TO INDEX DIFFERENTIAL FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD) FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) REAR DIFFERENTIAL CARRIER OIL SEAL

TO INDEX DRIVE LINE / AXLE DIFFERENTIAL DIFFERENTIAL SYSTEM PRECAUTIONS.............................................. OPERATION CHECK......................................... PROBLEM SYMPTOMS TABLE................................. DIFFERENTIAL OIL ADJUSTMENT............................................... FRONT DIFFERENTIAL (4WD) COMPONENTS.............................................. FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD) REMOVAL.................................................. INSTALLATION.............................................. FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) REMOVAL.................................................. DISASSEMBLY.............................................. REASSEMBLY............................................... INSTALLATION.............................................. REAR DIFFERENTIAL COMPONENTS.............................................. REAR DIFFERENTIAL CARRIER OIL SEAL REMOVAL.................................................. INSTALLATION.............................................. REAR DIFFERENTIAL CARRIER ASSEMBLY REMOVAL.................................................. DISASSEMBLY.............................................. REASSEMBLY............................................... INSTALLATION.............................................. -1-1 -2-3 -5-9 -9-11 -12-17 -27-30 -32-32 -34-34 -41-50

1 DIFFERENTIAL SYSTEM DRIVE LINE / AXLE DIFFERENTIAL DIFFERENTIAL SYSTEM PRECAUTIONS 1. Before disassembly, clean the outside of the differential assembly and remove any sand or mud to prevent it from entering the inside of the assembly during disassembly or installation. 2. When disassembling a connecting part made of light alloy such as a differential carrier cover, lightly tap it in with a plastic hammer. Do not attempt to pry it off with a screw driver. 3. Always organize and arrange the disassembled parts properly to protect them from dust or other foreign matter. 4. Fully wash and dry each part before installing it, and apply differential gear oil.do not use alkaline cleaner for aluminum or rubber parts or ring gear set bolts.in addition, do not clean rubber parts such as O-rings or oil seals with cleaning oils (such as solvent). 5. Sufficiently coat the sliding and rotating surfaces with differential gear oil before installation. 6. When securing parts in a vise, do not place the parts directly in the vice. Be sure to place aluminum plates between the parts and the vice. 7. Be extremely careful not to damage the contact surfaces of the case. Such damage may cause oil leaks. 8. Before applying sealant, remove the old adhesive or old sealant from the seal, and clean the area with a solvent. 9. Do not fill oil immediately after installing sealed parts. Wait at least an hour. 10. As it may cause oil leaks, do not scratch or damage the contact surfaces of the oil seal, O-ring, or gasket. 11. When tapping the oil seal into the end of the differential carrier, inspect the installation depth at 3 or more locations on the oil seal circumference. To prevent oil leakage, make sure that the difference between the maximum and minimum measurement values is within the standard value range. 12. When press-fitting an oil seal, be extremely careful not to damage the oil seal lip or its outer circumference. 13. When replacing a bearing, replace the outer and inner races as a set. OPERATION CHECK 1. INSPECT DIFFERENTIAL OIL CHECK OIL LEVEL (See page -3 for the procedure.) CHECK FOR OIL LEAKS (1) Visually inspect whether oil is leaking from the oil seal, differential carrier, plug, case fitting surface, or any other parts.

DIFFERENTIAL DIFFERENTIAL SYSTEM PROBLEM SYMPTOMS TABLE 2 Symptom Suspected Area See Page Oil level (low) -3 Ring gear or pinion gear (worn or chipped) -12 Noise from the front differential Misalignment of the backlash -13 Misalignment of the preload -14 Misalignment of the tooth contact pattern -22 Worn bearing -12 Oil level (low) -3 Ring gear or pinion gear (worn or chipped) -34 Noises from the rear differential Misalignment of the backlash -35 Misalignment of the preload -46 Misalignment of the tooth contact pattern -46 Worn bearing -34 Oil leakage from the front differential Oil level (high) -3 Carrier oil seal (worn or damaged) -9 Oil leakage from the rear differential Oil level (high) -3 Carrier oil seal (worn or damaged) -32

3 DIFFERENTIAL OIL DRIVE LINE / AXLE DIFFERENTIAL DIFFERENTIAL OIL ADJUSTMENT 1. DRAIN DIFFERENTIAL OIL Put an oil tray under the drain plug. Remove the drain plug, then remove the filler plug. (c) Check that the oil has drained completely. (d) Tighten the drain plug using the specified torque. Torque: 61 N*m (625 kgf*cm) 2. ADD DIFFERENTIAL OIL Make sure that the vehicle is level. Remove the differential filler plug and gasket. (c) Insert the gear oil injection nozzle, and slowly fill with hypoid gear oil (differential oil). If the oil is filled too quickly, it may flow back. This may cause you think mistakenly that the specified amount has been added. (d) Leave to stand for 5 minutes after the oil overflow from the filler plug stops. 0-5 mm Oil Level Filler Plug Wire C132685 3. INSPECT AND ADJUST DIFFERENTIAL OIL Using your fingers or a wire, inspect the oil level. Within 0 to 5 mm from the bottom edge of the filler plug hole As it may take some time for the oil to fill into the differential, be sure to wait before checking the oil level. If the oil level is too high or too low, it may cause trouble. Stop the vehicle on a level road. If the oil level is low, check for oil leaks and add oil. (c) After oil is added, re-check that the oil has been filled up to the specified level. (d) Install the differential filler plug and a new gasket. T = 49 N*m (500 kgf*cm) (front differential) T = 61 N*m (625 kgf*cm) (rear differential) 4. ADD DIFFERENTIAL OIL Remove the differential filler plug and gasket. Rear differential (with LSD) (1) Add differential hypoid gear oil (LSD) Within 0-5 mm from the bottom edge of the filler plug opening. Full capacity: Approx. 1.81 liter (c) Front and rear deferential (1) Add hypoid gear oil (differential oil) Within 0-5 mm from the bottom edge of the filler plug opening.

DIFFERENTIAL DIFFERENTIAL OIL 4 (d) (e) Full capacity: Approx. 0.45 liter Approx. 1.81 liter (rear differential) Check the oil level. Install the differential filler plug and a new gasket. T = 49 N*m (500 kgf*cm) (front differential) T = 61 N*m (625 kgf*cm) (rear differential) After adding oil, re-check the oil level after driving.

5 FRONT DIFFERENTIAL(4WD) DRIVE DIFFERENTIAL LINE / AXLE COMPONENTS DIFFERENTIAL FRONT DIFFERENTIAL(4WD) 7 T=5.4{55} ENGINE UNDER COVER RR RH 4 T=5.4{55} ENGINE UNDER COVER RR LH ENGINE UNDER COVER 11 TIGHTENING TORQUE [N*m{kgf*cm}] C139174J02

DIFFERENTIAL FRONT DIFFERENTIAL(4WD) 6 FRONT DRIVE SHAFT ASSEMBLY LH T=18.2{186} SPEED SENSOR FR LH (With ABS) T=8.4{86} TIE ROD END LH T=46.6{475} CLIP FRONT STABILIZER LINK ROD FRONT AXLE HUB NUT LH T=76.5{780} T=205.8{2099} FRONT SUSPENSION LOWER ARM NO. 1 LH T=37.3{380} T=58.1{592} CLIP TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C140799J01

7 DIFFERENTIAL FRONT DIFFERENTIAL(4WD) T=76{775} 3 T=41.7{425} FRONT DIFFERENTIAL MOUNT CUSHION NO. 1 FRONT DIFFERENTIAL BRACKET RR T=76{775} 3 FRONT DIFFERENTIAL CARRIER ASSEMBLY 4 T=76{775} T=76{775} 4 T=41.7{425} FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET... TIGHTENING TORQUE [N*m{kgf*cm}] C136382J01

DIFFERENTIAL FRONT DIFFERENTIAL(4WD) 8 FRONT DIFFERENTIAL PINION FRONT DIFFERENTIAL PINION SHAFT DIFFERENTIAL SIDE GEAR THRUST WASHER DIFFERENTIAL SIDE GEAR DIFFERENTIAL SIDE OIL SEAL FRONT DIFFERENTIAL PINION DIFFERENTIAL SIDE GEAR FILLER PLUG GASKET FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER DIFFERENTIAL SIDE GEAR THRUST WASHER DIFFERENTIAL CARRIER FRONT DRIVE PINION COMPANION FLANGE FR FRONT DRIVE PINION NUT FRONT DRIVE PINION TAPERED ROLLER BEARING RR T=118{1203} BREATHER PLUG T=11.3{115} FRONT DIFFERENTIAL CASE BEARING SHIM T=83.4{849} 8 T=49{500} T=30{306} DIFFERENTIAL CASE NO.1 DRAIN PLUG GASKET SHIM SHIM FRONT DIFFERENTIAL CARRIER OIL SEAL 8 T=20.6{210} DIFFERENTIAL CARRIER COVER DIFFERENTIAL RING GEAR SHIM FRONT DIFFERENTIAL CASE BEARING DIFFERENTIAL DRIVE PINION FRONT DRIVE PINION TAPERED ROLLER BEARING FR DIFFERENTIAL SIDE OIL SEAL TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C140217J01

9 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD) FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD) DRIVE DIFFERENTIAL LINE / AXLE REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE ENGINE UNDER COVER RR RH (WITH ENGINE UNDER COVER RR RH) 3. REMOVE ENGINE UNDER COVER RR LH (WITH ENGINE UNDER COVER RR LH) 4. DRAIN TRANSFER OIL(See page TF-7) 5. REMOVE FRONT SUSPENSION CROSS MEMBER LWR(See page PR-3) 6. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR- 3) 7. DRAIN DIFFERENTIAL OIL(See page -11) 8. REMOVE FRONT DRIVE PINION COMPANION FLANGE FR Using a chisel and a hammer, unstake the companion flange nut. When removing the nut, completely unstake it. Do not damage the threads of the drive pinion. Using the, secure the companion flange FR. (c) Using a deep socket wrench (0.87in), remove the companion flange nut and plate washer. (d) Using the, remove the companion flange. Apply grease to the threads and tip of the center bolt before use. 9. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL 09308-10010 Using the, remove the oil seal. Apply grease to the threads and tip of the center bolt before use. INSTALLATION 1. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL 09636-20010 C137413

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD) 10 Using the and a hammer, drive in a new carrier oil seal. Make sure that the seal is installed according to the standard below. 0.5 ± 0.5 mm (from the carrier end face) Apply MP grease to the lip of the carrier oil seal. C139818 2. INSTALL FRONT DRIVE PINION COMPANION FLANGE FR Install the companion flange FR. Using the, secure the companion flange FR. (c) Using the, hold the companion flange and install the plate washer and lock nut. (d) Using a chisel and a hammer, stake the companion flange nut. 3. INSTALL FRONT PROPELLER SHAFT ASSEMBLY(See page PR- 4) 4. INSTALL FRONT SUSPENSION CROSS MEMBER LWR(See page PR-4) 5. ADD TRANSFER OIL(See page TF-6) 6. ADD DIFFERENTIAL OIL (See page -3) 7. INSPECT AND ADJUST TRANSFER OIL(See page TF-6) 8. INSPECT AND ADJUST DIFFERENTIAL OIL (See page -3) 9. INSTALL ENGINE UNDER COVER RR RH (WITH ENGINE UNDER COVER RR RH) 10. INSTALL ENGINE UNDER COVER RR LH (WITH ENGINE UNDER COVER RR LH) 11. INSTALL ENGINE UNDER COVER

11 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) DRIVE DIFFERENTIAL LINE / AXLE REMOVAL 1. DRAIN DIFFERENTIAL OIL Remove the differential filler plug and gasket. Remove the drain plug and gasket and drain the oil. (c) Install the drain plug and a new gasket. Torque: 30 N*m (306 kgf*cm) 2. REMOVE FRONT TIRE 3. REMOVE ENGINE UNDER COVER 4. REMOVE ENGINE UNDER COVER RR RH 5. REMOVE ENGINE UNDER COVER RR LH 6. REMOVE FRONT AXLE HUB NUT LH(See page DS-5) 7. REMOVE FRONT AXLE HUB NUT RH Perform the same procedure for the RH side as for the LH side. 8. REMOVE TIE ROD END LH (See page DS-5) 9. REMOVE TIE ROD END RH Perform the same procedure for the RH side as for the LH side. 10. REMOVE FRONT STABILIZER LINK ROD(See page SP-14) 11. DISCONNECT FRONT SUSPENSION LOWER ARM NO. 1 LH(See page DS-5) 12. DISCONNECT FRONT SUSPENSION LOWER ARM NO. 1 RH Perform the same procedure for the RH side as for the LH side. 13. DISCONNECT FRONT AXLE HUB LH(See page DS-5) 14. DISCONNECT FRONT AXLE RH Perform the same procedure for the RH side as for the LH side. 15. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH(See page DS-6) 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Perform the same procedure for the RH side as for the LH side. 17. REMOVE FRONT SUSPENSION CROSS MEMBER LWR(See page PR-3) 18. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR- 3) 19. SUPPORT FRONT DIFFERENTIAL CARRIER ASSEMBLY Support the front differential carrier assembly with a transmission jack. As the front differential carrier assembly is heavy, be sure that it is securely supported with the transmission jack.

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 12 20. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY Remove the bolt and disconnect front differential mount cushion No. 1 from the front suspension cross member. C137248J01 Remove the 2 bolts, then remove the front differential carrier assembly (with bracket). Do not lose the front differential carrier assembly. When removing the front differential carrier assembly, there is a possibility of leakage of residual oil. C136011 21. REMOVE FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET Remove the 4 bolts, then remove the front differential carrier support bracket from the front differential carrier. 22. REMOVE FRONT DIFFERENTIAL MOUNT CUSHION NO. 1 Remove the 3 bolts, then remove front differential mount cushion No. 1 from front differential mount No. 1. 23. REMOVE FRONT DIFFERENTIAL BRACKET RR Remove the 7 bolts, then remove the front differential bracket RR from the front differential carrier. DISASSEMBLY 1. REMOVE FRONT DIFFERENTIAL CARRIER COVER BREATHER PLUG Remove the breather plug from the carrier plug. 2. REMOVE DIFFERENTIAL SIDE OIL SEAL Using the, remove the right and left side gear shaft oil seal. 09308-00010 C136916 3. REMOVE FRONT DIFFERENTIAL CARRIER COVER Remove the 8 bolts. Using a brass bar and a hammer, lightly tap on the differential carrier cover to remove it. Place the brass bar against the ribs of the carrier cover. Do not damage the contact surfaces of the differential carrier. C137249 4. SECURE DIFFERENTIAL CARRIER ASSEMBLY 09219-87701, 09219-87202

13 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) Install the to the front differential carrier assembly. C139756 Secure the front differential carrier assembly to the. C139757 C137270 5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Install a dial indicator at a right-angle to the back side of the ring gear. Check the runout of the ring gear by turning the companion flange FR. Maximum limit: 0.10 mm If the runout exceeds the specified maximum value, remove the ring gear and check the case runout. C137410 6. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH Install a dial indicator at a right-angle to the edge of the tooth surface of the ring gear. Secure the companion flange FR by hand, and move the ring gear to check the backlash. 0.10 to 0.17 mm Check the backlash at 3 or more locations on the ring gear circumference. 7. REMOVE DIFFERENTIAL CASE NO. 1 Remove rear differential case assembly and the shim. 8. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH Secure the differential case in a vise. Do not tighten the vise too firmly.

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 14 (c) Install a dial indicator at a right-angle to the edge of the tooth surface of the side gear shaft. Secure the pinion gear to the differential case, and turn the side gear to check the side gear backlash. 0.025 to 0.10 mm C123386 9. INSPECT TOTAL PRELOAD Using a torque wrench and a deep socket wrench, inspect the total preload (activation torque) while the drive pinion and ring gear teeth are in contact. T = 0.69 to 1.07 N*m (7.04 to 10.9 1kgf*cm) C139807 10. REMOVE DRIVE PINION COMPANION FLANGE NUT 09330-00021, 09213-58013 Using a chisel and a hammer, unstake the lock nut. Using the, secure the companion flange FR. (c) Using a deep socket wrench, remove the companion flange nut. When removing the nut, completely unstake it. Do not damage the threads of the drive pinion. 11. REMOVE FRONT DRIVE PINION COMPANION FLANGE FR 09510-87301 C139755 Using the, remove the companion flange FR. Apply grease to the threads and tip of the center bolt before use. C139758

15 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL Using the, remove the oil seal. 09308-10010 Apply grease to the threads and tip of the center bolt before use. C139759 13. REMOVE DIFFERENTIAL DRIVE PINION Using a press, remove the differential drive pinion. C139760 14. REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING RR Remove the tapered roller bearing RR (inner race) from the differential carrier. Remove the drive pinion bearing spacer and shim. C139761 15. REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING FR Using the and a press, remove the tapered roller bearing FR (inner race) from the drive pinion. C137302 16. REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING FR Using a brass bar and a hammer, lightly and uniformly tap on the tapered roller bearing FR (outer race) to remove it. C088550

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 16 17. REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING RR Using a brass bar and a hammer, lightly and uniformly tap on the tapered roller bearing RR (outer race) to remove it. 18. REMOVE FRONT DIFFERENTIAL CASE BEARINGS O9502-10012 Remove the shim. C088551 Using the, remove the LH side bearing and the RH side bearing. As a reference for assembly, the shims should be stored separately in for the ring gear back side and tooth side. Apply grease to the threads and tip of the center bolt before use. C139762 19. REMOVE DIFFERENTIAL RING GEAR Secure the differential case in the vise between aluminum plates. Do not tighten the vise too firmly. Put match marks on the ring gear and the differential case. (c) Remove the 8 bolts. Matchmarks C135701 3 2 4 1 4 2 3 C137301 20. DISASSEMBLE THE DIFFERENTIAL CASE ASSEMBLY Remove the parts listed below from the differential case assembly. When removing the parts, identify the installation position on the case differential. Store the gear and washer differential side gear thrust as a set.(do not mix up the gears and washer differential side gear thrusts.) (1) Differential pinion shaft (1 in the diagram) (2) Differential pinion gear (2 pieces) (2 in the diagram) (3) Front differential side gear thrust washer No. 1 (2 pieces) (3 in the diagram) (4) Differential side gear (2 pieces) (4 in the diagram)

17 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) A B 21. INSPECT DIFFERENTIAL CASE ASSEMBLY Pinion differential drive, gear differential ring (1) Visually inspect parts (A), (B), and (C) as shown in the diagram. There is no notable wear or damage. C C135702 A Shaft differential pinion, pinion differential, gear differential side (1) Visually inspect parts (A), (B), (C), (D), (E), and (F) as shown in the diagram. There is no notable wear or damage. F D C B E C135703 C E B (c) CASE DIFFERENTIAL (1) Visually inspect parts (A), (B), (C), (D), and (E) as shown in the diagram. There is no notable wear or damage. REASSEMBLY D A D C135704 1. INSTALL FRONT DRIVE PINION TAPERED ROLLER BEARING FR 09950-60010 Using the and a press, press in the tapered roller bearing FR (outer race). 2. INSTALL FRONT DRIVE PINION TAPERED ROLLER BEARING RR 09950-60010 C088552 Using the and a press, press in the tapered roller bearing RR (outer race). 3. INSTALL DIFFERENTIAL DRIVE PINION 09257-87202, 09330-87301, 09530-87504, 09350-87202 Install the tapered roller bearing. Install the. (c) Install the companion flange and plate washer. C088553

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 18 (d) (e) Using the, tighten the lock nut to the specified torque. Torque: 118 N*m (1200 kgf*cm) Install the. C139777 PMD 83.0mm A (f) Select the shims so that (A) in the diagram becomes the standard value. 0.5 ± 0.05 mm PMD (pinion mounting distance) Shim Selection Table (for adjustment of differential drive pinion protrusion) Product Number Thickness (mm) C139778 (g) (h) 90045-64318 0.15 90045-64319 0.20 90045-64320 0.25 90045-64321 0.50 Remove the lock nut. Remove the plate washer and companion flange. (i) Using the, install the tapered roller bearing into the pinion. Press in the bearing by pushing its inner side. If either the front or rear bearing is damaged, replace them both as a set. When replacing the drive pinion, replace it with the ring gear as a set. C139779 (j) Using the and a press, install the pinion to the differential carrier. Do not install the bearing spacer and shim (for preload adjustment). C139780

19 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) C139781 (k) (l) (m) Using the and a press, install the companion flange. Do not assemble the type T oil seal. Install the plate washer and lock nut. To work in the bearing, turn the flange several times forward and backward. 4. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 09330-87301 C139782 Using the and a torque wrench, gradually tighten the lock nut to the preload standard. 0.59 to 0.98 N*m (6.0 to 10.0 kgf*cm) C139777 5. INSTALL FRONT DIFFERENTIAL CASE When installing the side gear thrust washer No. 1, side gear, pinion gear, or other parts, make sure that there is no dirt or foreign matter on the parts, such as dust or cutting powder. When replacing either the side gear or the pinion gear, be sure to replace the side gear and the pinion gear together as a set. Apply gear oil to the rotating and moving parts. 3 2 4 1 4 2 3 C137301 Install the parts listed below to the the differential case. Differential pinion shaft (1 in the diagram) Differential pinion gear (2 pieces) (2 in the diagram) Front differential side gear thrust washer No. 1 (2 pieces) (3 in the diagram) Differential side gear (2 pieces) (4 in the diagram) (1) Apply oil to the differential side gear and side gear thrust washer No. 1 and install them to the differential case. (2) Apply oil to the differential pinion and install it to the differential case. (3) Apply oil to the differential pinion shaft and insert it into the differential case. Lubricants: Differential hypoid gear oil SAE80W-90 (API category GL5)

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 20 ZD07930 (c) (d) Install a dial indicator at a right-angle to the edge of the tooth surface of the pinion gear. Secure the drive pinion against the differential case, and check the backlash. 0.025 to 0.10 mm Use the same-sized side gear thrust washer No. 1 in order to be able adjust the backlash of the side gear to within the standard value and to ensure that the gear rotates smoothly. Slide Gear Thrust Washer No. 1 Types Product Number Thickness (mm) 41361-87501 0.80 41361-87705 0.85 41361-87506 0.90 41361-87507 1.00 Matchmarks C135701 6. INSTALL DIFFERENTIAL RING GEAR Wipe off any grease or moisture from the ring gear contact surface of the differential case. Secure the differential case in the vise between aluminum plates. Do not tighten the vise too firmly. (c) Clean the threaded holes of the differential case. (d) Wipe off any grease or moisture from the ring gear (contact surface of the differential case). (e) (f) Align the match marks on the differential case and the ring gear, and install the ring gear. Align the bolt holes of the differential case and the threaded holes of the ring gear. Tighten the 8 set bolts. Torque: 83.4 N*m (849 kgf*cm) Wait until the ring gear has fully cooled off before tightening the bolts. Tighten the bolts in cross-diagonal order. Tighten gradually in several passes.. 7. INSTALL FRONT DIFFERENTIAL CASE 09309-87201 Using the and a press, press the LH and RH bearings into the differential case. CAUTION: If the bearing is damaged, replace it with new one. Align the with the center of the differential case. 8. INSTALL DIFFERENTIAL CASE ASSEMBLY Install the differential case to the differential carrier. C139806

21 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) Install using the same parts as those disassembled when removing only the shims for the back side of the gear differential ring. Check the shims. If the shims are worn or scratched, install a new shim of the same thickness. C137412 Front Differential Case Shim Types C137410 9. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH Set the dial indicator at a right-angle to the gear. Secure the flange S/A drive pinion companion, and move the gear to measure the backlash. Apply hypoid gear oil to each part. 0.10 to 0.17 mm Select and install a shim so that the backlash of the ring gear falls within the range of standard values. Product Number Thickness (mm) 90045-64598 1.30 90045-64599 1.35 90045-64600 1.40 90045-64601 1.45 90045-64602 1.50 90045-64603 1.55 90045-64604 1.60 90045-64605 1.65 90045-64606 1.70 90045-64607 1.75 90045-64608 1.80 Front Differential Case Shim Types 10. DIFFERENTIAL CASE NO. 1 (PLAY ADJUSTMENT) Measure the play of the differential carrier and the radial ball bearing on the differential ring gear tooth surface side. Select shims (for use in the direction of the differential case thrust) so that the play is within the specified value. Product Number Thickness (mm) 90045-64598 1.30 90045-64599 1.35 90045-64600 1.40 90045-64601 1.45 90045-64602 1.50 90045-64603 1.55 90045-64604 1.60 90045-64605 1.65

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 22 Product Number Thickness (mm) 90045-64606 1.70 90045-64607 1.75 90045-64608 1.80 11. INSPECT TOOTH CONTACT BETWEEN DIFFERENTIAL RING GEAR AND DRIVE PINION Apply a light coat of red primer uniformly to the tooth surface side of the ring gear, and turn the ring gear several times forward and backward. The pattern of the red primer indicates the tooth contact position. Heel Contact Face Contact Select The Front Differential Case Washer To Allow The Drive Pinion To Come Close To The Differential Ring Gear. Flank Contact Toe Contact Normal Gear Contact Select The Front Differential Case Washer To Allow The Drive Pinion To Avoid Contact With The Differential Ring Gear. C089686J01 Check the contact state at 4 locations on the differential ring gear circumference. If the tooth alignment is off, use the appropriate shim selected from the table to adjust the drive pinion protrusion and re-install. In the case of face contact or flank contact, the error may be adjustable within the range of standard backlash values. Shim Selection Table (for differential drive pinion protrusion adjustment) Product Number Thickness (mm) 90045-64318 0.15 90045-64319 0.20 90045-64320 0.25 90045-64321 0.50 12. REMOVE DIFFERENTIAL CASE NO.1 Remove rear differential case No. 1 and the shim. 13. REMOVE FRONT DRIVE PINION COMPANION FLANGE FR 09330-87301, 09510-87301

23 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) Using the, secure the companion flange FR. Remove the lock nut and the plate washer. C139755 (c) Using the, remove the companion flange FR. Apply grease to the threads and tip of the center bolt before use. C139758 14. REMOVE DIFFERENTIAL DRIVE PINION Using a press, remove the differential drive pinion. C139760 Remove the tapered roller bearing from the differential carrier. 15. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Install a new bearing spacer and shim (same as the one removed) to the drive pinion. Check the shims. If the shims are worn or scratched, install a new shim of the same thickness. C139761 16. INSTALL DIFFERENTIAL DRIVE PINION 09330-87301, 09257-87202, 09350-87202

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 24 Using and a press, install the differential drive pinion. C139780 Using, install the companion flange. C139782 (c) Using the and a torque wrench, tighten the lock nut. Torque: 118 N*m (1200 kgf*cm) C139777 C139807 17. MEASURE DIFFERENTIAL DRIVE PINION PRELOAD Measure the preload of the drive pinion. If the preload is not within the specified range, select a shim (for preload adjustment) and adjust. Product Number Thickness (mm) 90045-64533 1.65 90045-64534 1.70 90045-64535 1.75 90045-64536 1.80 90045-64537 1.85 90045-64538 1.90 90045-64539 1.95 90045-64540 2.00 90045-64541 2.05 90045-64542 2.10 90045-64543 2.15 90045-64544 2.20 90045-64545 2.25 90045-64546 2.30 90045-64547 2.35

25 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) Product Number Thickness (mm) 90045-64548 2.40 90045-64549 2.45 18. REMOVE FRONT DRIVE PINION COMPANION FLANGE FR 09330-87301, 09510-87301 Using the, remove the lock nut and the plate washer. C139777 Using the, remove the companion flange. 19. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL 09636-20010 Apply MP grease No. 2 to the lip of the carrier oil seal. C139758 Using the and a press, tap in a new carrier oil seal. Make sure that the seal is installed to the standard value. 0.5 ± 0.5 mm (from the carrier end face) 20. INSTALL FRONT DRIVE PINION COMPANION FLANGE FR 09257-87202, 09330-87301, 09350-87202 C139783 Using the and a press, install the companion flange. C139782

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 26 Using the and a torque wrench, tighten the lock nut. Torque: 118 N*m (1200 kgf*cm) C139777 (c) Using a chisel and a hammer, stake the companion flange nut. 21. INSTALL DIFFERENTIAL CASE NO. 1 Install differential case No. 1 and the shim to the differential carrier. 22. INSTALL DIFFERENTIAL CARRIER COVER Using a scraper and wire brush, clean the liquid gasket attached to the differential carrier and the differential carrier cover. Then remove any oils using cleaning fluid or equivalent. ZK07449 C136379 (c) Apply the liquid gasket to the cover, and install the cover to the differential carrier. Make sure that there are no gaps in the liquid gasket before installing the cover to the carrier. If the liquid gasket dries before the cover is installed, remove and re-apply the liquid gasket. After installing the cover to the differential carrier, wait at least 1 hour before filling with oil or driving the vehicle. In addition, avoid rapid acceleration/ deceleration for at least 12 hours. Before the liquid gasket dries, install the differential side oil seal. (See procedure 23.) Using the 8 bolts, install the differential carrier cover. Torque: 20.6 N*m (210 kgf*cm) 23. INSTALL DIFFERENTIAL SIDE OIL SEAL 09636-20010 Apply MP grease No. 2 to the lip of the carrier oil seal. C137249

27 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) Using the and a hammer, drive in a new carrier oil seal up to the edge surface of the seal attachment part. C137976 24. INSPECT TOTAL PRELOAD Using a torque wrench and a deep socket wrench, inspect the total preload (activation torque) while the drive pinion and ring gear teeth are in contact. 0.69 to 1.07 N*m (7.03 to 10.9 kgf*cm) C139807 25. INSTALL FRONT DIFFERENTIAL CARRIER COVER BREATHER PLUG Install the breather plug to the carrier cover. Torque: 11.3 N*m (115 kgf*cm) INSTALLATION 1. INSTALL FRONT DIFFERENTIAL BRACKET RR Using the 7 bolts, install the front differential bracket RR to the front differential carrier. Torque: 76 N*m (775 kgf*cm) 2. INSTALL FRONT DIFFERENTIAL MOUNT CUSHION NO. 1 Using the 3 bolts, install front differential mount cushion No. 1 to front differential mount No. 1. Torque: 76 N*m (775 kgf*cm) 3. INSTALL FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET Using the 4 bolts, install the front differential carrier support bracket to the front differential carrier. Torque: 76 N*m (775 kgf*cm) 4. SUPPORT FRONT DIFFERENTIAL CARRIER ASSEMBLY Using the transmission to support the front differential carrier assembly (with bracket), lift up to the installation position. As the front differential carrier assembly is heavy, be sure that it is securely supported with the transmission jack. Do not damage the attachment surfaces when installing the front differential carrier assembly. Do not lose the front differential carrier assembly.

DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 28 5. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY Using the 2 bolts, install the front differential carrier support bracket to the front suspension cross member. Torque: 41.7 N*m (425 kgf*cm) C136011 Using the 2 bolts, install the front differential mount cushion No. 1 to the front suspension cross member. Torque: 41.7 N*m (425 kgf*cm) 6. INSTALL FRONT PROPELLER SHAFT ASSEMBLY(See page PR- 4) 7. INSTALL FRONT SUSPENSION CROSS MEMBER LWR(See page PR-4) C137248 8. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH(See page DS-10) 9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Perform the same procedure for the RH side as for the LH side. 10. INSTALL FRONT AXLE HUB LH(See page DS-10) 11. INSTALL FRONT AXLE HUB RH Perform the same procedure for the RH side as for the LH side. 12. CONNECT FRONT SUSPENSION LOWER ARM NO. 1 LH(See page DS-10) 13. CONNECT FRONT SUSPENSION LOWER ARM NO. 1 RH Perform the same procedure for the RH side as for the LH side. 14. INSTALL FRONT STABILIZER LINK ROD (See page SP-15) 15. CONNECT TIE ROD END LH(See page DS-10) 16. CONNECT TIE ROD END RH Perform the same procedure for the RH side as for the LH side. 17. INSTALL FRONT AXLE HUB NUT LH(See page DS-10) 18. INSTALL FRONT AXLE HUB NUT RH Perform the same procedure for the RH side as for the LH side. 19. INSTALL FRONT DISC 20. ADD DIFFERENTIAL OIL (See page -3) 21. INSTALL ENGINE UNDER COVER RR RH (WITH ENGINE UNDERCOVER RR RH) 22. INSTALL ENGINE UNDER COVER RR LH (WITH ENGINE UNDERCOVER RR LH)

29 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD) 23. INSTALL ENGINE UNDER COVER 24. INSTALL FRONT TIRE Torque: 103 N*m (1050 kgf*cm)

DIFFERENTIAL REAR DIFFERENTIAL 30 REAR DIFFERENTIAL DRIVE DIFFERENTIAL LINE / AXLE COMPONENTS REAR BRAKE DRUM REAR AXLE SHAFT RH FILLER PLUG T=61.2{624.5} FILLER PLUG GASKET REAR DIFFERENTIAL CARRIER ASSEMBLY REAR AXLE HOUSING ASSEMBLY T=8.4{86} x10 SPEED SENSOR FR LH x4 T=32{326} T=61.2{624.5} DRAIN PLUG DRAIN PLUG GASKET T=60{612} PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY REAR AXLE SHAFT LH 4 T=42{425.2} REAR AXLE BEARING RETAINER OUT LH REAR BRAKE DRUM TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C139224J02

31 DIFFERENTIAL REAR DIFFERENTIAL 2WD DIFFERENTIAL SPIDER REAR DIFFERENTIAL PINION REAR DIFFERENTIAL PINION SHAFT REAR DIFFERENTIAL PINION REAR DIFFERENTIAL CARRIER FILLER PLUG BEARING CAP REAR DIFFERENTIAL BEARING ADJUST NUT LOCK FILLER PLUG GASKET FRONT BEARING OUTER RACE REAR DIFFERENTIAL CARRIER OIL SEAL REAR DRIVE PINION WASHER T=157{1600} REAR BEARING OUTER RACE REAR DRIVE PINION TAPERED ROLLER BEARING RR T=84{857} 4 REAR DRIVE PINION TAPERED ROLLER BEARING FR REAR DIFFERENTIAL DUST DEFLECTOR REAR DRIVE PINION COMPANION FLANGE RR REAR DRIVE PINION NUT 2 2 REAR DIFFERENTIAL SIDE GEAR THRUST WASHER REAR DIFFERENTIAL CASE BEARING BEARING OUTER RACE DIFFERENTIAL RING GEAR DIFFERENTIAL DRIVE PINION REAR DIFFERENTIAL DRIVE PINION BEARING SPACER REAR DIFFERENTIAL DRIVE PINION WASHER T=5.4{55} REAR DIFFERENTIAL CASE REAR DIFFERENTIAL SIDE GEAR REAR DIFFERENTIAL PINION REAR DIFFERENTIAL SIDE GEAR REAR DIFFERENTIAL SIDE GEAR THRUST WASHER REAR DIFFERENTIAL PINION SHAFT REAR DIFFERENTIAL PINION 8 T=97{989} REAR DIFFERENTIAL CASE BEARING BEARING OUTER RACE REAR DIFFERENTIAL BEARING ADJUST NUT TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C139206J02

DIFFERENTIAL REAR DIFFERENTIAL CARRIER OIL SEAL REAR DIFFERENTIAL CARRIER OIL SEAL DRIVE DIFFERENTIAL LINE / AXLE REMOVAL 1. DRAIN DIFFERENTIAL OIL(See page -34) 32 2. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY(See page PR-6) 3. REMOVE REAR DRIVE PINION NUT 09330-87301 Using a chisel and a hammer, unstake the pinion nut. When removing the nut, completely unstake it. Do not damage the threads of the drive pinion. Using the, remove the lock nut and the plate washer. (c) Using a socket wrench (24 mm), remove the pinion nut and washer. 4. REMOVE REAR DRIVE PINION COMPANION FLANGE RR Remove the companion flange RR. 5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL 09308-10010 C139822 Using the, remove the carrier oil seal. Apply grease to the threads and tip of the center bolt before use. Apply Force Hold C137974 INSTALLATION 1. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL 09515-87302 Apply MP grease No. 2 to the lip of the carrier oil seal. Using the and a hammer, drive in a new carrier oil seal to the standard value. 0.5±0.5 mm (from the carrier end face) C139820 2. INSTALL REAR DRIVE PINION COMPANION FLANGE RR 09330-87301 Install the companion flange. Apply a light coat of gear oil to the screw part of a new pinion nut. (c) Using the, secure the companion flange RR.

33 DIFFERENTIAL REAR DIFFERENTIAL CARRIER OIL SEAL (d) (e) Using a torque wrench and a socket wrench (24 mm), install the plate washer and the lock nut. Using a chisel and a hammer, stake the pinion nut. C139821 3. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY(See page PR-7) 4. ADD DIFFERENTIAL OIL (See page -3) 5. INSPECT AND ADJUST DIFFERENTIAL OIL (See page -3)

DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY REAR DIFFERENTIAL CARRIER ASSEMBLY DRIVE DIFFERENTIAL LINE / AXLE REMOVAL 1. REMOVE REAR TIRE 34 2. DRAIN DIFFERENTIAL OIL Remove the differential filler plug and gasket. Remove the drain plug and gasket. Drain the oil. (c) Install the drain plug and a new gasket. Torque: 61.2 N*m (624.5 kgf*cm) 3. REMOVE REAR BRAKE DRUM(See page BR-30) 4. DISCONNECT SPEED SENSOR FR LH Remove the bolt and speed sensor RR LH. 5. DISCONNECT SPEED SENSOR FR RH Perform the same procedure for the RH side as for the LH side. 6. REMOVE REAR AXLE BEARING RETAINER OUT LH(See page AH-13) C133712 7. REMOVE REAR AXLE BEARING RETAINER OUT RH Perform the same procedure for the RH side as for the LH side. 8. REMOVE REAR AXLE SHAFT LH (See page AH-13) 9. REMOVE REAR AXLE SHAFT RH Perform the same procedure for the RH side as for the LH side. 10. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY(See page PR-6) 11. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY Support the rear differential carrier assembly with a jack. As the differential is heavy, be sure that it is securely supported with the jack. While supporting the rear differential carrier assembly with the jack, remove the 10 bolts and remove the rear differential carrier assembly. Do not damage the attachment surfaces when removing the rear differential carrier assembly. When removing the front differential carrier assembly, there is a possibility of leakage of residual oil. C137447 DISASSEMBLY 1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY 09548-87202, 09219-87202

35 DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY Secure the differential carrier assembly to the disassembly stand as shown in the diagram. 2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Install a dial indicator at a right-angle to the back side of the ring gear. C139639 Check the runout of the ring gear by turning the companion flange RR. Maximum limit: 0.16 mm If the runout exceeds the specified maximum value, remove the ring gear and check the case runout. C137448 3. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH Install a dial indicator at a right-angle to the edge of the tooth surface of the ring gear. Secure the companion flange RR by hand, and move the ring gear to check the backlash. 0.08 to 0.13 mm Measure in 3 locations on the ring gear circumference. In at least 2 of these locations, the measurement should be within 0.08 to 0.13 mm. In one location, however, a value as high as 0.15 mm may be allowed. C139640 4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH 09564-97401, 09330-87301 Place the dial indicator at a right-angle against the tooth surface edge of the differential side gear. Secure the differential pinion to the differential case, and inspect the backlash of the differential side gear. 2WD 0.025 to 0.1 mm 4WD 0 to 0.075 mm C139641

DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY 36 (c) If the backlash is 0 mm, use the to measure the activation torque of the side gear. Torque: 39.2 N*m (399 kgf*cm) or less C143343 5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Using a socket wrench and a torque wrench, measure the preload with the drive pinion in contact with the ring gear tooth surface. T = 0.78 to 1.17 N*m (8 to 11.9 kgf*cm) 6. REMOVE REAR DRIVE PINION NUT 09330-87301, O9213-31021 C139642 Using a chisel and a hammer, unstake the pinion nut. Always wear gloves and safety glasses when performing work. When removing the nut, completely unstake it. Do not damage the threads of the drive pinion. C139643 Using the, secure the companion flange, and remove the lock nut. 7. REMOVE REAR DRIVE PINION COMPANION FLANGE RR O9213-31021 C139644 Using the, remove the companion flange RR. Apply grease to the threads and tip of the center bolt before use. C139645

37 DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY 8. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Using the, remove the carrier oil seal. 09308-10010 Apply grease to the threads and tip of the center bolt before use. C139646 9. REMOVE REAR DIFFERENTIAL CASE 09504-87501 Remove the 2 bolts, then remove the 2 adjusting nut locks. Put match marks on the bearing cap and differential carrier. Put identification marks on one side only. (c) Remove the 4 bolts, and remove the 2 bearing caps and 2 adjusting nuts. As the bearing cap and carrier is processed as one unit, do not mix up the parts. Matchmarks C139653 (d) (e) Using the, remove the adjusting nut. Remove rear differential case No. 1 together with the case bearing (outer race). C139648 (f) Put identification marks on the adjusting nut and case bearing (outer race) or organize the parts separately. 10. REMOVE REAR DIFFERENTIAL CASE BEARING 09950-97201 Do not the remove the differential case bearing except when replacing the case bearing or the differential case. C014047

DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY 38 C139650 Using the, remove the 2 case bearings (inner race). Apply grease to the threads and the tip of the center bolt before use. Do not deform the gauge of the bearing (when re-using the bearing). Hook the claw from the notch of the differential case to the inner race of the case bearing. If it is difficult to hook the claw, lightly tap it using a hammer. 11. REMOVE DIFFERENTIAL RING GEAR Secure the differential case in the vise between aluminum plates. Do not tighten the vise too firmly. Put mach marks on the ring gear and the differential case. Matchmarks C135437 (c) (d) (e) Remove the 10 bolts, then remove the differential ring gear. Using a plastic hammer, uniformly tap the outer circumference of the ring gear to remove it. Place a rag over the tooth surface side of the ring gear to prevent damage. Secure the differential case in the vise between aluminum plates. Do not tighten the vise too firmly. 3 2 4 1 4 2 3 C137301 (f) (g) (h) Remove the parts listed below from the differential case.(2 pinion differential) (1) Rear differential pinion shaft (1 in the diagram) (2) Rear differential pinion gear (2 pieces) (2 in the diagram) (3) Rear differential side gear thrust washer No. 1 (2 pieces) (3 in the diagram) (4) Rear differential side gear (2 pieces) (4 in the diagram) Secure the differential case in the vise between aluminum plates. Do not tighten the vise too firmly. Remove the parts listed below from the differential case.(4 pinion differential) 5 2 1 1 2 4 4 3 1 5 2 1 C137453 (1) Rear differential pinion gear (4 pieces) (1 in the diagram) (2) Rear differential pinion gear (3 pieces) (2 in the diagram) (3) Spider differential (3 in the diagram)

39 DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY (4) Rear differential side gear (2 pieces) (4 in the diagram) (5) Rear differential side gear thrust washer No. 1 (2 pieces) (5 in the diagram) 12. REMOVE DIFFERENTIAL DRIVE PINION Using the plastic hammer or a similar tool, tap the differential drive pinion lightly to remove it. Do not drop the differential drive pinion. Remove the drive pinion bearing spacer from the differential drive pinion. C139651 Recommended Tool NO. 145 13. REMOVE REAR DRIVE PINION TAPERED ROLLER BEARING RR Using the bearing pulling attachment and a press, remove the tapered roller bearing RR (inner race) from the drive pinion. Do not drop the differential drive pinion. C139652 14. REMOVE REAR DRIVE PINION TAPERED ROLLER BEARING FR Using a brass bar and a hammer, lightly and uniformly tap on the tapered roller bearing FR (outer race) to remove it. C091046 15. REMOVE REAR DRIVE PINION TAPERED ROLLER BEARING RR Using a brass bar and a hammer, lightly and uniformly tap on the tapered roller bearing RR (outer race) and remove it. C091047

DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY 40 A 16. INSPECT REAR DRIVE PINION COMPANION FLANGE RR Check for any wear or damage on the oil contact part (A) or the spline (B) of the rear drive pinion companion flange RR. 17. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR Perform this task only if the dust deflector is damaged. B C139654 Using the bearing pulling attachment and a press, remove the dust deflector from the companion flange RR. Do not lose the companion flange. C090136J01 A B C 18. INSPECT REAR DIFFERENTIAL CARRIER ASSEMBLY Check for any damage to the side bearing attachment part of the differential carrier (A), the outer race attachment part of the tapered roller bearing (B), the oil seal insertion part (C), the carrier cover attachment part (D), and the carrier body (E). B D E C139655 A B 19. INSPECT FRONT DIFFERENTIAL CASE PINION DIFFERENTIAL DRIVE, GEAR DIFFERENTIAL RING (1) Visually inspect parts (A), (B), and (C) as shown in the diagram. There is no notable wear or damage. C C135702 A Shaft differential pinion, pinion differential, gear differential side (1) Visually inspect parts (A), (B), (C), (D), (E), and (F) as shown in the diagram. There is no notable wear or damage. F D C B E C135703

41 DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY C E B (c) CASE DIFFERENTIAL (1) Visually inspect parts (A), (B), (C), (D), and (E) as shown in the diagram. There is no notable wear or damage. REASSEMBLY D A D C135704 1. INSTALL REAR DRIVE PINION TAPERED ROLLER BEARING RR 09608-87302 Using the and a press, press in the tapered roller bearing RR (outer race). If either the front or rear bearing is damaged, replace them both as a set. Check the shims. If the shims are worn or scratched, install a new shim of the same thickness. C092467 2. INSTALL REAR DRIVE PINION TAPERED ROLLER BEARING FR 09608-87302 Using the and a press, press in the tapered roller bearing FR (outer race). If either the front or rear bearing is damaged, replace them both as a set. Check the shims. If the shims are worn or scratched, install a new shim of the same thickness. C092466 3. INSTALL REAR DRIVE PINION TAPERED ROLLER BEARING RR 09310-87301, 09608-03071 Using the and a press, press the tapered roller bearing RR (inner race) into the drive pinion. If either the front or rear bearing is damaged, replace them both as a set. When replacing the drive pinion, replace it with the ring gear as a set. C139724 TAPERED ROLLER BEARING (INNER RACE) 4. INSTALL DIFFERENTIAL DRIVE PINION Apply hypoid gear oil to the drive pinion tapered roller bearing FR (inner race), and temporarily install it together with the differential drive pinion to the differential carrier. Do not install the drive pinion bearing spacer and shim. C139725

DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY 42 Using the, press in the tapered roller bearing FR (inner race). 5. INSTALL REAR DRIVE PINION COMPANION FLANGE RR 09330-87301 C139726 Using the, secure companion flange RR, and gradually tighten the plate washer and the locknut to the standard preload. As the locknut does not contain a spacer, tighten it gradually. Do not tighten excessively. To work in the bearing, turn the flange several times forward and backward. C139727 (c) Using a torque wrench and a socket wrench (24 mm), measure the preload of the drive pinion. 0.88 to 1.27 N*m (9 to 13 kgf*cm) For the total preload measurement, record the preload. 6. INSTALL DIFFERENTIAL CASE NO. 1 09564-97401 C139728 Install the thrust washer to the side gear. When installing the side gear thrust washer, side gear, pinion gear, or other parts, make sure that there is no dirt or foreign matter on the parts, such as dust or cutting powder. When replacing the side gear or pinion, be sure to replace the side gear and pinion together as a set. Apply gear oil to the rotating and moving parts. C137459 (c) (d) Install the side gear (with thrust washer) and pinion, and pinion shaft. Secure the differential case in the vise between aluminum plates. Do not tighten the vise too firmly. Install a dial indicator at a right-angle to the edge of the tooth surface of the pinion gear. C139186

43 DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY (e) Secure the pinion against the differential case, and check the backlash. 2WD 0.025 to 0.00 mm 4WD 0 to 0.075 mm ZK01883 C143344 (f) (g) If the backlash is 0 mm, use the to measure the activation torque of the side gear. Side gear activation torque of 39.2 N*m (399 kgf*cm) or less In order to ensure that backlash of the side gear position falls within the range of standard values, select side gear thrust washers of the same size for both left and right sides. Then adjust. Thrust Washer Types Product Number Thickness (mm) 41361-87509 1.10 41362-87407 1.15 41363-87709 1.20 41361-87408 1.25 41361-87510 1.30 41361-87409 1.35 7. INSTALL DIFFERENTIAL RING GEAR Secure the differential case in a vise between aluminum plates. Do not tighten the vise too firmly. Align the match marks on the differential case and ring gear, and install the ring gear. (c) Install the 10 ring gear bolts. Torque: 97 N*m (989 kgf*cm) Tighten the bolts in cross-diagonal order. Tighten gradually in several passes. Matchmarks 8. INSTALL REAR DIFFERENTIAL CASE BEARING 09707-87302 C135437

DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY 44 Using the and a press, press the left and right case bearings (inner race) into the differential case. CAUTION: If the bearing is damaged, replace it with new one. When using a new bearing, do not apply the gear oil. Align the with the center of the differential case. When replacing the case bearing (inner race), also replace the case bearing (outer race) together as set. C139729 9. INSTALL DIFFERENTIAL CASE NO. 1 Install the case bearing (outer race) to the case bearing (inner race) Be sure to install the case bearing (outer races) in the correct left-right position. Install differential case No. 1 to the differential carrier. C139730 10. INSTALL REAR DIFFERENTIAL DRIVE BEARING ADJUST NUT Install the 2 rear differential bearing adjust nuts. Align the match marks of the bearing cap and carrier. C139731 (c) Tighten the bearing cap bolt 2 or 3 turns, then press down on the bearing cap with your hand to temporarily install it. 11. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH 09504-87501 Matchmarks C139653