the boots are not twisted. A B B A 7. INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Front A: Inside B: Outside SA0028 Inside wheel Outside wheel <Reference> 2JZGE ( ) 35 (33 36 ) (30.75 ) 2JZGTE ( ) ( ) (30.58 ) If the wheel angle are not within the specifications, check to see if the lengths of the left and right rack ends are the same. If the tie rods lengths are not equal, the wheel angle cannot be adjusted properly. Reinspect the toein after adjusting the tie rods lengths. 1695

6 SA6 FRONT WHEEL ALIGNMENT Example Camber Caster Z HOW TO READ ADJUSTMENT CHART (a) Mark on the graph the measurements taken from the vehicle. Example (2JZGE): Camber: (+0.16 ) Caster: (+4.33 ) (b) Read from the graph the amounts of the front and/or rear cams to be adjusted. Amount to turn adjusting cam (by graduation): Front cam: + (Longer) 1.8 Rear cam: (Shorter) 2.2 Front Front Cam Front Cam Rear Cam Rear Cam R

7 FRONT WHEEL ALIGNMENT SA7 Camber Caster Front Cam Graduation + (Longer) For 2JZGE (Shorter) Rear Cam Graduation + (Longer) (Shorter) Front Cam Graduation + (Longer) For 2JZGTE (Shorter) Rear Cam Graduation + (Longer) (Shorter) Z

8 SA8 REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT INSPECTION 1. MEASURE REAR VEHICLE HEIGHT (See page SA3 ) SA0OS02 2. INSTALL CAMBER CASTER KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER 2JZGE 2JZGTE Camber Leftright error 1 35 ± 45 (1.58 ± 0.75 ) 30 (0.5 ) or less 1 30 ± 45 (1.5 ± 0.75 ) 30 (0.5 ) or less A D Front B 4. INSPECT TOEIN Toein A + B: 0 18 ± 12 (0.3 ± 0.2 ) (Total) C D: 3 ± 2 mm (0.12 ± 0.08 in.) C SA3213 LH RH C A B E = B A 5. ADJUST CAMBER AND TOEIN (a) Measure the length of the lower suspension arm No.1 and No.2, as shown in the illustration. Length: (E F) or (F E) should be less than 4.0 mm (0.16 in.). If not, adjust the length of the arms by turning the adjusting cam as shown, until (E F) or (F E) is less than 4.0 mm (0.16 in.). (b) Measure the camber and toein. If the camber and toein are still not within the specification, adjust the camber and toein with the adjusting cam. (c) Remove the bolt and disconnect the parking brake cable bracket. D F = D C R05816 R05817 F

9 REAR WHEEL ALIGNMENT SA9 (d) Loosen and adjust the No.1 and/or No.2 cams. (e) Adjust camber and toein by turning the No.1 and/or No.2 cams (See adjustment chart). Try to adjust the camber and toein to the center value. (f) Torque the No.1 and/or No.2 cam nuts. Torque: 184 N m (1,880 kgf cm, 136 ft lbf) (g) Connect the parking brake cable bracket with the bolt. R06947 Example Camber Toein 6. HOW TO READ ADJUSTMENT CHART (a) Mark on the graph the measurements taken from vehicle. Example (2JZGTE): Camber (LH): 1 00 (1 ) Camber (RH): 1 30 (1.5 ) (b) Read from the graph the amounts of the front and/or rear cam to be adjusted. Amount to turn adjusting cam (by graduation) LH Front cam: + (Longer) 1.1 LH Rear cam: + (Longer) 3.0 RH Front cam: (Shorter) 1.0 RH Rear cam: + (Longer) 0.9 Z18438 Front LH + (Longer) (Shorter) (Shorter) + (Longer) RH (Shorter) + (Longer) + (Longer) (Shorter) R

10 SA10 REAR WHEEL ALIGNMENT Camber Toein (Total) Front Cam Graduation (+) Longer () Shorter Rear Cam Graduation (+) Longer () Shorter Z

11 FRONT AXLE HUB SA1 1 FRONT AXLE HUB COMPONENTS SA0OT02 ABS Speed Sensor Cotter Pin Steering Knuckle with Axle Hub Cotter Pin Clip Brake Caliper Tie Rod End Disc Grease Cap Hub Bolt ABS Speed Sensor Rotor Bearing Snap Ring Oil Seal Brake Dust Cover Steering Knuckle Axle Hub Nonreusable part R

12 SA12 FRONT AXLE HUB SA0OU02 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 bolts and brake caliper from the steering knuckle. Torque: 118 N m (1,200 kgf cm, 87 ft lbf) (b) Support the brake caliper securely. (c) Place matchmarks on the disc and axle hub. (d) Remove the disc. R CHECK BEARING BACKLASH AND AXLE HUB DEVI ATION (a) Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm ( in.) If the backlash exceeds the maximum, replace the bearing. (b) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm ( in.) If the deviation exceeds the maximum, replace the bearing. 4. DISCONNECT ABS SPEED SENSOR FROM STEER ING KNUCKLE Remove the bolt and disconnect the ABS speed sensor from the steering knuckle. Torque: 7.8 N m (80 kgf cm, 69 in. lbf) 5. DISCONNECT TIE ROD END FROM STEERING KNUCKLE (a) Remove the cotter pin and nut. Torque: 49 N m (500 kgf cm, 36 ft lbf) (b) Using, disconnect the tie rod end from the steering knuckle SA

13 FRONT AXLE HUB SA13 6. REMOVE STEERING KNUCKLE (a) Remove the upper side of the cotter pin and nut. Torque: 103 N m (1,050 kgf cm, 76 ft lbf) (b) Remove the lower side of the clip and nut. Torque: 125 N m (1,270 kgf cm, 92 ft lbf) (c) Using, remove the steering knuckle from the upper and lower suspension arms R

14 SA14 R07243 FRONT AXLE HUB SA0OV01 DISASSEMBLY 1. REMOVE HUB GREASE CAP Using a screwdriver, remove the grease cap from the steering knuckle. 2. REMOVE FRONT AXLE HUB LOCK NUT AND ABS SPEED SENSOR ROTOR (a) Clamp the axle hub in a soft jaw vise. Close vise until it holds hub bolt. Do not tighten further. (b) Using a chisel and hammer, loosen the staked part of the lock nut and remove it. (c) Remove the sensor rotor. NOTICE: Take care not to scratch the serrations of the sensor rotor. 3. REMOVE AXLE HUB FROM STEERING KNUCKLE (a) Remove the 4 bolts and shift the brake dust cover toward the axle hub side (outside). (b) Using, remove the axle hub from the steering knuckle ( , , , , , ) R REMOVE INNER RACE (OUTSIDE) FROM AXLE HUB Using, remove the inner race from the axle hub ( , , , , , ) R REMOVE OIL SEAL Using, remove the oil seal from the steering knuckle SA

15 FRONT AXLE HUB SA15 6. REMOVE BEARING FROM STEERING KNUCKLE (a) Using snap ring pliers, remove the snap ring. (b) Position the inner race above the bearing on the inner side. (c) Using and a press, remove the bearing from the steering knuckle ( ) R

16 SA16 R15730 FRONT AXLE HUB REASSEMBLY SA0OW02 1. INSTALL BEARING TO STEERING KNUCKLE (a) Using and a press, install a new bearing ( ) NOTICE: If the inner race and balls come loose from the bearing outer race, be sure to install them on the same side as before. (b) Using snap ring pliers, install the snap ring. R01024 R INSTALL OIL SEAL (a) Install the inner race (outside). (b) Using and a hammer, install a new oil seal until it becomes flush with the end surface of the steering knuckle (c) Coat MP grease to the oil seal lip. 3. INSTALL AXLE HUB TO STEERING KNUCKLE (a) Install the brake dust cover to the steering knuckle with the 4 bolts. Torque: 8.0 N m (85 kgf cm, 74 in. lbf) (b) Using and a press, install the axle hub to steering knuckle , INSTALL ABS SPEED SENSOR ROTOR ON AXLE SHAFT NOTICE: Do not scratch the serrations of the sensor rotor. 5. INSTALL AXLE HUB LOCK NUT (a) Install and torque a new axle hub lock nut. Torque: 199 N m (2,030 kgf cm, 147 ft lbf) (b) Using a chisel and hammer, stake the lock nut. 6. INSTALL HUB GREASE CAP Using a screwdriver and hammer, install the grease cap to the steering knuckle. 1706

17 SA18 FRONT WHEEL HUB BOLT FRONT WHEEL HUB BOLT REPLACEMENT 1. REMOVE FRONT WHEEL SA0OY01 2. REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 bolts and brake caliper from the steering knuckle. (b) Support the brake caliper securely. (c) Place matchmarks on the disc and axle hub. (d) Remove the disc. 3. REMOVE HUB BOLT Using, remove the hub bolt R07035 R INSTALL HUB BOLT (a) Install washer and nut to a new hub bolt, as shown in the illustration. (b) Turn the wheel nut to pull the hub bolt through until the underside of the hub bolt head touches the axle hub. 5. INSTALL DISC AND BRAKE CALIPER (a) Install the disc. (b) Install the 2 bolts and brake caliper to the steering knuckle. Torque: 118 N m (1,200 kgf cm, 87 ft lbf) 6. INSTALL FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 1708

18 FRONT SHOCK ABSORBER SA19 FRONT SHOCK ABSORBER COMPONENTS SA0OZ02 Plug Suspension Support Spring Support Reinforcement Washer Tank Front Shock Absorber Assembly Insulator Bushing Upper Suspension Arm Coil Spring Cotter PIn ABS Speed Sensor Front Shock Absorber Stabilizer Bar Brake Caliper Front Fender Splash Shield Nonreusable part F

19 SA20 FRONT SHOCK ABSORBER SA0P001 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. REMOVE BRAKE CALIPER (a) Remove the 2 bolts and brake caliper from the steering knuckle. Torque: 118 N m (1,200 kgf cm, 87 ft lbf) (b) Support the brake caliper securely. SA DISCONNECT ABS SPEED SENSOR AND WIRE HAR NESS (a) Remove the bolt and disconnect the speed sensor from the steering knuckle. Torque: 7.8 N m (80 kgf cm, 69 in. lbf) (b) Remove the 3 bolts and disconnect the wire harness clamp to prevent the wire harness from being damaged when removing or installing the through bolt of the upper suspension arm. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) 4. REMOVE FRONT FENDER SPLASH SHIELD 5. LH side only: MOVE WASHER TANK (a) Remove the 2 washer tank set bolts. (b) Move the washer tank away from the body. 6. DISCONNECT UPPER SUSPENSION ARM (a) Remove the bolt and nut and disconnect the upper suspension arm from the subframe. Torque: 164 N m (1,670 kgf cm, 121 ft lbf) At the time of installation, after stabilizing the suspension, torque the nut. (b) Support the upper suspension arm securely. 7. DISCONNECT STABILIZER BAR LINK Remove the nut and disconnect the stabilizer bar link. Torque: 74 N m (750 kgf cm, 54 ft lbf) If the ball joint stud turns together with the nut, use a hexagon wrench to hold the stud. R

20 FRONT SHOCK ABSORBER SA21 R REMOVE SHOCK ABSORBER (a) Remove the nut, washer and bolt and disconnect the shock absorber from the lower suspension arm. Torque: 143 N m (1,460 kgf cm, 106 ft lbf) At the time of installation, after stabilizing the suspension torque the nut. (b) Remove the plug from the suspension support. (c) Loosen the lock nut in the middle of the suspension support. NOTICE: Do not remove the nut. Torque: 29 N m (300 kgf cm, 22 ft lbf) (d) Remove the 3 nuts, spring support reinforcement and shock absorber from the body. Torque: 35 N m (360 kgf cm, 26 ft lbf) 1711

21 SA22 R08295 FRONT SHOCK ABSORBER DISASSEMBLY SA0P REMOVE SUSPENSION SUPPORT AND COIL SPRING (a) Using, compress the coil spring NOTICE: Do not use an impact wrench. It will damage the. (b) Install the nut and bolt to the lower part of the shock absorber and secure it in a vise. (c) Remove the suspension support center nut. (d) Remove the suspension support and coil spring. 2. REMOVE INSULATOR FROM SUSPENSION SUP PORT 1712

22 R05829 FRONT SHOCK ABSORBER SA23 SA0P201 INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sound. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, see DISPOSAL on page SA

23 SA24 30 mm (1.18 in.) 50 mm (1.97 in.) R07597 FRONT SHOCK ABSORBER SA0P301 DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder within the shaded region to remove the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. 1714

24 FRONT SHOCK ABSORBER SA25 SA0P401 REPLACEMENT 1. REMOVE BUSHING Using and a deep socket wrench, remove the bushing ( ) R INSTALL NEW BUSHING Using and a deep socket wrench, install a new bushing ( ) NOTICE: Do not apply grease or oil to the bushing. R

25 SA26 FRONT SHOCK ABSORBER SA0P501 REASSEMBLY 1. INSTALL INSULATOR TO SUSPENSION SUPPORT Match the bolt of the suspension support with the cutout part of the insulator. W02903 R INSTALL COIL SPRING TO SHOCK ABSORBER (a) Using, compress the coil spring NOTICE: Do not use an impact wrench. It will damage the. (b) Install the coil spring to the shock absorber. Fit the lower end of the coil spring into the gap of the spring seat of the shock absorber. 90 R INSTALL SUSPENSION SUPPORT (a) Install the suspension support to the rod. (b) Temporarily tighten a new nut. (c) Turn the suspension support so that one of the bolts on the suspension support faces the same direction, as shown in the illustration. Align the bolt so that a line drawn between the rod and the bolt would be 90 to the direction of the lower bushing. (d) Remove the After removing the, again check the direction of the suspension support. 1716

26 SA28 FRONT UPPER SUSPENSION ARM COMPONENTS FRONT UPPER SUSPENSION ARM SA0P702 Plug Suspension Support Spring Support Reinforcement Washer Tank Front Shock Absorber Assembly Insulator Bushing Upper Suspension Arm Coil Spring Cotter PIn ABS Speed Sensor Front Shock Absorber Stabilizer Bar Brake Caliper Front Fender Splash Shield Nonreusable part F

27 FRONT UPPER SUSPENSION ARM SA29 SA0P801 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. REMOVE BRAKE CALIPER (a) Remove the 2 bolts and brake caliper from the steering knuckle. Torque: 118 N m (1,200 kgf cm, 87 ft lbf) (b) Support the brake caliper securely. SA DISCONNECT ABS SPEED SENSOR AND WIRE HAR NESS CLAMP (a) Remove the bolt and disconnect the speed sensor from the steering knuckle. Torque: 7.8 N m (80 kgf cm, 69 in. lbf) (b) Remove the 3 bolts and disconnect the wire harness clamp to prevent the wire harness being damaged when removing or installing the through bolt. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) R DISCONNECT UPPER SUSPENSION ARM (a) Remove the cotter pin and the nut. Torque: 103 N m (1,050 kgf cm, 76 ft lbf) (b) Using, disconnect the upper suspension arm from the steering knuckle REMOVE FRONT FENDER SPLASH SHIELD 6. LH side only: MOVE WASHER TANK (a) Remove the 2 washer tank set bolts. (b) Move the washer tank away from the body. 7. REMOVE UPPER SUSPENSION ARM (a) Remove the nut, 2 washers and bolt. Torque: 164 N m (1,670 kgf cm, 121 ft lbf) At the time of installation, after stabilizing the suspension, torque the nut. (b) Remove the upper suspension arm. 1719

28 SA30 R06927 INSPECTION FRONT UPPER SUSPENSION ARM SA0P901 INSPECT UPPER BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. (b) Using a torque wrench, turn the nut continuously taking 2 4 seconds per a turn and take the torque reading on the 5th turn. Torque (turning): N m (10 35 kgf cm, 9 30 in. lbf) 1720

29 SA32 FRONT LOWER SUSPENSION ARM COMPONENTS FRONT LOWER SUSPENSION ARM SA0PC02 ABS Speed Sensor Brake Caliper Lower Suspension Arm Bracket Stay Stabilizer Bar Adjusting Cam Plate Adjusting Cam Plate Rear Adjusting Cam Shock Absorber Bracket Lower Suspension Arm Clip Front Adjusting Cam Engine Under Cover Nonreusable part W

30 R00159 FRONT LOWER SUSPENSION ARM SA33 SA0PD01 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. REMOVE ENGINE UNDER COVER 3. REMOVE BRAKE CALIPER (a) Remove the 2 bolts and brake caliper from the steering knuckle. Torque: 118 N m (1,200 kgf cm, 87 ft lbf) (b) Support the brake caliper securely. 4. DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER BRACKET Remove the nut and disconnect the stabilizer bar link from the shock absorber bracket. Torque: 74 N m (750 kgf cm, 54 ft lbf) If the ball joint stud turns together with the nut, use a hexagon wrench to hold the stud. R DISCONNECT STEERING KNUCKLE (a) Remove the clip and nut. Torque: 125 N m (1,270 kgf cm, 92 ft lbf) (b) Using, disconnect the steering knuckle from the lower suspension arm REMOVE LOWER SUSPENSION ARM (a) Remove the nut, washer and bolt and disconnect the lower suspension arm from the shock absorber. Torque: 143 N m (1,460 kgf cm, 106 ft lbf) At the time of installation, after stabilizing the suspension, torque the nut. (b) Remove the nut, 2 bolts and the lower suspension arm bracket stay. Bolt: 44 N m (450 kgf cm, 32 ft lbf) Nut: 59 N m (600 kgf cm, 43 ft lbf) At the time of installation, before installing the lower suspension arm bracket stay, adjust the front wheel alignment. R

31 SA34 FRONT LOWER SUSPENSION ARM (c) Before loosening the adjusting cam, place matchmarks on the front and rear adjusting cams and subframe. Matchmarks Matchmarks R06929 R06930 (d) Remove the 2 nuts, washers, adjusting cam plates and adjusting cams and lower suspension arm. Torque: 226 N m (2,300 kgf cm, 166 ft lbf) At the time of installation, after stabilizing the suspension, torque the nuts. 7. REMOVE SHOCK ABSORBER BRACKET FROM LOWER SUSPENSION ARM Remove the 2 bolts and bracket from the lower suspension arm. Torque: 52 N m (530 kgf cm, 38 ft lbf) 1724

32 R06931 INSPECTION FRONT LOWER SUSPENSION ARM SA35 SA0PE02 INSPECT LOWER BALL JOINT FOR ROTATION CONDI TION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. (b) Using torque wrench, turn the nut continuously taking 2 4 seconds per a turn and take the torque reading on the 5th turn. Torque (turning): N m (10 35 kgf cm, 9 30 in. lbf) 1725

33 FRONT STABILIZER BAR SA37 FRONT STABILIZER BAR COMPONENTS SA0PG02 Stabilizer Bar Link Bushing Stabilizer Bar Bracket Bushing Bracket Front Fender Splash Shield Stabilizer Bar Link Apron Seal Engine Under Cover Apron Seal Front Fender Splash Shield R

34 SA38 R07309 FRONT STABILIZER BAR SA0PH01 REMOVAL 1. REMOVE FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. REMOVE ENGINE UNDER COVER 3. REMOVE LEFT AND RIGHT FRONT FENDER SPLASH SHIELDS 4. REMOVE BOTH STABILIZER BAR LINKS (a) Remove the 2 nuts and stabilizer bar link from the stabilizer bar and the lower suspension arm. Torque: 74 N m (750 kgf cm, 54 ft lbf) If the ball joint stud turns together with the nut, use a hexagon wrench to hold the stud. (b) Employ the same manner described above to the other side. 5. REMOVE STABILIZER BAR (a) Remove the left and right apron seal set bolts. R07310 Paint Line (b) Remove the 4 bracket bolts and the stabilizer bar with the 2 bushings and brackets. Torque: 18 N m (180 kgf cm, 13 ft lbf) 6. REMOVE CUSHIONS AND BRACKETS At the time of installation, install the cushion to the outside of the paint line. Z

35 Z00340 INSPECTION FRONT STABILIZER BAR SA39 SA0PI01 INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTA TION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. (b) Using a torque wrench, turn the nut continuously taking 2 4 seconds per a turn and take the torque reading on the 5th turn. Torque (turning): N m ( kgf cm, in. lbf) 1729

36 REAR AXLE HUB SA41 REAR AXLE HUB COMPONENTS SA0PK02 Upper Suspension Arm Washer Parking Brake Cable ABS Speed Sensor Drive Shaft Brake Caliper Shoe Guide Plate Hub Bolt Lower Suspension Arm No. 2 Lower Suspension Arm No. 1 Rear Shock Absorber Parking Brake Disc Lock Cap Lower Suspension Arm Brace Strut Rod Exhaust Pipe Supprot ORing Cotter Pin Exhaust Pipe Exhaust Pipe Supprot Ring Nonreusable part W

37 SA42 REAR AXLE HUB Dust Deflector Backing Plate Oil Seal Axle Carrier Bearing Snap Ring Oil Seal Axle Hub Nonreusable part R

38 Z18437 REAR AXLE HUB SA43 SA0PL02 REMOVAL 1. REMOVE REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 bolts and brake caliper from the rear axle hub. Torque: 104 N m (1,065 kgf cm, 77 ft lbf) (b) Support the brake caliper securely. (c) Place matchmarks on the disc and axle hub. (d) Remove the disc. 3. CHECK BEARING BACKLASH AND AXLE HUB DEVI ATION (a) Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm ( in.) If the backlash exceeds the maximum, replace the bearing. (b) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm ( in.) If the deviation exceeds the maximum, replace the axle hub. 4. REMOVE DRIVE SHAFT LOCK NUT (a) Install the disc and brake caliper. Torque: 104 N m (1,065 kgf cm, 77 ft lbf) (b) Remove the cotter pin and lock cap. (c) With applying the brakes, remove the nut. Torque: 289 N m (2,950 kgf cm, 213 ft lbf) (d) Remove the brake caliper and disc. 5. REMOVE DRIVE SHAFT (See page SA51 ) 6. REMOVE PARKING BRAKE SHOE (See page BR60 ) 7. DISCONNECT ABS SPEED SENSOR Remove the bolt and disconnect the ABS speed sensor. Torque: 7.8 N m (80 kgf cm, 69 in. lbf) 8. DISCONNECT PARKING BRAKE CABLE (a) Remove the 2 parking brake cable set bolts. Torque: 8.0 N m (80 kgf cm, 69 in. lbf) (b) Remove the 2 backing plate set bolts. Torque: 26 N m (260 kgf cm, 19 ft lbf) (c) Remove the bolt and shoe guide plate. Torque: 18 N m (185 kgf cm, 13 ft lbf) R

39 SA44 REAR AXLE HUB (d) (e) Using a 14 mm hexagon wrench, remove the hexagon bolt. Torque: 180 N m (1,825 kgf cm, 132 ft lbf) Slide the backing plate to the outside and disconnect the parking brake cable. R REMOVE STRUT ROD Remove the 2 bolts and nuts. Torque: 184 N m (1,880 kgf cm, 136 ft lbf) At the time of installation, after stabilizing the suspension, torque the bolt. R07312 Matchmarks Z DISCONNECT LOWER SUSPENSION ARM NO.1 (a) Remove the 2 bolt and disconnect the parking brake cable clamps. Torque: 19 N m (190 kgf cm, 14 ft lbf) (b) Place matchmarks on the adjusting cam and subframe. (c) Remove the nut, washer, adjusting cam plate and adjusting cam and disconnect the lower suspension arm No.1. Torque: 184 N m (1,880 kgf cm, 136 ft lbf) At the time of installation, after stabilizing the suspension, torque the nut. 11. DISCONNECT LOWER SUSPENSION ARM NO.2 (a) Remove the nut, washer and bolt and disconnect the shock absorber from the lower suspension arm No.2. Torque: 137 N m (1,400 kgf cm, 101 ft lbf) At the time of installation, after stabilizing the suspension, torque the nut. (b) Remove the nut and disconnect the stabilizer bar link from the lower suspension arm No.2. Torque: 74 N m (750 kgf cm, 54 ft lbf) 1734

40 REAR AXLE HUB SA45 R07042 (c) Loosen the nut. Torque: 150 N m (1,525 kgf cm, 110 ft lbf) (d) Using, disconnect the lower suspension arm No.2 from the axle carrier NOTICE: Be careful not to damage the ball joint bolt. (e) Remove the nut. R REMOVE REAR AXLE CARRIER (a) Remove the nut. Torque: 108 N m (1,100 kgf cm, 80 ft lbf) (b) Using, disconnect the upper suspension arm from the axle carrier NOTICE: Be careful not to damage the dust boot. (c) Remove the rear axle carrier. R REMOVE REAR SUSPENSION ARM NO.1 (a) Remove the nut. Torque: 59 N m (600 kgf cm, 43 ft lbf) (b) Using, disconnect the lower suspension arm No.1 from the axle carrier NOTICE: Be careful not to damage the dust boot. At the time of installation, before install the suspension arm No.1, install the axle carrier to the vehicle. 1735

41 SA46 REAR AXLE HUB DISASSEMBLY 1. REMOVE DUST DEFLECTOR Using a screwdriver, remove the dust deflector. 2. REMOVE AXLE HUB FROM AXLE CARRIER (a) Mount the axle carrier in a vise. Use a set of soft jaws in the vise to protect the axle carrier. NOTICE: Do not tighten the vise too tight. SA0PM01 (b) (c) Using, remove the axle hub Remove the backing plate. Z06771 (d) Using, remove the outside inner race from the axle hub , ( , , , , , , ) R REMOVE OIL SEALS Using, remove the inner and outer oil seals Z REMOVE BEARING (a) Using snap ring pliers, remove the snap ring. (b) Place the inner race (inside) to the bearing. (c) Using and a press, remove the bearing ( ), ( ) R

42 Z06776 REAR AXLE HUB REASSEMBLY SA47 SA0PN01 1. INSTALL NEW BEARING (a) Using and a press, install a bearing to the axle carrier , NOTICE: If the inner races come loose from the bearing outer race, be sure to install them on the same side as before. (b) Using snap ring pliers, install the snap ring. 2. INSTALL OIL SEAL (Outer) (a) Place the inner race (outside). (b) Using and a hammer, tap in a new oil seal until it becomes flush with end surface of the carrier NOTICE: Be careful not to damage the oil seal. (c) Coat MP grease to the oil seal lip. Z INSTALL AXLE HUB (a) Temporarily install the backing plate with the hexagon bolt. (b) Place the inner race (inside). (c) Using and a press, install the axle hub , ( ), ( ) R INSTALL OIL SEAL (Inner) (a) Using and a hammer, install a new oil seal NOTICE: Be careful not to damage the oil seal. (b) Coat MP grease to the oil seal lip. R INSTALL DUST DEFLECTOR Using and a press, install a new dust deflector ( ), ( ) Align the holes for the ABS speed sensor in the dust deflector and carrier. W

43 Z04024 REAR WHEEL HUB BOLT REAR WHEEL HUB BOLT REPLACEMENT 1. REMOVE REAR WHEEL SA49 SA0PP01 2. REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 bolts and brake caliper from the rear axle hub. (b) Support the brake caliper securely. (c) Place matchmarks on the disc and axle hub. (d) Remove the disc. 3. REMOVE HUB BOLT Using, remove the hub bolt Z INSTALL HUB BOLT (a) Install washer and nut to a new hub bolt, as shown in the illustration. (b) Turn the wheel nut to pull the hub bolt through until the underside of the hub bolt head touches the axle hub. 5. INSTALL DISC AND BRAKE CALIPER (a) Install the disc. (b) Install the 2 bolts and brake caliper to the rear axle hub. Torque: 104 N m (1,065 kgf cm, 77 ft lbf) 6. INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 1739

44 SA50 REAR DRIVE SHAFT REAR DRIVE SHAFT COMPONENTS SA0PQ02 Washer Drive Shaft 2JZGTE: Washer Washer Lower Suspension Arm Brace Lock Cap Washer Cotter Pin Exhaust Pipe Exhaust Pipe Supprot Ring 2JZGTE: Boot Clamp Boot Clamp Boot Boot Clamp Boot Clamp Outboard Joint with Drive Shaft Inboard Joint End Cover Snap Ring Gasket 2JZGTE: Inboard Joint Inboard Joint Cover Boot Clamp End Cover Boot Nonreusable part Boot Clamp W

45 Tailpipe Center Pipe REAR DRIVE SHAFT SA51 SA0PR02 REMOVAL 1. REMOVE REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2. DISCONNECT EXHAUST PIPE SUPPORTS (a) Remove the 2 exhaust pipe support rings. (b) Support the exhaust pipe securely. (c) Remove the 2 exhaust pipe support Orings. 3. REMOVE COTTER PIN, LOCK CAP AND LOCK NUT (a) Remove the cotter pin and lock cap. (b) With applying the brakes, remove the nut. Torque: 289 N m (2,950 kgf cm, 213 ft lbf) 4. REMOVE LOWER SUSPENSION ARM BRACE Remove the 4 bolts and lower suspension arm brace. Torque: 18 N m (180 kgf cm, 13 ft lbf) Z08967 Matchmarks R REMOVE REAR DRIVE SHAFT (a) Place matchmarks on the drive shaft and side gear shaft. (b) 2JZGE: Using 8 mm hexagon wrench, remove the 6 hexagon bolts and 3 washers with applying the brakes. Torque: 68 N m (695 kgf cm, 50 ft lbf) (c) 2JZGTE: Using a 10 mm hexagon wrench, remove the 6 hexagon bolts and 2 washers with applying the brakes. Torque: 83 N m (850 kgf cm, 61 ft lbf) (d) Disconnect the inboard joint from the differential side gear shaft. (e) Hold the inboard joint side of the drive shaft so that the outboard joint side does not bend too much. R07024 (f) Using a hammer, lightly tap the end of the drive shaft to disengage the axle hub and remove the drive shaft. NOTICE: Be careful not to damage the boots and speed sensor rotor of the drive shaft, and oil seal of the axle hub. At the time of installation, make sure the outboard joint side of the drive shaft does not bend too much. R

46 SA52 R05813 REAR DRIVE SHAFT DISASSEMBLY SA0PS01 1. CHECK DRIVE SHAFT (a) Check that operation of the joint is smooth within the sliding region in the axial direction. If a large angle is used for the crossgroove type joint, the joint will feel like it is catching, but this does not indicate an abnormality. (b) Check that the boots are not cracked, damaged or leaking. (c) Check that there are no scratches on the speed sensor rotor. R REMOVE END COVER (a) Using a screwdriver, remove the end cover. (b) Use bolts, nuts and washers to keep the inboard joint together. NOTICE: Tighten the bolt by hand to avoid scratching the flange surface. 3. REMOVE BOOT CLAMPS Using a side cutter or pliers, remove the 4 boot clamps. 4. REMOVE INBOARD JOINT (a) Place matchmarks on the inboard joint and drive shaft. (b) Using a snap ring expander, remove the snap ring. Matchmarks R11083 (c) Using, an extension bar and a press, remove the inboard joint from the drive shaft ( ) R

47 REAR DRIVE SHAFT SA53 (d) Mount the inboard joint in a soft jaw vise. (e) Using a screwdriver and hammer, remove the inboard joint cover from the inboard joint. NOTICE: Make sure the cage and inner race are not positioned too much to one side of the outer race. 5. REMOVE BOOTS FROM DRIVE SHAFT Remove the inboard joint boot and outboard boot. SA

48 SA54 Matchmarks REAR DRIVE SHAFT SA1TE01 REASSEMBLY 1. ASSEMBLE INBOARD JOINT If the joint has come apart, reassemble it in the following order. (a) Align the matchmarks placed before removal. SA0721 Narrow Wide SA1328 When the matchmarks have disappeared, do the following procedure. (1) Install the inner race to the cage so that the indented bevelled part of the inner race is on the opposite side to the bevelled top of the cage. (2) Install the outer race so that the indented side of the outer race is facing the same side as the bevelled surface of the cage. (3) Match the narrow projections of the inner race with the wide projections of the outer race. (b) Tilt the cage and inner race to the side and insert the balls one by one. NOTICE: When the cage and inner race are tilted over, support the joint with your hand to prevent the balls from falling out. SA0830 Vinyl tape 2. TEMPORARILY INSTALL 2 NEW BOOTS AND 4 NEW BOOT CLAMPS (a) Place 4 new boot clamps to the boots. Before installing the boots, wrap vinyl tape around the spline of the shaft to prevent damaging the boots. (b) Install 2 boots to the drive shaft. R

49 REAR DRIVE SHAFT SA55 Seal Diameter mm ( in.) FIPG SA INSTALL INBOARD JOINT COVER (a) Apply FIPG to the inboard joint cover as shown in the illustration. FIPG: Part No , THREE BOND 1121 or equivalent Install a nozzle that is cut to 1 mm (0.04 in.) opening. Avoid applying an excessive amount to the surface. Cover (b) (c) (d) Clean the surface of the inboard joint facing the cover. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts. Use a plastic hammer to tap the rim of the inboard joint cover in place. Do this in the order shown, and repeat several times. Z08195 Matchmarks 4. INSTALL INBOARD JOINT (a) Align the matchmarks placed before removal. (b) Using a brass bar and hammer, install the inboard joint onto the drive shaft. NOTICE: Check that the brass bar is touching the inner race, and not the cage. (c) Using a snap ring expander, install a new snap ring. R00194 R ASSEMBLE BOOTS TO JOINTS Before assembling the boot, pack with only the same amount of grease that was wiped off. Grease capacity: Inboard and Outboard joint: g ( oz.) Use the grease supplied in the boot kit. NOTICE: Keep grease off the joint connection groove of the boot. Pack with grease all over the ball contact surface inside the joint. 1745

50 SA56 REAR DRIVE SHAFT 30 W JZGTE: INSTALL NEW BOOT CLAMPS TO BOTH BOOTS (a) Position the clamp onto the boot. Pinch the inboard side of the boot clamp, as shown in the illustration. (b) Place onto the clamp (c) Tighten the so that the clamp is pinched. NOTICE: Do not overtighten the clamp by the. 0.8 mm (0.031 in.) or less (d) Using, adjust the clearance of the clamp Clearance: 0.8 mm (0.031 in.) or less R06938 (e) The drive shaft is designed to move ±20 mm from the standard position. Drive shaft standard length RH LH M/T mm ( in.) mm ( in.) A/T mm ( in.) mm ( in.) R JZGE: INSTALL NEW BOOT CLAMPS TO BOTH BOOTS (a) Be sure the boot is on the shaft groove. (b) Using a screwdriver, bend the clamp and lock it as shown. (c) The drive shaft is designed to move ± 20 mm from standard position. Drive shaft standard length SA1465 RH LH mm ( in.) mm ( in.) 1746

51 REAR DRIVE SHAFT SA57 8. INSTALL NEW END COVER (a) Pack grease into the end cover. Grease capacity: g ( oz.) (b) Clean the surface of the inboard joint facing the cover. (c) Glue on a new gasket, with the side with adhesive on it facing toward the outer race side of the inboard joint. Z04028 R07026 (d) Align the bolt holes of the cover with those of the inboard joint. (e) Install the 6 hexagon bolts and 2 washers to the end cover side. (f) Install the 6 nuts to the boot side. (g) 2JZGE: Using a 8 mm hexagon wrench, tighten the bolts. Do this in the order shown, and repeat several times. (h) 2JZGTE: Using a 10 mm hexagon wrench, tighten the bolts. Do this in the order shown, and repeat several times. (i) Check that the claw of the end cover touches the inboard joint. 9. CHECK DRIVE SHAFT (See page SA52 ) 1747

52 REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL COMPONENTS SA59 SA0PV02 Differential Oil Seal Snap Ring Differential Side Gear Shaft Washer 2JZGTE Rear Drive Shaft Washer Washer Lower Suspension Arm Brace Cotter Pin Lock Cap ORing Exhaust Pipe Gasket Exhaust Pipe Support Ring Nonreusable part W

53 SA60 REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL REPLACEMENT 1. DRAIN HYPOID GEAR OIL 2. REMOVE REAR DRIVE SHAFT (See page SA51 ) SA0PW01 3. REMOVE SIDE GEAR SHAFT (a) 2JZGTE M/T: Equally tighten both bolts at the same time and pull out the side gear shaft. NOTICE: Pull out the side gear shaft until a nut can fit behind the shaft. Pulling the shaft out too far will damage the dust cover. R07211 (b) Using and 2 bolts, nuts, remove the side gear shaft REMOVE SNAP RING Remove the snap ring from the side gear shaft. R REMOVE SIDE GEAR SHAFT OIL SEAL Using, remove the oil seal R INSTALL SIDE GEAR SHAFT OIL SEAL (a) 2JZGTE M/T: Using and a hammer, install a new oil seal , ( ) (b) Except 2JZGTE M/T: Using and a hammer, install a new oil seal , ( ) (c) Apply MP grease to the oil seal lip. R

54 REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL SA61 Z INSTALL SIDE GEAR SHAFT (a) Install a new snap ring to the side gear shaft. (b) Coat MP grease onto the snap ring. (c) Using a brass bar and hammer, install the side gear shaft to the differential. NOTICE: Be careful not damage the side gear shaft and oil seal. Whether or not the side gear shaft is making contact with the pinion shaft can be determined by the sound or feeling when driving it in. 8. CHECK INSTALLATION OF SIDE GEAR SHAFT Check that the side gear shaft will not come out by trying to pull it out by hand. 9. INSTALL REAR DRIVE SHAFT (See page SA58 ) Less than 5 mm (0.20 in.) 10. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 49 N m (500 kgf cm, 36 ft lbf) Oil grade: Hypoid gear oil API GL5 Viscosity: Above 18 C (0 F) SAE 90 Below 18 C (0 F) 80W90 or SAE 80W Capacity: 1.35 liters (1.43 US qts, 1.19 lmp. qts) R

55 SA62 REAR DIFFERENTIAL CARRIER COMPONENTS REAR DIFFERENTIAL CARRIER SA0PX02 Washer 2JZGTE: Washer 2JZGTE: Washer Drive Shaft Stabilizer Bar Washer Adjusting Shim Upper Mount Stopper Lower Mount Stopper (2JZGTE Only) 2JZGTE: Differential Mounting Cushion Propeller Shaft Sport Roof Heat Insulator Center Floor Crossmember Brace Center Floor Crossmember Brace Heat Insulator Oxygen Sensor ORing Heat Insulator 2JZGTE: Gasket Exhaust Pipe Gasket Oxygen Sensor Cover Nonreusable part W

56 SA63 REAR DIFFERENTIAL CARRIER 2JZGTE M/T Side Bearing Drive Pinion Rear Bearing Ring Gear Differential Case Adjusting Washer Side Gear Shaft Snap Ring Drive Pinion Bearing Outer Race Oil Seal Differential Carrier Retainer Drain Plug Side Bearing Dust Cover Oring Gasket Breather Plug Adjusting Plate Washer x8 Filler Plug x8 Differential Carrier Cover Gasket Differential Carrier Retainer Differential Carrier Bearing Outer Race Snap Ring Oil Seal Oil Slinger Oring x8 Companion Flange Dust Cover Spacer Drive Pinion Front Bearing Adjusting Plate Washer Side Gear Shaft Dust Deflector Nonreusable part Precoated part W

57 SA64 REAR DIFFERENTIAL CARRIER Except 2JZGTE M/T Conventional Type Side Gear Thrust Washer Pinion Gear Thrust Washer Pinion Gear Thrust Washer Side Gear Pinion Gear Shaft Straight Pin Thrust Washer Side Bearing Driving Pinion Rear Bearing Drive Pinion Adjusting Washer Snap Ring Oil Seal Differential Carrier Retainer Side Gear Shaft Dust Cover x8 Filler Plug Gasket Companion Flange Oil Seal ORing Adjusting Plate Washer Bearing Outer Race Drain Plug Gasket Ring Gear Differential Case Deflector Oring Breather Plug x8 Side Bearing Differential Carrier Cover Oil Seal x10 Spacer Driven Pinion Dust Deflector Front Bearing Oil Slinger Nonreusable part Precoated part Differential Carrier Bearing Outer Race Adjusting Plate Washer Differential Carrier Retainer x8 Dust Cover Snap Ring Side Gear Shaft W

58 Matchmarks R06615 REAR DIFFERENTIAL CARRIER SA65 SA0PY02 REMOVAL 1. DRAIN HYPOID GEAR OIL 2. REMOVE PROPELLER SHAFT (See page PR4 ) 3. DISCONNECT BOTH REAR DRIVE SHAFTS FROM DIFFERENTIAL (a) Place matchmarks on the drive shaft and side gear shaft. (b) 2JZGE: Using a 8 mm hexagon wrench, remove the 16 bolts and disconnect both drive shafts from the differential. (c) 2JZGTE: Using a 10 mm hexagon wrench, remove the 16 bolts and disconnect both drive shafts from the differential. Torque: 83 N m (850 kgf cm, 61 ft lbf) Apply a light coat of engine oil on the threads of the bolts. Torque: 65 N m (660 kgf cm, 48 ft lbf) (d) Support both drive shafts securely. 4. REMOVE REAR STABILIZER BAR (See page SA108 ) 5. REMOVE DIFFERENTIAL (a) Support the differential with a jack. (b) Using a 12 mm hexagon wrench, remove the bolts. Torque: 142 N m (1,450 kgf cm, 105 ft lbf) R06904 (c) (d) Remove the 2 bolts and lower mount stoppers. Torque: 147 N m (1,500 kgf cm, 108 ft lbf) Remove the differential. R

59 SA66 REAR DIFFERENTIAL CARRIER Adjusting Shim (e) Remove the upper mount stopper from the differential carrier. During production, some vehicles did not need adjusting shims to be fitted. Use the upper mount stopper which was removed. R

60 REAR DIFFERENTIAL CARRIER DISASSEMBLY SA67 SA0PZ01 1. SET DIFFERENTIAL CARRIER TO OVERHAUL STAND ETC., AS SHOWN R CHECK DRIVE PINION SHAFT RUNOUT Using dial indicator, measure the drive pinion shaft runout. Maximum runout 10 mm (0.39 in.) R07213 ALL 0.08 mm ( in.) If the runout is not within the specification, replace the drive pinion and/or ring gear. 3. REMOVE DIFFERENTIAL CARRIER COVER (a) Remove the 8 bolts from the carrier cover. (b) Using a brass bar and hammer, separate the cover and carrier. 4. CHECK RING GEAR RUNOUT Using a dial indicator, measure the ring gear runout. 2JZGTE M/T Others Maximum runout 0.08 mm ( in.) 0.05 mm ( in.) If the runout is not within the specification, replace the drive pinion, ring gear and/or differential case. R

61 SA68 REAR DIFFERENTIAL CARRIER 5. CHECK RING GEAR BACKLASH Using a dial indicator, measure the backlash of the ring gear and drive pinion at 3 points (minimum) and check that the average value is within the specification. Backlash (average value) R00027 ALL mm ( in.) NOTICE: The difference between the maximum and minimum measured values must be less than 0.05 mm ( in.). If the backlash is not within the specification, adjust the ring gear backlash (See page SA74 ). (or 36 mm Deep Socket) 6. MEASURE DRIVE PINION PRELOAD Using (or a 36 mm deep socket) and a torque wrench, measure the preload of backlash between the drive pinion and ring gear Preload (at starting) 2JZGTE M/T N m (10 12 kgf cm, in. lbf) Z08859 Others N m (5 8 kgf cm, in. lbf) 7. CHECK TOTAL PRELOAD Using (or a 36 mm deep socket) and 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 2JZ GTE M/T N m (4 6 kgf cm, in. lbf) Others N m (5 8 kgf cm, in. lbf) If necessary, disassemble and inspect the differential. R CONVENTIONAL DIFFERENTIAL ONLY: CHECK PINION GEAR BACKLASH Using a dial indicator, measure the pinion gear backlash while holding one side gear toward the case. Backlash: mm ( in.) If the backlash is not within the specification, install the correct thrust washer (See page SA74 ). 9. CHECK TOOTH CONTACT PATTERN (See page SA74 ) 1758

62 REAR DIFFERENTIAL CARRIER SA REMOVE SIDE GEAR SHAFT (a) 2JZGTE M/T: Equally tighten both bolts at the same time and pull out the side gear shaft. NOTICE: Pull out the side gear shaft until a nut can fit behind the shaft. Pulling the shaft out too far will damage the dust cover. R07214 (b) (c) Using, 2 bolts and nuts, remove the side gear shaft Using a screwdriver, remove the snap ring from the side gear shaft. R REMOVE SIDE GEAR SHAFT OIL SEALS Using, remove the oil seal R07215 R REMOVE DIFFERENTIAL CARRIER RETAINER (AND ADJUSTING PLATE WASHER) (a) Remove the 8 bolts. (b) 2JZGTE M/T: Using, remove the carrier retainer and adjusting plate washer ( ), ( , , , , , , ) (c) Others: Using 2 screwdrivers, remove the carrier retainer. (d) Using a screwdriver, remove the Oring from the carrier retainer. R

63 SA70 REAR DIFFERENTIAL CARRIER 13. REMOVE DIFFERENTIAL CASE Take the differential case out of the carrier while lifting the ring gear side, as shown in the illustration. R REMOVE SIDE BEARING OUTER RACE (AND AD JUSTING PLATE WASHER) (a) 2JZGTE M/T: Using a brass bar and hammer, remove the outer race. Z09012 (b) Others: Using and a press, remove the outer race and adjusting plate washer ( ), ( ) R00051 (or 36 mm Deep Socket) 15. REMOVE DRIVE PINION, OIL SLINGER (2JZ GTE M/T), SPACER AND COMPANION FLANGE (a) Using a chisel and hammer, loosen the staked part of the nut. (b) Using (or 36 mm deep socket wrench), remove the nut , R07218 (c) Using a press, remove the drive pinion with the rear bearing and spacer. NOTICE: Be careful not to drop the drive pinion. (d) Remove the companion flange. (e) Remove the oil slinger (2JZGTE M/T) and spacer from the drive pinion. R

64 REAR DIFFERENTIAL CARRIER SA REMOVE OIL SEAL Using, remove the oil seal REMOVE OIL SLINGER (EXCEPT 2JZGTE M/T) AND FRONT BEARING Remove the oil slinger (except 2JZGTE M/T) and front bearing by hand. R REMOVE REAR BEARING FROM DRIVE PINION Using and a press, remove the rear bearing from the drive pinion R REMOVE FRONT AND REAR BEARING OUTER RACES AND ADJUSTING PLATE WASHER Using a brass bar and hammer, remove the outer races and adjusting plate washer from the differential carrier. Measure the adjusting plate washer thickness and make a note down of it for reassemble. R07387 R REMOVE LH AND RH SIDE BEARINGS Using, remove the LH and RH side bearings from the differential case ( ), ( , , , , , , ) Fix the claws of to the notch in the differential case. Matchmarks 21. REMOVE RING GEAR (a) Place matchmarks on the ring gear and differential case. (b) Remove the ring gear set bolts. (c) Using a plastic hammer, tap on the ring gear to separate it from the differential case. R