GENERAL PROPELLER SHAFT ASSEMBLY

PROPELLER SHAFT
FRONT AXLE
FRONT HUB / KNUCKLE DIFFERENTIAL CARRIER ASSEMBLY
FRONT DIFFERENTIAL
REAR AXLE REAR DIFFERENTIAL CARRIER
REAR HUB / AXLE
DS -2 DRIVESHAFT AND AXLE

GENERAL
SPECIFICATIONS EBE00D25

PROPELLER SHAFT

1. TOTAL LENGTH

D4BH mm (in) J3 C/R mm (in)

MT MT AT

Long wheelbase(High 725.5 (28.56) 712 (28.03) 690.5(27.18)

long wheelbase) 924 (36.38) 910 (35.83) 888.5(34.98)
Front (4WD) - 871.6 (34.31) -
1.4TON (2WD) - 1174.5 (46.24) -

2. PROPELLER SHAFT RUN-OUT : 0.3 mm (0.12 in)

3. OUTER DIAMETER : 63.5 mm (2.5 in)

REAR AXLE AND DIFFERENTIAL

Items Specification
Rear axle
• Rear axle housing type Banjo type
• Supporting type Full-floating type
Differential
• Reduction gear type Hypoid gear
• Reduction gear ratio
3.727 J3 C/R (MT)
2WD J3 C/R (AT)
3.909
D4BH (MT)
4WD 4.444 J3 C/R (MT)
1.4TON 4.666 J3 C/R (MT)
GENERAL DS -3

TORQUE SPECIFICATIONS EB71DD29

Items Nm Kgf·m lbf·ft

Yoke flange mounting nut 50 ~ 60 5 ~ 6 36.9 ~ 44.3
Caliper mounting bolt 120~140 12 ~ 14 87.3 ~ 101.8
Disc brake mounting nut 65 ~ 87 6.5 ~ 8.7 47.3 ~ 63.3
Knuckle to tie rod end mounting 35 ~ 45 3.5 ~ 5.4 25.8 ~ 32.7
Knuckle to upper arm ball joint mounting 140 ~ 180 14 ~ 18 101.8 ~ 132.8
Knuckle to lower arm ball joint mounting 140 ~ 180 14 ~ 18 101.8 ~ 132.8
Brake tube flare nut 22 ~ 30 2.2 ~ 3 16.0 ~ 21.8
Knuckle to dust cover mounting 16 ~ 23 1.6 ~ 2.3 11.6 ~ 16.7
Rear axle shaft mounting bolt 60 ~ 75 6 ~ 7.5 44.3 ~ 54.5
Rear axle housing mounting nut 80 ~ 110 8 ~ 11 58.2 ~ 80.0
Differential carrier gear oil supply plug 40 ~ 55 4 ~ 5.5 29.5 ~ 40.0
Differential carrier gear oil drain plug 40 ~ 55 4 ~ 5.5 29.5 ~ 40.0
Differential carrier to rear axle housing 23 ~ 27 2.3 ~ 2.7 16.7 ~ 19.6
mounting
Wheel sensor mounting 8 ~ 10 8 ~ 10 5.8 ~ 7.3
Front wheel nut 190 ~ 220 19 ~ 22 138.2 ~ 160.0
Rear wheel nut 190 ~ 220 19 ~ 22 138.2 ~ 160.0

CAUTION
Replace self-locking nuts with new ones after removal.

LUBRICATIONS

Items Specified lubricants Quantity

Front hub
• Inner bearing Li-COMPLEX(WBG-2) About 10g
• Outer bearing Li-COMPLEX(WBG-2) About 7g
• Oil seal Li-COMPLEX(WBG-2) About 2g
• Hub inner Li-COMPLEX(WBG-2) About 45g
• Grease cap inner Li-COMPLEX(WBG-2) About 7g
Rear hub
• Inner bearing Li-COMPLEX(WBG-2) Required
• Outer bearing Li-COMPLEX(WBG-2) Required
• IInner/Outer oil seal Li-COMPLEX(WBG-2) Required
Universal joint ALVANIA EP #2 About 3.5gr.(About 0.23g)
Differential carrier General zone(-30~30 C) : API GL-#4, GS 90(SAE 90) Fill the reservoir to the
gear oil plug hold
Severe heat zone(30 C MIN.) : API GL-#4,
(About 1.7L)
GS 90(SAE 140)
Severe frigid zone(-30 C MAX.) : API GL-#5,
GH 90(SAE 80)

SEALANTS AND ADHESIVES

Items Specified sealants and adhesives

Contact surface of the rear axle shaft and hub THREE BOND #1104 or equivalent
Differential cover installation surface(to gear carrier) THREE BOND #1215(liquid gasket) or equivalent
DS -4 DRIVESHAFT AND AXLE

SPECIAL TOOL EC653ACA

TOOL
Illustration Use
(Number and Name)
09568-4A000 Dissembly of ball joint
Ball joint puller

AI8C002A

09568-34000 Dissembly of tie rod end

Ball joint puller

E6834000

0K670 990 AA0 Dissembly of side bearing

Bearing installer set

AI8C002B

09433-43000 Removal or istallation of journal bearing

Universal joint (Used with 09493-43100)
remover/installer

AIBE101I

09433-43100 Removal or istallation of journal bearing

Universal joint remover (Used with 09493-43000)
adapter

AIBE101J
GENERAL DS -5

TOOL
Illustration Use
(Number and Name)
09527-47000 Dissembly or assembly of rear axle locking nut
Rear axle hub wheel nut
remover/installer

AIBE101K

09517-21400 Removal or istallation of front hub

Draft bearing outer lace

AIBE101L

09517-43401 Differential carier working base

Working base

LIAC003R

09517-43001 Dissembly of front lower arm ball joint

Bearing puller or differential side bearing

LIAC003K

09517-21700 Removal of differential self locking nut

End york holder

LIAC003S
DS -6 DRIVESHAFT AND AXLE

TOOL
Illustration Use
(Number and Name)
09500-11000 - Oil seal or bearing istallation
Bar - Istallation of axle shaft bearing outer lace
(Used with 09432-33400)
- Oil seal installation
(Used with 09432-33400)

AIBE101M

09500-21000 Front hub bearing installation

Bar (Used with 09432-33700)

LIAC003C

09432-33700 Front hub bearing installation

Bearing outer lace installer (Used with 09500-21000)

LIAC003B

09532-32000 Installation of differential drive pinion

Oil seal installer front bearing outer lace

LIAC003N

0K993 270 A09 Drive pinion height adjustment

Drive pinion

LIAC003T
GENERAL DS -7

TOOL
Illustration Use
(Number and Name)
0K993 270 A10 Drive pinion height adjustment
Drive pinion model

LIAC003V

0K993 270 A08 Drive pinion height adjustment

Gauge block

LIAC003U

09517-43500 Differential carrier installation

Adapter

AIBE101N

09532-11600 Drive pinion

Free rod socket (Used with torque wrench)

LIAC003M
DS -8 DRIVESHAFT AND AXLE

TROUBLESHOOTING E0E2DE04

Symptom Suspect Area Remedy

Propeller Noise at start Worn journal bearing Replace
shaft
Worn sleeve yoke spline or flange yoke Replace
Loose propeller shaft installation Readjust
Noise and vibration Unbalanced propeller shaft Replace
at high speed
Improper snap ring selection Readjust
Worn journal bearing Replace
Axle shaft, Noise while wheels Bent axle shaft Replace
axle housing are rotating
Worn or scarred axle shaft bearing Replace
Grease leakage Worn or damaged oil seal Replace
Malfunction of bearing seal Replace
Differential Constant noise Improper drive gear and drive pinion gear Readjust
tooth contact
Loose, worn or damaged side bearing
Readjust or replace
Loose, worn or damaged drive pinion bearing
Worn drive gear, drive pinion
Worn side gear thrust washer or pinion shaft
Replace
Deformed drive gear of differential case
Damaged gear
Foreign material Remove on replace
Insufficient oil Refill
Gear noise while Poor gear engagement Readjust or replace
driving
Improper gear adjustment
Improper drive pinion preload adjustment Readjust
Damaged gear Replace
Foreign material Remove or replace
Insufficient oil Refill
Gear noise while Improper drive pinion preload adjustment Readjust
coasting
Damaged gear Replace
Bearing noise while
Cracked or damaged drive pinion rear bearing Replace
driving or coasting
Noise while turning Loose side bearing Replace
Damaged side gear, pinion gear or pinion shaft
Heat Improper gear backlash Readjust
Excessive preload
Insufficient oil Refill
GENERAL DS -9

Symptom Suspect Area Remedy

Differential Oil leakage Differential carrier not tightened Refair or replace gasket
Seal malfunction
Worn or damaged oil seal
Excessive oil Readjust
DS -10 DRIVESHAFT AND AXLE

FRONT AXLE

FRONT HUB / KNUCKLE

COMPONENTS(1TON) ECF6FB8A

LIBE101A
FRONT AXLE DS -11

LIBE010D
DS -12 DRIVESHAFT AND AXLE

ON VEHICLE MAINTENANCE E4C73D02 Preload : 40~80 Nm (4~8 kgf·m, 29~58 lbf·ft)

Read on spring weight :
1. Raise the vehicle and support it with a safety stand. 2WD : 7~12 Nm (0.7~1.2 kgf·m, 5.1~8.7 lbf·ft)
4WD : 5~10 Nm (0.5~1 kgf·m, 3.6~8.7 lbf·ft)
2. Turn the tire strongly with a hand to check whether
the tire spins smoothly and the bearing makes any
strange sound.

AIBE003C

AIBE003A
7. Remove the hub cap and install the cotter pin. With
measuring a preload, tighten and adjust the nut.
3. Remove wheels and tires.
CAUTION
4. Remove the disk brake caliper assembly, then tie it
with a proper string. After the adjustment, prevent the wheel from spin-
ing by using a brand new cotter pin.
5. Install a dial gauge to the wheel hub and measure the
wheel bearing play by pushing and pulling it to the
shaft direction.
Replace the wheel bearing if necessary.

Wheel bearing free play :

2WD : 0.05 mm (0.002 in)
4WD : 0.2~0.5 mm (0.008 ~ 0.019 in)

AIBE003D

8. Install the caliper assembly, wheel, and tire, then re-

move the safety stand.

AIBE003B

6. Install a spring weight on the wheel set bolt, and mea-

sure the preload.
FRONT AXLE DS -13

REMOVAL(1TON) E0B66BF9

1. Loosen the wheel nuts slightly.

Raise the front of the vehicle, and make sure it is
securely supported.

2. Remove the front wheel and tire(A) from front hub(B).

AIBE003H

CAUTION
Apply a few drops of oil to the special tool.
(Boot contact part)

5. Remove the shock absorber mounting pin nut(A) and

AIBE003E lower arm link(B).

CAUTION
Be careful not to damage the hub bolts(C) then
remove the front wheel and tire(A).

3. Remove the caliper mounting bolts(A), and hang the

caliper assembly(B) to one side.
To prevent damage to the caliper assembly or brake
hose, use a short piece of wire to hang the caliper
from the undercarriage.

AIBE003I

6. Disconnect the upper arm(A) and lower arm(B) using

the special tool(09568-4A000).

AIBE003F

4. Disconnect the tie rod end ball joint(C) from the

knuckle(D) using the special tool(09568-34000).

AIBE003J
DS -14 DRIVESHAFT AND AXLE

7. Remove the hub and knuckle assembly(C).

CAUTION
Be careful not to damage the boot.

DISASSEMBLY(2WD) E6BEB49D

1. Remove the hub cap(A), split pin(B), hub bearing lock

nut(C), hub bearing outer washer(D) and outer hub
bearing(E).

AIBE003M

4. Remove the disc brake mounting bolts(D).

CAUTION
When mounting the disc in vice, fix copper or alu-
minum board to the jaws of it.

5. Remove the hub bolts(A).

AIBE003K

2. Remove the hub and disc assembly(A) from the

knuckle(B).

AIBE003N

6. Disassemble the front hub grease oil seal(A), inner

bearing(B), inner bearing race(C) and outer bearing
race(D) using the special tool (09517-21400) or brass
bar.

AIBE003L

3. Make the matchmark(C) on the brake disc(B) and

front hub(A).
FRONT AXLE DS -15

AIBE003O AIBE003U

CAUTION b. Outer bearing race

Do not hit except for hub inner groove part(A) us-

ing the special tool(09517-21400) or brass bar.

AIBE003R

CAUTION
AIBE003P
The inner bearing race(A) and outer bearing
race(B) should be replaced as an assembly.
INSPECTION EA65DA72

3. Insert the inner bearing(A).

1. Check the hub for cracks and the splines for wear.

2. Check the brake disc for scoring and damage.

3. Check the knuckle for cracks.

4. Check the bearing for cracks or damage.

REASSEMBLY EA668E25

1. Apply the specified grease to the hub inner, hub bear-

ing and new oil seal.

2. Press-fit the inner bearing race(A) and outer bearing

race(B) with special tools.
a. Inner bearing race AIBE003S
DS -16 DRIVESHAFT AND AXLE

4. Apply grease on the lip of new front hub grease oil

seal(B) and press-fit on the front hub(C).

CAUTION
Replace the oil seal with new ones after removal.

5. Press-fit the hub bolts(A).

Inserting load : 4 ~ 4.5TON

Rotating torque(after inserting) : MIN. 1.5Nm

AIBE003L

8. Reassemble the hub cap(A), split pin(B), hub bearing

lock nut(C), hub bearing outer washer(D) and outer
hub bearing(E) in the reverse order of disassembly.

AIBE003T

6. Align the matchmark(B) on the front hub and brake

disc.
Install the disc brake mounting bolts(A).

Specified torque Nm(kgf·m, lbf·ft)

65 ~ 87 (6.5 ~ 8.7, 47.0 ~ 62.9)
AIBE003K

AIBE003Q

7. Install the hub and disc assembly(A) to the

knuckle(B).
FRONT AXLE DS -17

INSTALLATION E0EF7E7F

1. Installation is in the reverse order of removal.

NOTE
Tighten the components below to the specified
torque.

2. Greace hub’s inner part before installing the hub to

the knuckle.

3. Tighten the hub bearing nut by the following proce-

dures.
a. Hub bearing nut must be fastened with torque
3kgf·m and front hub must be rotated above 3 AIBE102B
times enough for secure placement of hub bear-
ing.
b. Unfasten hub bearing nut until its tightening
torque is 0kgf·m.
c. Hub bearing nut must be fastened again with
torque 1.8Kgf·m.

AIBE102A

4. Assemble sprit pin.

CAUTION
Use a new split pin.

5. If the direction of sprit pin is not in line with the hole

of knuckle unfasten hub bearing nut within 30 and
assemble sprit pin.
DS -18 DRIVESHAFT AND AXLE

COMPONENTS(1.4TON) ECD588CB

[1.4TON] 13~20
(1.3~2, 9.5~14.5)
100~120
(10~12, 72.7~87.2)

60~85
(6~8.5, 43.6~61.8)

20~30
(2~3, 14.5~21.8)

250~410
(25~41, 18.1~29.8)

13~20
(1.3~2, 9.5~14.5)

90~110
(9~11, 65.5~80.0)

LIBE102C
FRONT AXLE DS -19

REMOVAL(1.4TON) EDB83FD6 7. Remove drag link(B) and tie-rod(C) from the knuckle
arm(A) with the special tool (09568-4A000).
1. Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is
securely supported.

2. Remove the front wheel and tire from front hub.

3. Remove the brake caliper assembly.

CAUTION
Hang the brake caliper assembly on at appropriate
level with a lope as shown below.

AIBE102F

8. Remove the king-pin oil level gauge.

9. Remove the king-pin caps (upper and lower).

NOTE
King-pin oil flows out in the above condition.
Place a dish under the king-pin.

10. Remove the lock pin of the king-pin.

AIBE102D

NOTE
4. Remove the hub cab.
Never reuse the lock pin of the king-pin.
5. Remove the stop retainer and the nuts.

6. Remove both the disk plate and the front hub together.

CAUTION
Be careful not to drop the wheel bearing. Place
a jack under the disk plate before removing both
the disk plate and the front hub because it may
too heavy to bear on hand.

AIBE102G

11. Remove the king-pin with a suitable brass rod and

hammer.

NOTE
a. The king-pin is tightly fitted in the front axle.
Take care to avoid injury when removing.
b. Pull out the king-pin after placing a jack under the
LIBE102E knuckle.
DS -20 DRIVESHAFT AND AXLE

12. Remove the knuckle together with the knuckle arm. NOTE
When striking the king-pin, ensure that the lock
groove of the king-pin accurately fits the lock hole of
the front axle.

8. Install the lock pin of the king-pin and tighten the nut
to the specified torque.

Tightening torque: 20~30 Nm (2~3 kgf·m,14~22 lbf·ft)

Knuckle

Front axle
AIBE102H

INSTALLATION (1.4TON) EBD83DAC

1. Install the new o-rings on the knuckle.

2. Install the knuckle and thrust bearing on the front axle.

3. Place a jack under the knuckle and raise it a little.

4. Measure the clearance between the knuckle and front AIBE102J

axle with a feeler gauge.
9. Install the king-pin cap at top and bottom and tighten
nuts to the specified torque.

Tightening torque: 13~20 Nm, (1.3~2 kgf·m, 9~14 lbf·ft )

CAUTION
Use a new gasket. Apply sealing agent to the gas-
ket before fitting it.

10. Pour king-pin oil (API Service GL-4) into the oil inlet of
the king-pin cap until the oil level reaches the marking
(where the diameter is expanded) on the level gauge.
AIBE102I

NOTE
5. Select the adjust shims that are suitable for the clear-
ance measured in procedure 4 and make sure that When measuring the oil quantity, do not screw with
the clearance between the front axle and knuckle is the gauge while measuring.
adjusted properly when shims are inserted.
11. Tighten the level gauge to the specified torque.
Standard clearance: 0.02~0.1 mm (0.0008~0.004 in)
12. Install the drag link and tie-rod on the knuckle and
tighten the nut to the specified torque.
6. Insert the king-pin guide from the lower part of
knuckle, aligning the holes of the front axle and
knuckle. 13. Install the front brake assembly and tighten the bolts
to the specified torque.
7. Drive in the king-pin from the top of knuckle by striking
the pin with a nylon hammer. 14. Install the front hub.
REAR AXLE DS -21

REAR AXLE

REAR HUB / AXLE

COMPONENTS(1TON) E6796AA3

LIBE006A
DS -22 DRIVESHAFT AND AXLE

LIBE006B
REAR AXLE DS -23

ON VEHICLE INSPECTION EB1BCBCE

1. Raise the rear part of vehicle, and stand it with a safety

stand. Then, inspect the free play by moving the tire
with hand.

AIBE007C

Remove the bearing set plate, then loosen the bearing

lock nut by using the Special tool(09527-47000).

AIBE007A

Freeplay : 0 mm (0 in)

2. Rotate the tire strongly with hands, and check whether

it rotates smoothly or whether it makes any strange
sounds.

AIBE007D

3. Remove the rear brake drum(A).

AIBE007B

3. Remove a wheel and a tire.

4. Check the preload, then lower the vehicle.

REMOVAL(1TON) EF8AF771

1. Remove a wheel and a tire.

2. Remove the rear axle shaft(A) from the casing. AIBE007E

DS -24 DRIVESHAFT AND AXLE

DISASSEMBLY (1TON) EF6F4DBB 3. Wear or rust on the oil seal.

1. Remove the bearing outer. 4. Wear or damage of oil seal set bolt.

2. Remove the bearing outer race by using a proper steel

pipe. CAUTION
The bearing have to replaced inner and outer to-
CAUTION gether as a set.

• The inner race and an oil seal will be removed

with the outer race. REASSEMBLY (1TON) EEDD0FE6

• Do not reuse the oil seal.

1. Press in the wheel set bolt by using a press and a
proper steel stick.

2. Press in the bearing outer race to the drum, and install

the inner race.

AIBE008A

3. Remove the wheel set bolt by using a hammer.

CAUTION
AIBE009A
Do not reuse the removed wheel set bolt.
3. Press in the oil seal, until it touches to the drum sur-
face.

CAUTION
Apply a grease to the oil seal lip part.

AIBE008B

INSPECTION E5B5F1EF

Check the following points, and replace it if necessary.

1. Damage and rotating condition of bearing. AIBE009B

2. Crack or damage of hub and drum. 4. Apply a grease to the shaded areas in the right figure.
REAR AXLE DS -25

AIBE009C AIBE010B

INSTALLATION(1TON) E830225D
CAUTION
• Apply a sealant on the assembly surface of
1. Install the drum, then install the bearing inner race. drum and shaft.
• Be careful not to damage the oil seal when
2. Adjust the bearing preload like following steps. assemble the rear axle shaft.

1) Install the drum, then install the bearing inner

race.

2) Loosen the lock nut.

3) Install the spring weight on the wheel set bolt, and

measure the resistance of an oil seal.

4) Tighten the hub nut until the measured spring

weight is equal to the measured resistance plus
8.8~23 N·m(0.9~2.3 kgf·m, 6.5~17 lbf·ft).

AIBE010C

4. Install a wheel and a tire.

AIBE010A

3. Tighten the set plate and axle shaft to the specified

torque.

Tightening torque
Set plate : 7.9~12 N·m(0.8~1.2 kgf·m, 5.8~8.7 lbf·ft)
Rear axle shaft : 60~75 N·m (6.0~7.5
kgf·m, 43~54 lbf·ft)
DS -26 DRIVESHAFT AND AXLE

COMPONENTS(1.4TON) E4BF987D

[1.4TON] 40~55
(4~5.5, 29.1~40.1)

11

10

7 40~55
(4~5.5, 29.1~40.0)

6
80~110
5
4 (8~11, 58.2~80.0)
3
2 60~75
(6~7.5, 43.6~54.5)
8
1

1. Axle shaft 7. Brake drum

2. Oil seal 8. Hub bolt
3. Bearing locking nut 9. Rear wheel hub
4. Locking washer 10. Brake assembly
5. Bearing locking nut 11. Rear axle housing
6. Locking washer
LIBE020A
REAR AXLE DS -27

REMOVAL(1.4TON) E53D7154

1. Loosen the wheel nuts(D) slightly.

Raise the front of the vehicle, and make sure it is
securely supported.

2. Remove the front wheel and tire(A) from front hub(B).

AIBE020D

5. Remove the oil seal(C).

6. Remove the lock nut mounting bolts(A) and lock

washer(B).

AIBE020B

CAUTION
Be careful not to damage the hub bolts(C) then
remove the rear wheel and tire(A).

3. Remove the brake drum(A).

AIBE020E

7. Remove the lock nut using the special tool. (09527-

47000)

AIBE020C

NOTE
If the brake drum(A) is difficult to remove, insert a bolt
into a hole(B) on brake drum flange.

4. Release the bolt(A) mounting the axle shaft(B) and

rearwheel hub to remove the shaft.

AIBE020F

8. Remove the rear wheel hub(B) and outer bearing(C)

from the rear axle housing(A).
DS -28 DRIVESHAFT AND AXLE

AIBE020G AIBE020H

CAUTION CAUTION
Be careful that the outer hub bearing dose not Do not hit except for hub inner groove part(A) us-
drop. ing the special tool(09517-21400) or brass bar.

DISASSEMBLY(1.4TON) E1ECAA29

1. Remove the outer hub bearing(A).

AIBE020J

3. Remove the hub bolts(A).

AIBE020I

2. Disassemble the inner oil seal(A), inner bearing(B),

inner bearing race(C) and outer bearing race(D) using
the special tool(09517-21400) or brass bar.

AIBE020K
REAR AXLE DS -29

REASSEMBLY(1.4TON) E978C3E3

1. Apply the specified grease to the hub bearing and new

oil seal.

2. Press-fit the inner bearing race(A) and outer bearing

race(B) with special tools.
a. Inner bearing race

AIBE020L

4. Press-fit the new oil seal(B) at the rear hub(C) surface.

CAUTION
Replace the oil seal with new ones after removal.

5. Press-fit the hub bolts(A).

AIBE020N
Inserting load : 4~5TON
b. Outer bearing race Rotating torque(after inserting) : MIN. 1.5Nm

AIBE020M
AIBE003T

CAUTION
The inner bearing race(A) and outer bearing
race(B) should be replaced as an assembly.

3. Insert the inner bearing(A).

DS -30 DRIVESHAFT AND AXLE

INSTALLATION(1.4TON) E56F27BF
CAUTION
1. Install the rear wheel hub(B) and outer bearing(C) Replace the oil seal with new ones after removal.
from the rear axle housing(A).
5. Install the brake drum(A).

AIBE020Q
AIBE020R

2. Bearing preload adjustment.

a. Fasten lock nut with 18 ~ 22kgf·m and than loose 6. Install the front wheel and tire(A) from front hub(B).
in completely.
b. Fasten lock nut with 2 ~ 3kgf·m after rotating hub.
c. Insert lock washer into spindle groove of housing
and fix by fastening lock nut with bolt(2 pieces).
d. Must be operated smoothly under preload 1.5 ~
3.0kgf·m at the point of hub bolts.

3. Apply the specified sealant on the contact surface of

the axle housing(A) and hub(B).

Specified sealant
THREE BOND #1104 or equivalent

AIBE020B

CAUTION
Be careful not to damage the hub bolts(C) then
install the rear wheel and tire(A).

7. Fasten the rear wheel nut(D).

Specified torque Nm(kgf·m, lbf·ft)

190 ~ 220 (19 ~ 22, 138 ~ 160)

AIBE020Q

4. Install the new oil seal(C) and axle shaft assembly(D).

Axle shaft mounting bolt specified torque

Nm(kgf·m, lbf·ft)
60 ~ 75 (6 ~ 7.5, 44.3 ~ 54.5)
PROPELLER SHAFT ASSEMBLY DS -31

PROPELLER SHAFT
ASSEMBLY
PROPELLER SHAFT

COMPONENTS EC51F0AA

50~60
(5~6, 36.4~43.6) 5
4
6

4 5

7 6
3
2
2
1

7
3

2 5
4 6

50~60
(5~6, 36.4~43.6)

6 7
5 4 2 3

(1.4TON) 7

6
5 4

LIBE201A
DS -32 DRIVESHAFT AND AXLE

REMOVAL EA31024C

1. After making a matchmark(C) on the rear differential

companion(A) and flange yoke(B), remove the pro-
peller shaft(D).

AIBE202H

2. Reassemble the snap rings(D) from the yoke(A).

3. Press a journal bearing(A) by using the special tools

(09493-43000 & 09493-43100) to force out the journal
AIBE202A bearing on opposite side.

CAUTION
• Do not lower the rear of manual transmission
vehicles because this may cause the trans-
mission oil to flow out.
• Be careful not to damage the lip(A) of the
transmission oil seal.
• Do not allow foreign matter to enter the trans-
mission.

AIBE202G

CAUTION
Do not tap the journal bearings(A) to remove
them, as this will up set the balance of the pro-
peller shaft.

4. Remove the remaining bearing(A) and the yoke(B).

AIBE202B

DISASSEMBLY EA83EC4D

1. Make the matchmark(C) on the yoke(A) and the uni-

versal joint(B) that is to be disassembled.
PROPELLER SHAFT ASSEMBLY DS -33

AIBE202F AIBE202D

INSPECTION E5D9C8FA 5. Measure the propeller shaft runout with a dial indica-
tor.
1. Check the sleeve yoke and flange yoke for wear, dam-
age or cracks. Limit mm(in) : 0.3 (0.012) or less

2. Check the propeller shaft yokes for wear, damage or

cracks. REASSEMBLY EFC9A9AE

3. Check the propeller shaft for bends, twisting or dam- 1. Apply specified grease to the following parts of uni-
age. versal joint kit.
a. Shafts and grease sumps of journal.
4. Check the universal joints for smooth operation in all
b. Dust seal lips.
directions.
c. Needle roller of bearings.
a. Input part
Specified grease : ALVANIA EP #2

AIBE202C

b. Output part
AIBE202I

CAUTION
Use of excessive amounts of grease may result in
difficulty in assembling unit and incorrect selec-
tion of snap rings.

2. Use special tools (09493-43000 & 09493-43100) to

press the journal bearing(A) into the yoke until the
snap ring groove is fully visible.
DS -34 DRIVESHAFT AND AXLE

AIBE202G AIBE202L

3. Use special tools (09493-43000 & 09493-43100) to 6. If the clearance exceeds the standard value, adjust by
press the opposite journal bearing into the yoke. changing the thickness of the new snap ring.

CAUTION
Be careful when pressing the journal bearings, as
if they are pressed at an angle, the inside of the
journal bearing will be damaged by the journal.

4. Install the new snap rings(B) at the snap ring hole(A).

AIBE202E

AIBE202K

5. Measure the clearance(C) of the snap ring hole and

snap ring(B) with a feeler gauge(A).

Standard value mm(in) : 0 ~ 0.03 (0 ~ 0.0012)

PROPELLER SHAFT ASSEMBLY DS -35

INSTALLATION EB85987B

1. Connect propeller shaft flange to companion flange

on rear differential.
a. Align index marks on the flange and connect the
flange with four bolts and nuts.
b. Tighten the bolts and nuts.

Tightening torque :
50-60 Nm (5.0-6.0 kgf·m, 36-43 lbf·ft)

LIAC044F

2. After installing the propeller shaft fill the grease into

the nipple until it comes out from the sleeve yoke plug
hole.

Gear oil : Hypoid gear oil (80W,75W-85W)

DS -36 DRIVESHAFT AND AXLE

DIFFERENTIAL CARRIER
ASSEMBLY
FRONT DIFFERENTIAL

COMPONENTS(4WD) E7913CBF

70~85
(7~8,50.9~161.8)

38~53
(3.8~5.3,
27.6~38.5)

7~10
(0.7~1,5.1~6.2)
38~53
(3.8~5.3,27.6~38.5)

LIBE011B
DIFFERENTIAL CARRIER ASSEMBLY DS -37

REMOVAL E7B5267D

1. Drain oil.

LIAC044F

4. Remove the power steering tube mounting bracket.

AIBE011C
Tightening torque :
18~23 Nm (1.8~2.3 kgf·m, 13~16 lbf·ft)
2. Remove the drive shaft and the output shaft.

CAUTION
When removing the driveshaft, be careful not to
damage the differential carrier oil seal by interfer-
ence of spline part.

LIAC071B

5. Remove the differential mounting bracket.

LIAC071C

3. Remove the front propeller shaft.

NOTE
Make matchmark on the flange yoke and differen-
tial companian flange to avoid any mistake when in-
stalling them again.

AIBE011D

6. Remove the differential mounting bolt.

7. Remove the differential carrier.

DS -38 DRIVESHAFT AND AXLE

INSPECTION BEFORE 2. If the runout is beyond the limit, check that there are
no foreign substances between the drive gear and
DISASSEMBLY E4C6CDA7
differential case and, that the bolts fixing the drive
gear are not loose.
Mount the differential carrier on the special tool(09517-
43401).
3. If nothing is wrong in check (2), adjust the drive gear
depth and remeasure.

NOTE
If these adjustments are impossible, replace the case
or install a new drive gear/drive pinion as a set.

LIAC072A

FINAL DRIVE GEAR BACKLASH

1. Fix the drive gear so it cannot move and measure the

final drive gearbacklash with a dial indicator.

LIAC072C
NOTE
Measure at four points or more on the circumference DIFFERENTIAL GEAR BACKLASH
of the drive gear.
1. Fix the side gear with a wedge so it cannot move and
Standard value : 0.09-0.11mm (0.0035-0.0043 in) measure the differential gear backlash with a dial in-
dicator on the pinion gear.

NOTE
Take the measurements at two places (4 places for
LSD) on the pinion gear.

Standard value : 0-0.1 mm (0-0.0039 in)

Wedge

LIAC072B

DRIVE GEAR RUNOUT

Side gear
Check the back-face lash as follows: thrust spacer

1. Place a dial gauge on the back-face of the drive gear Side gear
thrust spacer
and measure the runout.

Limit : 0.05 mm (0.0020 in)

LIAC073A
DIFFERENTIAL CARRIER ASSEMBLY DS -39

2. If the backlash exceeds the limit, adjust using side • Take heed not to snap or bend the piping
bearing spacers. hose.

NOTE
If adjustment is impossible, replace the side gear and
pinion gears as a set.

FINAL DRIVE GEAR TOOTH CONTACT To atmosphere

Check the final drive gear tooth contact by following the Front differential
steps below : (Actuator)

Air pump motor

1. Apply the same amount of machine blue slightly to
both surfaces of the drive gear teeth.

LIAC073L

2. Turn the ignition switch on and shift the transfer lever

2H→4H.

3. Check that the motor starts to revolve in 1 second and

stops when Air pressure gauge value displayed the
specified value.

Specified pressure :
37~57 kPa (5.4~8.2 lb/in², 0.38~0.58 kgf/cm²)

LIAC072E

CAUTION
2. Insert a brass rod between the differential carrier and
the differential case, and then rotate the companion Check also air leak.
flange by hand (once in the normal direction, and then
once in the reverse direction) while applying a load
to the drive gear so that some torque (approximately
25-30 kg-cm) is applied to the drive pinion.

CAUTION
If the drive gear is rotated too much, the tooth
contact pattern will become unclear and difficult
to check.

3. Check the tooth contact pattern.

4WD CONTROL SYSTEM (PART TIME 4WD)

FUNCTION CHECK
LIAC072M

1. Air pressure gauge is attached in between air hoses

that connect differential (actuator) with air pump motor 4. Check that if transfer lever is shifted to 2H then
assy. Air pressure gauge adjustment screw shall be promptly Air pressure gauge value drops down.
fastened until it stops ultimately. And make a blind
stopper at air check side by using fuel hose etc. 5. Confirm that motor returns when Air pressure adjust-
ment screw has been loosened to lower the gauge
pressure value after motor had started to revolve by
CAUTION
shifting transfer lever to 4H. And also check that the
• Air pressure gauge shall be installed by using motor stops after several seconds since it started to
3-way union etc. run.
DS -40 DRIVESHAFT AND AXLE

DISASSEMBLY EE32BF2C a. Make the matchmarks to the differential case and

the drive gear.
1. REMOVAL OF THE DIFFERENTIAL CASE ASSEM- b. Loosen the drive gear attaching bolts in diagonal
BLY sequence to remove the drive gear.

CAUTION
Remove the differential case assembly slowly and
carefully. Be careful so that the side bearing outer
race is not dropped.
Matchmarks
NOTE
Keep the right and left side bearings separate so that
they are not mixed during reassembly.

LIAC075C

4. REMOVAL OF LOCK PIN (FOR CONVENTIONAL

DIFFERENTIAL)

LIAC075A

LIAC075D
2. REMOVAL OF THE SIDE BEARING INNER RACES
Fit the nut on top of the differential case, and then 5. REMOVAL OF SELF-LOCKING NUT
use the special tool(09517-43001) to remove the side
bearing inner race.

NOTE
Attach the prongs of the special tool to the inner race
of the side bearing through the notched section in the
differential case.

LIAC075E

6. REMOVAL OF DRIVE PINION

a. Make the matchmarks to the drive pinion and
companion flange.

LIAC075B

3. REMOVAL OF DRIVE GEAR

DIFFERENTIAL CARRIER ASSEMBLY DS -41

CAUTION
Matchmarks should not be made to the contact
surfaces of the companion flange and the pro-
peller shaft.

b. Drive out the drive pinion together with the drive

pinion spacer and drive pinion front shims.

LIAC075H

9. REMOVAL OF DRIVE PINION INNER BEARING

OUTER RACE

LIAC075F

7. REMOVAL OF DRIVE PINION INNER BEARING IN-

NER RACE

LIAC075I

INSPECTION E9064DC3

1. Check the companion flange for wear or amage.

2. Check the bearings for wear or discoloration.

3. Check the gear carrier for cracks.

LIAC075G

4. Check the drive pinion and drive gear for wear or

8. REMOVAL OF OIL SEAL / DRIVE PINION OUTER
cracks.
BEARING INNER RACE / DRIVE PINION OUTER
BEARING OUTER RACE 5. Check the side gears, pinion gears and pinion shaft
for wear or damage.

6. Check the side gear spline for wear or damage.

7. Check the length of the distance piece.

Standard length :
56.85~57.15 mm(2.24~2.25 in)
DS -42 DRIVESHAFT AND AXLE

CAUTION
Loosen adjustment screw before attaching air
hose to air pressure gauge.

BI7C074A

LIAC075J
8. Check the air pump motor
2) Check that actuator is operated when air pres-
1) Attach air pressure gauge, voltmeter and battery sure gauge adjustment screw has been tightened
to air pump motor. as in figure. Air pressure to set at specified pressure. Also check air leak
gauge adjustment screw shall be fastened until from actuator.
it stops ultimately. And make a blind stopper at
air check side by using fuel hose etc. Adjusted pressure :
37 kPa (5.4 lb/in², 0.38 kgf/cm²)

CAUTION
Take heed that there is potential for diaphragm
breakage if pressure beyond 200 kPa (28 lb/in², 2.0
kgf/cm²) is applied.
Do not use the air gun.

LIAC075P

2) Confirm that motor runs when battery has been

connected. And check that motor stops when
returned to specified pressure.

Specified pressure :
37-57 kPa (5.4-8.2 lb/in², 0.38-0.58kgf/cm²)
LIAC075K

CAUTION
Check also air leak.

3) Read voltmeter indication value so as to check if

it is within specified range.

Voltage :
about 0 V (when motor runs)
10-14 V (when motor stopped)

9. Check the actuator.

1) Attach air pressure gauge to actuator as in figure.

DIFFERENTIAL CARRIER ASSEMBLY DS -43

REASSEMBLY E62D68E5

1. PRESS-FITTING OIL SEAL

Oil seal

LIAC076A LIAC076C

2. DRIVE PINION OUTER BEARING OUTER RACE IN- 4. ADJUSTMENT OF PINION HEIGHT
STALLATION Adjustment the drive pinion height by the following
procedure.
CAUTION
1) For assembly of pinion, use drive pinion
When press-fitting the outer race, do not incline model(0K993 270 A01), pinion height adjust-
it. ment gauge body(0K993 270 A09) and gauge
block(ht. 28 mm(1.102 in)).

LIAC076B

LIAC076D
3. DRIVE PINION INNER BEARING OUTER RACE IN-
STALLATION 2) Assemble spacer and inner bearing inner race to
pinion model and fix it with O-ring.
CAUTION
When press-fitting the outer race, do not incline NOTE
it. Use spacer disassembled.
DS -44 DRIVESHAFT AND AXLE

LIAC076E LIAC076G

3) Install pinion model assembly to carrier. 7) Put pinion height adjusting gauge body and
gauge block to the upper side of pinion model.
4) Assemble outer bearing, companion flange
washer, and lock nut. 8) Dial gauge needle should be placed at the lowest
part of side bearing.
NOTE
9) Measure minimum positions of both sides (LH,
Use washer and lock nut disassembled. RH).
5) Tighten lock nut.

NOTE
• Tighten to the extent the companion flange can
be screwed by hand.

LIAC076H

10) Add both values and divide it by 2.

11) If the value of the above step 10 is not within

specification, use new spacer adding the values
to current spacer.

Standard clearance :
-0.025~0.025 mm (-0.001~0.001 in)

LIAC076F MARK THICKNESS MARK THICKNESS

6) Put pinion height adjusting gauge body at right 08 3.08(0.1212) 29 3.29(0.1259)

angle and adjust it to 0. 11 3.11(0.1224) 32 3.32(0.1307)
14 3.14(0.1236) 35 3.35(0.1318)
17 3.17(0.1248) 38 3.38(0.1330)
20 3.20(0.1259) 41 3.41(0.1342)
23 3.23(0.1271) 44 3.44(0.1354)
26 3.26(0.1283) 47 3.47(0.1366)
DIFFERENTIAL CARRIER ASSEMBLY DS -45

LIAC076I LIAC076K

5. Adjustment of drive pinion preload. 7) Turn companion flange by hand so that bearing
be put at the right place.

8) Measure preload of drive pinion. If the result is

not within specification, use new distance piece
SPACER and measure again.

Preload :
127~176 Nm (13~18 kgf·m, 94~130 lbf·ft)

9) Remove the lock nut and then install the oil seal.

10) Install the companion flange and tighten lock nut.

LIAC076J

Tightening torque :
1) Install spacer. 127~284 Nm (13~29 kgf·m, 94~210 lbf·ft)

2) Push inner bearing in using SST. 6. ADJUSTMENT OF DIFFERENTIAL GEAR BACK-

LASH
NOTE Adjust the differential gear backlash according to the
following procedures :
• Keep pressuring until the sudden increase of
necessary power. 1) Assemble the side gears, side gear spacers, pin-
• Place the spacer for adjusting pinion height, en- ion gears, and pinion washers into the differential
suring exact direction of installation. case.

2) Temporarily install the pinion shaft.

3) Install distance piece.
NOTE
4) Push outer bearing in using SST.
Do not install the lock pin yet.

5) Install drive pinion assembly.

6) Install companion flange and tighten lock nut.

Tightening torque :
127~284 Nm (13-29 kgf·m, 94~210 lbf·ft)

NOTE
Do not install oil seal.
DS -46 DRIVESHAFT AND AXLE

2) Fix the lock pin in place by staking two points

around the lock pin hole with a punch.

LIAC076L

3) Insert a wedge in the side gear and measure the

differential gear backlash with a dial indicator on LIAC076N

the pinion gear.

8. INSTALLATION OF THE DRIVE GEAR
NOTE 1) Clean the drive gear attaching bolts.
Measure both pinion gears separately.
2) Remove the adhesive on the threaded holes of
Standard value : 0~0.1 mm (0~0.0039 in) the drive gear use a tap (M10 x 1.25), and then
Limit : 0.2 mm (0.008 in) clean the threaded holes with compressed air.

Attachment
Wedge

LIAC076M

4) If the differential gear backlash exceeds the limit,

LIAC076O
adjust the backlash by selecting thicker side gear
thrust spacers.
3) Apply the specified adhesive to the threaded
5) Measure the differential gear backlash once holes of the drive gear.
again, and confirm that it is within the limit.
Specified adhesive : LOCTITE #262 or equivalent

NOTE
• After adjustment, check that the backlash is
within the limit and the differential gear rotates
smoothly.
• When adjustment is impossible, replace the side
gear and the pinion gear as a set.

7. INSTALLATION OF THE LOCK PIN

1) Align the pinion shaft lock pin hole with the differ-
ential case lock pin hole, and drive in the lock pin.
DIFFERENTIAL CARRIER ASSEMBLY DS -47

1) Install side bearing spacers which are thinner

than those removed, to the side bearing outer
races, and then mount the differential case as-
sembly into the gear carrier.

NOTE
Select side bearing spacers with the same thickness
for both the drive pinion side and the drive gear side.

LIAC076P

4) Install the drive gear in the differential case with

the matchmarks properly aligned. Tighten the
bolts to the specified torque in a diagonal se-
quence.
LIAC076R
9. PRESS THE SIDE BEARING INNER RACE
2) Push the differential case to one side, and mea-
sure the clearance between the gear carrier and
Strap
Strap
the side bearing with a feeler gauge.

09532-32000

LIAC076Q

10. Attach actuator at differential case RH side as figure

CAUTION
Take heed of actuator direction.

LIAC076S

3) Select two pairs of spacers which correspond to

the value calculated according to the expression
in the illustration. Install one pair each to the drive
pinion side and the drive gear side.

LIAC077B

Clearance + 0.05 mm
11. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH +
2
Adjust the final drive gear backlash according to the
following procedures : = Thickness of the
spacer on one side

LIAC076T
DS -48 DRIVESHAFT AND AXLE

4) Install the side bearing spacers and differential 7) With the drive pinion locked in place, measure the
case assembly, as shown in the illustration, to the final drive gear backlash with a dial indicator on
gear carrier. the drive gear.

NOTE
Measure at four points or more on the circumference
of the drive gear.

Standard value : 0.09~0.11 mm (0.0035~0.0043 in)

LIAC076U

5) Tap the side bearing spacers with a brass bar to

fit them to the side bearing outer race.

LIAC076X

8) Change the side bearing spacers as illustrated

and then adjust the final drive gear backlash be-
tween the drive gear and the drive pinion.

NOTE
When increasing the number of side bearing spacers,
use the same number for each and as few as possible.

LIAC076V If backlash is too small

Thinner Thicker
6) Align the matchmarks on the gear carrier and the spacer spacer
bearing cap and tighten the bearing cap.

Thicker Thinner
spacer spacer
If backlash is too large
LIAC076Y

9) Check the drive gear and drive pinion for tooth

contact. If poor contact is evident, adjust again.

10) Measure the drive gear runout at the shoulder on

the reverse side of the drive gear.

Limit : 0.05 mm (0.002 in)

LIAC076W
DIFFERENTIAL CARRIER ASSEMBLY DS -49

LIAC076Z

11) If the drive gear runout exceeds the limit, reinstall

by changing the position of the drive gear and
differential case, and remeasure.

INSTALLATION E000EB37

1. Installation is the reverse of removal.

2. Align the matchmark on the flange yoke and the com-

panion flange.
Tighten the propeller shaft and the front differential
carrier.

LIAC044F
DS -50 DRIVESHAFT AND AXLE

REAR DIFFERENTIAL CARRIER

COMPONENTS EED716EE

LIBE011A
DIFFERENTIAL CARRIER ASSEMBLY DS -51

DIFFERENTIAL OIL CHECK EA89B684 Tightening torque : 40~55 N·m (4~5 kgf·m, 29~40 lbf·ft)

INSPECTION
REMOVAL ECA0CB1C
1. Remove the filler plug.

2. Check if the oil is enough to be seen from the filling 1. Drain the differential gear oil.
hole. Supply more specified oil if the oil is not enough.
2. Remove the rear disk brake.
3. Tighten the filler plug.
3. Remove the parking brake and cable.
REPLACEMENT
4. Remove the stabilizer bar.
1. Remove the drain plug and filler plug(A), then drain
the oil.
5. Pull out the rear axle shaft(A).
2. Clean the plug.
CAUTION
3. Apply a sealant on the thread of drain plug.
Be careful not to damage the oil seal when pulling
4. With new washer, tighten the drain plug(B). axle shaft.

Tightening torque : 40~55 N·m (4~5 kgf·m, 29~40 lbf·ft)

AIBE007C

6. After marking the matchmark on the flange yoke of

AIBE012B
the rear propeller shaft and the companion flange of
the differential case, remove the rear propeller shaft
5. Pour an oil until the level reaches to the filling hole.
assembly.

CAUTION
Suspend the propeller shaft from the body with
wire, etc.

Matchmark

AIBE012C

6. Tighten the filler plug. LIAC071D

DS -52 DRIVESHAFT AND AXLE

7. Remove the attaching nuts and strike the lower part

of differential carrier assembly with a piece of times
several times to loosen, then remove the differential
carrier assembly.

NOTE
Use care not to strike the companion flange.

AIBE301B

b. Adjust with the side bearing nuts if backlash val-

Squae lumber ues are not within standard range

LIAC078B
NOTE
After adjusting, check the tooth contact state of the
INSPECTION EBEFE22A final drive gear.

Install the differential carrier assembly(A) with the special

tools(09517-43101 & 09517-43500).
Then carry out the following inspection.

AIBE301C

2. Check the drive gear back-face lash by the following

procedure.
AIBE301A a. Place a dial gauge on the back-face of the drive
gear and measure the runout.
1. Check the final drive gear backlash by the following
procedure. Limit mm(in) : 0.05 (0.002)
a. Place the drive pinion and move the drive gear to
check backlash is within the standard range.

NOTE
Measure at 4 points on the gear periphery.

Standard value mm(in)

0.13 ~ 0.18 (0.0051 ~ 0.0071)
DIFFERENTIAL CARRIER ASSEMBLY DS -53

NOTE
If adjustment is impossible, replace the side gear and
pinion gear as a set.

4. Check the tooth contact of the final drive gear by the

following procedure.
a. Apply the same amount of machine blue slightly
to both surfaces of the drive gear teeth.

AIBE301D

b. If the runout is beyond the limit, check that there

are no foreign substances between the drive gear
and differential case and, that the bolts fixing the
drive gear are not loose.

3. Check the differential carrier backlash by the following

procedure.
a. Fix the side gear with a wedge so it cannot move
and measure the differential gear backlash with
a dial indicator on the pinion gear. AIBE301F

Standard value mm(in) b. Insert a brass rod between the differential carrier
0.010 ~ 0.076 (0.0004 ~ 0.0030) and the differential case, and then rotate the com-
Limit mm(in) : 0.2 (0.0079) panion flange by hand (once in the normal direc-
tion, and then once in the reverse direction) while
applying a load to the drive gear so that some
NOTE
torque (approximately 25~30Nm) is applied to
Take the measurements at two places on the pinion the drive pinion.
gear.

AIBE301G
AIBE301E

a. If the backlash exceeds the limit, adjust using CAUTION

side bearing spacers. If the drive gear is rotated too much, the tooth
contact pattern will become unclear and difficult
to check.

c. Check the tooth contact pattern.

DS -54 DRIVESHAFT AND AXLE

Tooth contact Contact state Solution

Standard contact

AIBE301H

Heal contact Increase the thickness of

the pinion height adjusting
shim, and position the drive
pinion closer to the center
of the drive gear.

Also, for backlash

adjustment, reposition
AIBE301I
the drive gear further from
Face contact the drive pinion.

AIBE301M

AIBE301J

Toe contact Decrease the thickness of

the pinion height adjusting
shim, and position the drive
pinion further from the
center of the drive gear.

Also, for backlash

adjustment, reposition
AIBE301K
the drive gear closer to
Flank contact the drive pinion.

AIBE301N

AIBE301L

NOTE 5. Check the companion flange for wear or damage.

• Tooth contact pattern is a method for judging the 6. Check the bearings for wear or discoloration.
result of the adjustment of drive pinion height and
final drive gear backlash. The adjustment of drive 7. Check the gear carrier for cracks.
pinion height and final drive gear backlash should
be repeated until the tooth contact patterns are 8. Check the drive pinion and drive gear for wear or
similar to the standard tooth contact pattern. cracks.
• When you cannot obtain a correct pattern, the
drive gear and drive pinion have exceeded their 9. Check the side gears, pinion gears and pinion shaft
limits. Both gears should be replaced as a set. for wear or damage.
DIFFERENTIAL CARRIER ASSEMBLY DS -55

10. Check the side gear spline for wear or damage.

INSTALLATION E96E32AF

1. Differential Carrier Assembly

Install the differential carrier assembly, after applying
the specified sealant to the axle housing flange sur-
face.

Specified sealant
THREE BOND #1215(liquid gasket) or equivalent

Differential carrier mounting nut

Specified torque Nm(kgf·m, lbf·ft)
23 ~ 27 (2.3 ~ 2.7, 16.7 ~ 19.6)

2. Propeller Shaft
Align the matchmark(C) on the flange yoke(A)
and companion flange(B), and install the propeller
shaft(D).

Propeller shaft mounting bolt & nut

Specified torque Nm(kgf·m, lbf·ft)
50 ~ 60 (5 ~ 6, 36.9 ~ 44.3)

3. Rear Axle Shaft Assembly

Apply the specified sealant on the contact surface of
the axle housing and hub.

Specified sealant
THREE BOND #1104 or equivalent