PROPELLER SHAFT &

DIFFERENTIAL CARRIER

SECTION PD
CONTENTS
PREPARATION................................................................1 Bearing.......................................................................19
Special Service Tools ..................................................1 LIMITED SLIP DIFFERENTIAL.....................................20
NOISE, VIBRATION AND HARSHNESS (NVH) Preparation for Disassembly .....................................20
TROUBLESHOOTING .....................................................4 Disassembly...............................................................21
NVH Troubleshooting Chart.........................................4 Inspection...................................................................21
PROPELLER SHAFT ......................................................5 Adjustment .................................................................23
Front Propeller Shaft ...................................................5 Assembly ...................................................................24
Rear Propeller Shaft ....................................................5 ADJUSTMENT ...............................................................27
On-vehicle Service.......................................................6 Drive Pinion Height....................................................27
Removal and Installation .............................................7 Tooth Contact.............................................................29 PD
Inspection.....................................................................7 ASSEMBLY....................................................................31
Disassembly.................................................................7 Differential Case — 4-pinion type —.........................31
Assembly .....................................................................8 Differential Case — 2-pinion type —.........................32
ON-VEHICLE SERVICE (Final Drive) ..........................10 Differential Carrier......................................................33
Front Oil Seal Replacement ......................................10 DIFFERENTIAL LOCK ..................................................37
REMOVAL AND INSTALLATION ..................................11 Actuator and Fork ......................................................37
Removal.....................................................................11 Disassembly...............................................................38
Installation..................................................................11 Inspection...................................................................39
FRONT FINAL DRIVE ...................................................12 Assembly ...................................................................40
REAR FINAL DRIVE .....................................................13 System Description....................................................43
DISASSEMBLY..............................................................14 Component Parts Location ........................................44
Pre-inspection ............................................................14 Wiring Diagram — DIFF/L —/LHD Models ...............45
Differential Carrier......................................................15 Wiring Diagram — DIFF/L —/RHD Models...............47
Differential Case ........................................................17 Electrical Components Inspection .............................49
INSPECTION..................................................................19 SERVICE DATA AND SPECIFICATIONS (SDS) ..........51
Ring Gear and Drive Pinion ......................................19 Propeller Shaft ...........................................................51
Differential Case Assembly........................................19 Final Drive..................................................................52
 PREPARATION

Special Service Tools

*: For front differential carrier only

Tool number Unit application

Description
Tool name H233B
ST0501S000 Mounting differential attach-
Engine stand ment
V1 ST05011000
Engine stand
V2 ST05012000 X
Base

NT042

ST06340000 Mounting final drive

Differential attachment

NT140

ST30611000 Installing pinion rear bearing

Drive pinion bearing outer outer race
race drift bar (Use with ST30621000 or
ST30613000) X

NT090

ST30613000 Installing pinion front bearing

Drive pinion front bearing outer race
outer race drift (Use with ST30613000)
X

a: 71.5 mm (2.815 in) dia.

NT073 b: 47.5 mm (1.870 in) dia.
ST30621000 Installing pinion rear bearing
Drive pinion rear bearing outer race
outer race drift (Use with ST30613000)
X*

a: 79 mm (3.11 in) dia.

NT073 b: 59 mm (2.32 in) dia.
ST3090S000 Removing and installing drive
Drive pinion rear bearing pinion rear inner race
inner race puller set
V 1 ST30031000
X
Puller
2 ST30911000 a: 79 mm (3.11 in) dia.
V
Base b: 45 mm (1.77 in) dia.
NT527 c: 35 mm (1.38 in) dia.

PD-1
 PREPARATION
Special Service Tools (Cont’d)
Tool number Unit application
Description
Tool name H233B
ST3127S000 Measuring pinion bearing
Preload gauge preload and total preload
V1 GG91030000
Torque wrench
X
V HT62900000
2
Socket adapter (1/2″)
V3 HT62940000
Socket adapter (3/8″) NT124

ST3125S000 Selecting pinion height

Drive pinion setting adjusting washer
gauge set
V1 ST31251000
Drive pinion height X
gauge
V2 ST31181001
Dummy shaft
NT524

KV40104000 Removing and installing pro-

Drive pinion flange peller shaft lock nut and drive
wrench pinion lock nut X

NT113

ST0237S000 Removing and installing side

Differential side bearing bearing inner race
puller set
V1 ST33051001
X
Puller
V2 ST02371000
a: 40 mm (1.57 in) dia.
Adapter
NT072 b: 50 mm (1.97 in) dia.
ST33081000 Installing side bearing inner
Adapter cone

a: 43 mm (1.69 in) dia.

NT431 b: 33.5 mm (1.319 in) dia.
ST33190000 Installing side bearing inner
Differential side bearing cone
drift
X
a: 52 mm (2.05 in) dia.
b: 45.5 mm (1.791 in) dia.
NT085 c: 34 mm (1.34 in) dia.
KV31100300 Removing pinion mate shaft
Fork rod pin punch lock pin
X

NT410 a: 4.5 mm (0.177 in) dia.

PD-2
 PREPARATION
Special Service Tools (Cont’d)
Tool number Unit application
Description
Tool name H233B
KV381025S0 Installing front oil seal
Oil seal fitting tool
V1 ST30720000
Drift bar
X
a: 77 mm (3.03 in) dia.
V KV38102510
2
Drift b: 55 mm (2.17 in) dia.
c: 71 mm (2.80 in) dia.
NT525 d: 65 mm (2.56 in) dia.
ST32580000 Adjusting side bearing pre-
Differential side bearing load and backlash (ring gear-
adjusting nut wrench drive pinion)
X

NT141

PD-3
 X: Applicable
Reference page

PRO-

Symptom SHAFT

ENTIAL
Possible cause and

PELLER

DIFFER-
SUSPECTED PARTS

Noise
Noise
Shake
Vibration
X
X
Uneven rotation torque —

X
X
X
Excessive joint angle —

X
X
Rotation imbalance PD-6

X
X
Excessive runout PD-6

X
Rough gear tooth PD-19

X
Improper gear contact PD-29

PD-4
Tooth surfaces worn PD-19

X
Incorrect backlash PD-14

X
Companion flange excessive runout —

X
Improper gear oil Refer to MA section.

X
PROPELLER SHAFT Refer to PROPELLER SHAFT in this chart.

X
DIFFERENTIAL Refer to DIFFERENTIAL in this chart.
NVH Troubleshooting Chart

X
X
X
X AXLE AND SUSPENSION NVH in FA, RA section

X
X
X
X

TIRES NVH in FA section

X
X
X

ROAD WHEEL NVH in FA section

X
X
X
X

DRIVE SHAFT NVH in RA section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

X
X
X

BRAKES NVH in BR section

X
X
X
X
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

STEERING NVH in ST section

PROPELLER SHAFT

Front Propeller Shaft

SPD434A

Rear Propeller Shaft

SPD457A

PD-5
 PROPELLER SHAFT

SPD458A

On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft runout
first.
1. Raise front and rear wheels.
2. Measure propeller shaft runout at several points by rotating
final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 in)

SPD728

3. If runout exceeds specifications, disconnect propeller shaft at

final drive companion flange; then rotate companion flange 180
degrees and reconnect propeller shaft.
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road tests.

APPEARANCE CHECKING
+ Inspect propeller shaft tube surface for dents or cracks. If
damaged, replace propeller shaft assembly.
SPD102

PD-6
 PROPELLER SHAFT

Removal and Installation

+ Put matchmarks on flanges and separate propeller shaft from
final drive.

SPD103

CAUTION:
When installing the propeller shaft, make sure it is facing the
correct direction. Each model is different.

Inspection
+ Inspect propeller shaft runout. If runout exceeds specifications,
replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)

SPD106

+ Inspect journal axial play.

If the play exceeds specifications, replace propeller shaft
assembly.
Journal axial play:
0.02 mm (0.0008 in) or less

SPD874

+ Check flange yoke and sleeve yoke for damage or wear.

Replace if necessary.

SPD189

Disassembly
JOURNAL
1. Put matchmarks on shaft and flange or yoke.

SPD128

PD-7
 PROPELLER SHAFT
Disassembly (Cont’d)
2. Remove snap ring.

SPD731

3. Remove pushed out journal bearing by lightly tapping yoke with

a hammer, taking care not to damage journal and yoke hole.

SPD732

4. Remove bearing at opposite side in above operation.

Put marks on disassembled parts so that they can be rein-
stalled in their original positions from which they were
removed.

SPD131

Assembly
JOURNAL
1. Assemble journal bearing. Apply recommended multi-purpose
grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.

SPD133

2. Select snap ring that will provide specified play in axial direc-
tion of journal, and install them. (Refer to SDS.)
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).

SPD134

PD-8
 PROPELLER SHAFT
Assembly (Cont’d)
3. Adjust thrust clearance between bearing and snap ring to zero
by tapping yoke.

SPD732

4. Check to see that journal moves smoothly and check for axial
play.
Axial play: 0.02 mm (0.0008 in) or less

SPD874

PD-9
ON-VEHICLE SERVICE (Final Drive)

Front Oil Seal Replacement

1. Remove propeller shaft.
2. Loosen drive pinion nut.
Tool number:
KV40104000

PD237

3. Remove companion flange.

SPD737

4. Remove front oil seal.

SPD738

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Press front oil seal into carrier.
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.
Tool number: KV381025S0

SPD739

PD-10
REMOVAL AND INSTALLATION

Removal
+ Remove propeller shaft.
+ Remove drive shaft. Refer to FA section (‘‘FRONT AXLE —
Knuckle Flange’’).
+ Remove axle shaft.
Refer to RA section (‘‘REAR AXLE’’).
+ Remove front and rear final drive mounting bolts.
CAUTION:
+ Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
SPD103 + Before removing the final drive assembly or rear axle
assembly, disconnect the ABS sensor harness connector
from the assembly and move it away from the final drive/
rear axle assembly area. Failure to do so may result in the
sensor wires being damaged and the sensor becoming
inoperative.

Installation
+ Fill final drive with recommended gear oil.

SPD123

+ Pay attention to the direction of gasket.

SPD767

PD-11
FRONT FINAL DRIVE

SPD436A

PD-12
REAR FINAL DRIVE

SPD437A

PD-13
 DISASSEMBLY

Pre-inspection
Before disassembling final drive, perform the following inspection.
+ Total preload
1) Turn drive pinion in both directions several times to set bearing
rollers.
2) Check total preload with Tool.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
SPD149 1.7 - 2.5 Nzm (17 - 25 kg-cm, 15 - 22 in-lb)
Used parts
1.5 - 1.7 Nzm (15 - 17 kg-cm, 13 - 15 in-lb)

+ Ring gear to drive pinion backlash

Check ring gear-to-drive pinion backlash with a dial indicator at
several points.
Ring gear-to-drive pinion backlash:
0.15 - 0.20 mm (0.0059 - 0.0079 in)

SPD246

+ Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)
+ Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-27).

SPD247

+ Side gear to pinion mate gear backlash

Measure clearance between side gear thrust washer and dif-
ferential case with a feeler gauge.
Clearance between side gear thrust washer and differ-
ential case:
0.15 - 0.20 mm (0.0059 - 0.0079 in)

SPD004

PD-14
 DISASSEMBLY

Differential Carrier
1. Mount differential carrier on Tools.
Tool number:
A ST0501S000
j
B ST06340000
j

SPD139

2. Put matchmarks on one side of side bearing cap with paint or

punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places.

SPD249

3. Remove side lock fingers and side bearing caps.

SPD250

4. Remove side bearing adjuster with Tool.

Tool number:
ST32580000

SPD684

5. Remove differential case assembly with a pry bar.

SPD685

PD-15
 DISASSEMBLY
Differential Carrier (Cont’d)
Be careful to keep the side bearing outer races together with
their respective inner cones — do not mix them up.

SPD011

6. Loosen drive pinion nut with Tool.

Tool number: KV38104700

SPD012

7. Remove companion flange with puller.

SPD686

8. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
shim with soft hammer.

SPD687

9. Remove front oil seal and pinion front bearing inner cone.
10. Remove pinion bearing outer races with a brass drift.

SPD563

PD-16
 DISASSEMBLY
Differential Carrier (Cont’d)
11. Remove pinion rear bearing inner cone and drive pinion height
adjusting washer with press and Tool.
Tool number: ST30031000

SPD018

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
jA ST33051001
jB ST02371000

SPD207A

Be careful not to confuse left and right hand parts.

Keep bearing and bearing race for each side together.

SPD022

2. Loosen ring gear bolts in a criss-cross pattern.

3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Drive out pinion mate shaft lock pin, with punch from ring gear
side (2-pinion type differential case).
Lock pin is calked at pin hole mouth on differential case.

SPD025

PD-17
 DISASSEMBLY
Differential Case (Cont’d)
5. Separate differential case LH and RH (4-pinion type differential
case).
Put matchmarks on both differential case LH and RH sides
prior to separating them.

SPD716

PD-18
 INSPECTION

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping. If any damaged
part is evident, replace ring gear and drive pinion as a set (hypoid
gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, thrust block and thrust washers.

SPD530

SPD717

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

PD-19
LIMITED SLIP DIFFERENTIAL

SPD439A

CAUTION:
Do not run engine when one wheel (rear) is off the ground.

Preparation for Disassembly

CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tool.
If it is not within the specifications, inspect components of limited
slip differential.
Differential torque:
108 - 137 Nzm (11 - 14 kg-m, 80 - 101 ft-lb)
Tool number: KV38106400

SPD508

PD-20
 LIMITED SLIP DIFFERENTIAL

Disassembly
1. Remove side bearing inner cone with Tool.
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD476

4. Loosen screws on differential cases A and B using a press.

5. Separate differential cases A and B. Draw out component parts
(discs and plates, etc.).
Put marks on gears, discs and plates so that they can be rein-
stalled in their original positions from which they were
removed.

SPD507

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.

SPD503

1
V Differential case A 4
V Thrust washer 7
V Pinion mate gear
2
V Differential case B 5
V Pinion mate shaft 8
V Side gear
3
V Pressure ring 6
V Thrust block

PD-21
LIMITED SLIP DIFFERENTIAL
Inspection (Cont’d)
DISC AND PLATE
1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

SPD478

3. To test if friction disc or plate is not distorted, place it on a sur-

face plate and rotate it by hand with indicating finger of dial
gauge resting against disc or plate surface.
Allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate possi-
bility of clutch slippage or sticking.

SPD279

4. Measure frictional surfaces and projected portions of friction

disc, friction plate, spring plate, and determine each part’s dif-
ferences to see if the specified wear limit has been exceeded.
If any part has worn beyond the wear limit, and deformed or
fatigued, replace it with a new one that is the same thickness
as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less

SPD403

PD-22
LIMITED SLIP DIFFERENTIAL

Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by using
following equation and should be adjusted within following range.
Adjustment can be made by selecting friction disc having two dif-
ferent thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
E = A − (B + C)
A: Length of differential case contact surface to differen-
SPD761
tial case inner bottom.
B: Total thickness of friction discs, friction plates, spring
disc and spring plate in differential case on one side.
C: Length of differential case contact surface to back side
of side gear.

1. Measure values of ‘‘A’’.

Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)

SPD417

2. Measure thickness of each disc and plate.

Total thickness ‘‘B’’:
19.24 - 20.26 mm (0.7575 - 0.7976 in)

SPD420

3. Measure values of ‘‘C’’.

(1) Attach a dial indicator to the base plate.
(2) Place differential case B on the base plate, and install a mas-
ter gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.

SPD418

PD-23
LIMITED SLIP DIFFERENTIAL
Adjustment (Cont’d)
(3) Install pinion mate gears, side gears and pinion mate shaft in
differential case B.
(4) Set dial indicator’s tip on the side gear, and read the indication.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C E=A−D
B .... 19.45 A ..... 49.52
SPD419
+C .... 29.7 −D .... 49.15
49.15 0.37

From the above equation, end play of 0.37 mm exceeds the speci-
fied range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.

Assembly
Assemble differential case in the reverse order of disassembly,
observing the following.
1. As an aid to installation, apply sufficient amounts of recom-
mended limited slip differential gear oil (refer to MA section) to
the faces of pressure rings, discs and plates to be assembled
together.

SPD479

2. Place differential case B on a level surface, then install thrust

washer.

SPD406

3. Install spring plates, friction plates and friction discs.

Pay particular attention to the direction of clutch plates and
their assembly sequence.

SPD504

PD-24
LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
4. Install pressure ring.

SPD481

5. Install side gear by inserting projected portion of disc.

SPD482

6. Install pinion mate gears and shaft.

Always attach pinion mate shaft to ‘‘V’’ groove in pressure ring
with flat surfaces facing up and down.

SPD483

7. Install thrust block.

SPD505

8. Install differential case A side components in the opposite way

of differential case B components.
9. Apply gear oil to differential case A, and attach thrust washer
to it.

SPD506

PD-25
LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
10. Install differential case A on differential case B. Align the match-
ing marks on the cases, then install screws while pushing dif-
ferential case down using a press.
Press force:
7,846 N (800 kg, 1,764 lb)

SPD507

11. After all parts have been assembled, check and adjust the fol-
lowing:

DIFFERENTIAL TORQUE INSPECTION

a. Place side gear in a vise with Tool into the gear splines.
b. Turn side gear several times, then measure the differential
torque after side gear begins to rotate in order to determine
whether it is within the specified range. If it is not, adjust it by
selecting a friction disc. (Refer to SDS for adjustment parts.)
Differential torque:
108 - 137 Nzm (11 - 14 kg-m, 80 - 101 ft-lb)
Tool number: KV38106400

SPD508

SIDE GEAR BACKLASH INSPECTION

Check backlash of side gear on both sides. Using a feeler gauge,
measure clearance between side gear and thrust washer. If it is not
within specifications, adjust it by selecting a thrust washer. (Refer
to SDS.)
Side gear backlash:
Differential case A side
0.05 - 0.20 mm (0.0020 - 0.0079 in)
Differential case B side
0.05 - 0.20 mm (0.0020 - 0.0079 in)
SPD411

12. After checking and adjusting, tighten ring gear bolts in a criss-
cross fashion.
13. Bend up lock straps to lock bolts in place.
14. Install side bearing inner race with Tool.

PD-26
 ADJUSTMENT

To avoid confusion while calculating bearing shims, it is absolutely

necessary to stay with the metric system. If you measure anything
in inches, the results must be converted to the metric system.

Drive Pinion Height

1. First prepare Tools for pinion height adjustment.
:V 1 Height gauge (ST31251000)
V 2 Dummy shaft (ST31181001)
V 3 Spacer [thickness: 2.50 mm (0.0984 in)]
V 4 Feeler gauge
2. To simplify the job, make a chart, like the one below, to orga-
nize your calculations.
HUNDREDTHS OF
LETTERS
A MILLIMETER
SPD758
H: Head number
D′: Figure marked on dummy shaft
S: Figure marked on height gauge
N: Measuring clearance

3. Write the following numbers down the chart.

H: Head number

SPD542

D′: Figure marked on dummy shaft.

SPD759

PD-27
 ADJUSTMENT
Drive Pinion Height (Cont’d)
S: Figure marked on height gauge.

SPD760

4. Place pinion rear bearing inner cone and Tools on gear carrier.
Tool number:
ST31181001

SPD271-A

5. Attach Tool (Height gauge) to gear carrier, and measure the

clearance between the height gauge tip and the dummy shaft
face.
Tool number:
ST31251000

SPD272-A

6. Substitute these values into the equation to calculate the thick-

ness of the washer.
If values signifying H, D′ and S are not given, regard them as
zero and calculate.
T (Thickness of washer)
= N − [(H − D′ − S) x 0.01] + 3.05

PD444-A

PD029

PD-28
 ADJUSTMENT
Drive Pinion Height (Cont’d)
Example (H233B):
N = 0.30
H=2
D′ = −1
S=0
T = N − [(H − D′ − S) x 0.01] + 3.05
= 0.30 − [{2 − (−1) − 0} x 0.01] + 3.05
(1) H ........................................................................ 2
−D′ ................................................................. −(−1)
3
−S ...................................................................... −0
3
(2) 3
x 0.01
0.03
(3) N ................................................................... 0.30
−0.03
0.27
(4) 0.27
+3.05
3.32
∴T = 3.32
7. Select the proper pinion height washer.
Drive pinion height adjusting washer:
Refer to SDS (PD-0, 53).
If you cannot find the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example (H233B):
Calculated value ... T = 3.32 mm
Used washer ... T = 3.33 mm

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation to
one another may be noisy, or have short life or both. With a pat-
tern check, the most desirable contact for low noise level and long
life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

PD-29
 ADJUSTMENT
Tooth Contact (Cont’d)
3. Hold companion flange steady by hand and rotate the ring gear
in both directions.

SPD695

SPD007-B

PD-30
 ASSEMBLY

Differential Case — 4-pinion type —

1. Measure clearance between side gear thrust washer and dif-
ferential case.
Clearance between side gear thrust washer
and differential case (A — B):
0.15 - 0.20 mm (0.0059 - 0.0079 in)
The clearance can be adjusted with side gear thrust washer.
Refer to SDS.
2. Apply oil to gear tooth surfaces and thrust surfaces and check
that they turn properly.

SPD656

3. Install differential case LH and RH.

SPD643

4. Place differential case on ring gear.

5. Apply locking sealer to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

6. Press-fit side bearing inner races on differential case with Tool.

Tool number:
jA ST33190000
jB ST02371000

PD353

PD-31
 ASSEMBLY

Differential Case — 2-pinion type —

1. Install side gears, pinion mate gears and thrust washers into
differential case.

SPD552

2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer. Refer to SDS.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
0.15 - 0.20 mm (0.0059 - 0.0079 in)

SPD258

4. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.

SPD030

5. Apply gear oil to gear tooth surfaces and thrust surfaces and
make sure they turn properly.
6. Install differential case assembly on ring gear.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.

SPD322

7. Press-fit side bearing inner cones on differential case with Tool.

Tool number:
jA ST33190000
jB ST02371000

PD353

PD-32
 ASSEMBLY

Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
jA ST30611000
jB ST30621000 (front differential)
or suitable pipe
jC ST30701000
CAUTION:
Do not damage roller side face.

SPD580

2. Select drive pinion height adjusting washer. Refer to ADJUST-

MENT (PD-27).
3. Install drive pinion height adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it, with press and
Tool.
Tool number: ST30911000

SPD377

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal.
Tool number:
A ST30720000
j
B KV38102510
j

SPD451A

PD-33
 ASSEMBLY
Differential Carrier (Cont’d)
6. Install drive pinion bearing spacer, pinion bearing adjusting
shim and drive pinion in gear carrier.

SPD935-A

7. Insert companion flange into drive pinion by tapping the com-

panion flange with a soft hammer.

SPD697

8. Tighten pinion nut to the specified torque.

The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: KV38104700

SPD040

9. Turn drive pinion in both directions several times, and measure

pinion bearing preload.
Tool number: ST3127S000
Pinion bearing preload (with front oil seal):
1.4 - 1.7 Nzm (14 - 17 kg-cm, 12 - 15 in-lb)
If preload is out of specification, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
+ Start from the combination of thickest spacer and shim.
+ Combine each spacer and shim thickness one by one until the
correct specification are achieved.
Drive pinion bearing preload adjusting spacer and
SPD149
shim:
Refer to SDS (PD-51).

PD-34
 ASSEMBLY
Differential Carrier (Cont’d)
10. Install differential case assembly with side bearing outer races
into gear carrier.

PD383

11. Position side bearing adjusters on gear carrier with threads

properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number:
ST32580000

SPD684

12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
+ Do not tighten at this point to allow further tightening of side
bearing adjusters.

SPD265

13. Tighten both right and left side bearing adjusters alternately and
measure ring gear backlash and total preload at the same time.
Adjust right and left side bearing adjusters by tightening them
alternately so that proper ring gear backlash and total preload
can be obtained.
Ring gear-to-drive pinion backlash:
0.15 - 0.20 mm (0.0059 - 0.0079 in)

SPD246

+ When checking preload, turn drive pinion in both direc-

tions several times to set bearing rollers.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
1.7 - 2.5 Nzm (17 - 25 kg-cm, 15 - 22 in-lb)
Used parts
1.5 - 1.7 Nzm (15 - 17 kg-cm, 13 - 15 in-lb)

SPD149

PD-35
 ASSEMBLY
Differential Carrier (Cont’d)
14. Tighten side bearing cap bolts.
15. Install side lock finger in place to prevent rotation during opera-
tion.

SPD698

16. Check runout of ring gear with a dial indicator.

Runout limit: 0.08 mm (0.0031 in)
+ If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
+ If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
17. Check tooth contact. Refer to ADJUSTMENT (PD-27).

SPD247

PD-36
DIFFERENTIAL LOCK

SPD441A

Actuator and Fork

SPD835-A

PD-37
 DIFFERENTIAL LOCK

Disassembly
1. Remove side bearing inner cone with Tool. For removal
procedure, refer to ordinary differential case.
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off the gear with a soft hammer.

SPD839

4. Put marks on both differential cases.

5. Loosen screws on differential cases A and B using a press.
Tool number: ST33081000
6. Separate differential cases A and B.

SPD449A

7. Drive out pinion mate shaft lock pin with Tool.

Draw out component parts.

SPD841

PD-38
 DIFFERENTIAL LOCK

Inspection

SPD842

CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.
V 1 Differential case A
V 2 Differential case B
V 3 Side gear thrust washer
V 4 Side gear
V 5 Pinion mate thrust washer
V 6 Pinion mate gear
V 7 Pinion mate shaft

ACTUATOR OPERATION
Apply a vacuum pressure of 66.7 kPa (667 mbar, 500 mmHg, 19.69
inHg) and check its operation and leakage within 10 seconds.

SPD906

PD-39
 DIFFERENTIAL LOCK

Assembly
DIFFERENTIAL CASE
1. Install side gears, pinion mate gears and thrust washers into
differential case B.
2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.

SPD844

3. Adjust backlash between side gear and pinion mate gear.

+ Opposite side of ring gear:
Select side gear thrust washer by measuring gap with feeler
gauge. Refer to SDS.

SPD845

+ Ring gear side:

Measure height H1.
Measure height H2.
H2 − H1 = Clearance between the side gear end face and dif-
ferential case B
Select side gear thrust washer. Refer to SDS.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
0.10 - 0.20 mm (0.0039 - 0.0079 in)

SPD846

4. Install pinion mate shaft lock pin with a punch. Make sure lock
pin is flush with case.
5. Install differential case A.
6. Place ring gear on differential case and install it by tightening
bolt. Use locking sealant.
7. Install side bearing inner cone.

SPD847

PD-40
 DIFFERENTIAL LOCK
Assembly (Cont’d)
ACTUATOR
+ If same differential carrier is used again, reuse actuator shim or
use a shim of the same thickness when used shim is damaged.

+ When differential carrier is replaced with a new one, select

actuator shim to keep differential lock mechanism functioning.
+ When installing the differential lock fork, make sure it is facing
the correct direction.

SPD848

1. Standard length ‘‘A’’ is between specified mounting surface of

actuator and differential case B surface ‘‘P’’. Refer to SDS.

SPD930

2. Install differential carrier on axle case.

3. Rotate ring gear until surface ‘‘P’’ is seen through actuator
mounting hole in axle case.
Measure dimension ‘‘L’’ between actual mounting surface of
actuator on axle case and surface ‘‘P’’, using suitable gauge
tool.
+ Put gauge as shown on drawing.
+ Put mark on gauge at actuator mounting surface.
+ Measure dimension ‘‘L’’.

SPD931

PD-41
 DIFFERENTIAL LOCK
Assembly (Cont’d)
4. If shim thickness determined by equation is assumed as ‘‘T’’,
‘‘T’’ will be expressed by equation ‘‘A’’ - ‘‘L’’. Select a combina-
tion of shims from those shown in SDS so that shim thickness
is within ‘‘T’’ range. Install actuator using selected shims.

SPD932

PD-42
DIFFERENTIAL LOCK

System Description
The differential lock operates only in 4WD.
The differential lock control unit interrupts current flowing through
differential lock solenoid-2 when vehicle speed exceeds 7 km/h (4
MPH). If the differential lock switch is accidentally turned on when
vehicle speed is greater than 7 km/h (4 MPH), the control unit will
prevent the differential lock from sustaining impact damage.
A warning buzzer will sound when the vehicle is driven over 20
km/h (12 MPH) with the differential lock engaged.

SPD446A

PD-43
DIFFERENTIAL LOCK

Component Parts Location

SPD442A

PD-44
DIFFERENTIAL LOCK

Wiring Diagram — DIFF/L —/LHD Models

TPD013

PD-45
DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/LHD Models
(Cont’d)

TPD014

PD-46
DIFFERENTIAL LOCK

Wiring Diagram — DIFF/L —/RHD Models

TPD016

PD-47
DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/RHD Models
(Cont’d)

TPD017

PD-48
 DIFFERENTIAL LOCK

Electrical Components Inspection

DIFFERENTIAL LOCK INDICATOR SWITCH CHECK
+ Check switch function by checking continuity.
Continuity:
ON Continuity should exist.
OFF Continuity should not exist.
If NG, replace differential lock indicator switch.

SPD443A

DIFFERENTIAL LOCK SOLENOID CHECK

1. Disconnect differential lock solenoid 4-pin connector.
2. Check continuity between terminals V 1 and V3 , V
2 and 4 .
V
Continuity should exist.
If NG, replace differential lock solenoid.

SPD444A

SPEED SENSOR CHECK

Refer to EL section.

PD-49
 DIFFERENTIAL LOCK
Electrical Components Inspection (Cont’d)
DIFFERENTIAL LOCK CONTROL UNIT CHECK
On-vehicle check
Be sure that vehicle is in 4WD.

.
Operate vehicle at a speed less than 7 km/h (4 MPH) or
when stopping.

.
Turn differential lock switch ON.

.
Ensure differential lock indicator lamp is on. No Malfunction is in system other than differential lock con-
c
trol unit, speed sensor. Check and correct.
Yes
.
Turn differential lock switch OFF while driving vehicle at
speed less than 7 km/h (4 MPH) or when stopping.

.
Drive vehicle at speed greater than 7 km/h (4 MPH) and
turn differential lock switch ON.

.
Ensure differential lock indicator lamp is on. Yes When speed sensor functions, differential lock control
c
unit functions improperly.
No

. .
Differential lock control unit is functioning properly. Check differential lock control unit.

Unit check
1. Ensure that wiring to differential lock control unit is correct and
that the unit is properly connected to power supply.
2. Place vehicle on a safety stand properly. Ensure that the front
and rear wheels rotate freely.

3. Check output voltage of differential lock at solenoid-2 connec-

tor.
+ Vehicle speed less than 7 km/h (4 MPH) on speedometer
Power supply: Approximately 12V
+ Vehicle speed greater than 7 km/h (4 MPH) on speedometer
Output voltage: Approximately 0V

SPD445A

PD-50
 SERVICE DATA AND SPECIFICATIONS (SDS)

Propeller Shaft
GENERAL SPECIFICATIONS
Front propeller shaft
Applied model RD28 Engine MT models

Propeller shaft model 2F80B

Number of joints 2

Type of journal bearing Solid (Disassembly type)

Coupling type with trans-

Flange type
mission

Distance between yokes

73 (2.87)
mm (in)

Shaft length (Spider-to-

832 (32.76)
spider) mm (in)
Shaft outer diameter
50.8 (2.000)
mm (in)

Rear propeller shaft

Applied model

Engine RD28

Transmission M/T

Body Hardtop Wagon

Propeller shaft model 2F100H 2F80B

Number of joints 2
Type of journal bearing Solid (Disassembly type)

Coupling type with trans-

Flange type
mission

Distance between yokes

94 (3.70) 73 (2.87)
mm (in)

Shaft length (Spider-to-

440 (17.32) 1,033 (40.67)
spider) mm (in)

Shaft outer diameter

57 (2.24) 89.6 (3.528)
mm (in)

INSPECTION AND ADJUSTMENT Available snap rings

Service data 2F80B
Thickness mm (in) Color Part number
Propeller shaft model 2F80B, 2F100H
1.99 (0.0783) White 37146-C9400
Propeller shaft runout limit
0.6 (0.024)
mm (in) 2.02 (0.0795) Yellow 37147-C9400
Journal axial play mm (in) 0.02 (0.0008) 2.05 (0.0807) Red 37148-C9400

2.08 (0.0819) Green 37149-C9400

2.11 (0.0831) Blue 37150-C9400

2.14 (0.0843) Light brown 37151-C9400

2.17 (0.0854) Black 37152-C9400

2.20 (0.0866) Black 37153-C9400

PD-51
 SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft (Cont’d)
2F100H
Thickness mm (in) Color Part number
1.95 (0.0768) White 37146-61502
1.98 (0.0780) Yellow 37147-61502
2.01 (0.0791) Red 37148-61502
2.04 (0.0803) Green 37149-61502
2.07 (0.0815) Blue 37150-61502
2.10 (0.0827) Light Brown 37151-61502
2.13 (0.0839) Pink 37146-61503
2.16 (0.0850) Gold 37147-61503
2.19 (0.0862) Black 37148-61503
2.22 (0.0874) Color less 37149-61503

Final Drive
GENERAL SPECIFICATIONS
Body type Wagon Hardtop
Engine RD28ETi
Transmission M/T
Standard
Front final drive [All] H233B
2-pinion
Gear ratio 4.625 4.625
Number of teeth (Ring
37/8 37/8
gear/drive pinion)
Oil capacity (Approx.)
5.4 (9-1/2)
! (Imp pt)
Optional Standard Standard Optional
Rear final drive
H233B H233B
[Grade]
Diff. lock 4 pinion 4 pinion Diff. lock
Gear ratio 4.625 4.625
Number of teeth (Ring
37/8 37/8
gear/drive pinion)
Without diff.
Oil capacity 2.4 (4-1/4) 2.4 (4-1/4)
lock
(Approx.)
! (Imp pt) With diff.
3.0 (5-1/4) 3.0 (5-1/4)
lock

With LSD model INSPECTION AND ADJUSTMENT

Body type Wagon Hardtop Ring gear runout
Engine RD28ETi Ring gear runout limit mm (in) 0.08 (0.0031)
Transmission All M/T

Rear final drive H233B

[Grade]
Side gear adjustment (without LSD)
LSD
Side gear backlash
Gear ratio 4,625
(Clearance between side gear to 0.15 - 0.20 (0.0059 - 0.0079)
Number of teeth differential case) mm (in)
(ring gear/drive 37/8
Available side gear thrust washers
pinion)
Thickness mm (in) Part number
Oil capacity
(Approx.) 2.1 (3-3/4) 1.75 (0.0689) 38424-T5000
! (Imp pt) 1.80 (0.0709) 38424-T5001
1.85 (0.0728) 38424-T5002

PD-52
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
— Additional service for LSD model — Drive pinion preload adjustment
Differential torque adjustment Drive pinion bearing preload adjust-
Adjusting shim and spacer
ing method
Differential torque 108 - 137
Nzm (kg-m, ft-lb) (11 - 14, 80 - 101) Drive pinion preload
Nzm (kg-cm, in-lb)
Number of discs and plates
Friction disc 4 1.4 - 1.7
With front oil seal
Friction plate 4 (14 - 17, 12 - 15)
Spring plate 4
1.2 - 1.5
Wear limit of plate and disc Without front oil seal
0.1 (0.004) (12 - 15, 10 - 13)
mm (in)
Allowable warpage of friction disc Available drive pinion preload adjusting shims
0.08 (0.0031)
and plate mm (in)
Thickness mm (in) Part number
Available discs and plates
2.31 (0.0909) 38125-82100
Part name Thickness mm (in) Part number
2.33 (0.0917) 38126-82100
1.48 - 1.52 38433-C6000 2.35 (0.0925) 38127-82100
(0.0583 - 0.0598) (Standard type) 2.37 (0.0933) 38128-82100
Friction disc
1.58 - 1.62 38433-C6001 2.39 (0.0941) 38129-82100
(0.0622 - 0.0638) (Adjusting type) 2.41 (0.0949) 38130-82100
1.48 - 1.52 2.43 (0.0957) 38131-82100
Friction plate 38432-C6000
(0.0583 - 0.0598) 2.45 (0.0965) 38132-82100
1.48 - 1.52 2.47 (0.0972) 38133-82100
Spring disc 38436-C6000 2.49 (0.0980) 38134-82100
(0.0583 - 0.0598)
2.51 (0.0988) 38135-82100
1.48 - 1.52
Spring plate 38435-C6010 2.53 (0.0996) 38136-82100
(0.0583 - 0.0598)
2.55 (0.1004) 38137-82100
2.57 (0.1012) 38138-82100
2.59 (0.1020) 38139-82100
Drive pinion height adjustment
Available pinion height adjusting washers Available drive pinion preload adjusting spacers

Length mm (in) Part number

Thickness mm (in) Part number
4.50 (0.1772) 38165-76000
2.58 (0.1016) 38151-01J00
4.75 (0.1870) 38166-76000
2.61 (0.1028) 38151-01J01
5.00 (0.1969) 38167-76000
2.64 (0.1039) 38151-01J02
5.25 (0.2067) 38166-01J00
2.67 (0.1051) 38151-01J03
5.50 (0.2165) 38166-01J10
2.70 (0.1063) 38151-01J04
2.73 (0.1075) 38151-01J05
2.76 (0.1087) 38151-01J06 Total preload adjustment
2.79 (0.1098) 38151-01J07
2.82 (0.1110) 38151-01J08 1.7 - 2.5
Total preload New
2.85 (0.1122) 38151-01J09 Drive pinion (17 - 25, 15 - 22)
2.88 (0.1134) 38151-01J10 Nzm (kg-cm, in-lb)
bearing 1.5 - 1.7
2.91 (0.1146) 38151-01J11 With front oil seal Old
(15 - 17, 13 - 15)
2.94 (0.1157) 38151-01J12
2.97 (0.1169) 38151-01J13 0.15 - 0.20
3.00 (0.1181) Ring gear backlash mm (in)
38151-01J14 (0.0059 - 0.0079)
3.03 (0.1193) 38151-01J15
3.06 (0.1205) 38151-01J16 Side bearing adjusting method Side adjuster
3.09 (0.1217) 38151-01J17
3.12 (0.1228) 38151-01J18
3.15 (0.1240) 38151-01J19
3.18 (0.1252) 38151-01J60
3.21 (0.1264) 38151-01J61
3.24 (0.1276) 38151-01J62
3.27 (0.1287) 38151-01J63
3.30 (0.1299) 38151-01J64
3.33 (0.1311) 38151-01J65
3.36 (0.1323) 38151-01J66
3.39 (0.1335) 38151-01J67
3.42 (0.1346) 38151-01J68
3.45 (0.1358) 38151-01J69
3.48 (0.1370) 38151-01J70
3.51 (0.1382) 38151-01J71
3.54 (0.1394) 38151-01J72
3.57 (0.1406) 38151-01J73
3.60 (0.1417) 38151-01J74
3.63 (0.1429) 38151-01J75
3.66 (0.1441) 38151-01J76

PD-53