27-1

GROUP 27
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 27-2
SPECIAL TOOLS. . . . . . . . . . . . . . . . 27-2
REAR AXLE DIAGNOSIS . . . . . . . . . 27-6
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 27-6
TROUBLESHOOTING STRATEGY . . . . . . 27-6
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 27-6
SYMPTOM PROCEDURES . . . . . . . . . . . . 27-6
ON-VEHICLE SERVICE. . . . . . . . . . . 27-12
REAR AXLE TOTAL BACKLASH CHECK . 27-12
GEAR OIL LEVEL CHECK . . . . . . . . . . . . . 27-12
WHEEL BEARING AXIAL PLAY CHECK. . 27-12
REAR AXLE HUB ASSEMBLY. . . . . 27-13
REMOVAL AND INSTALLATION . . . . . . . . 27-13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 27-15
KNUCKLE. . . . . . . . . . . . . . . . . . . . . . 27-16
REMOVAL AND INSTALLATION . . . . . . . . 27-16
DRIVE SHAFT ASSEMBLY . . . . . . . . 27-18
REMOVAL AND INSTALLATION . . . . . . . . 27-18
DISASSEMBLY AND ASSEMBLY . . . . . . . 27-20
DIFFERENTIAL CARRIER
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 27-24
REMOVAL AND INSTALLATION . . . . . . . . 27-24
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-27
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 27-31
SPECIFICATIONS . . . . . . . . . . . . . . . 27-40
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 27-40
GENERAL SPECIFICATIONS . . . . . . . . . . 27-41
SERVICE SPECIFICATIONS . . . . . . . . . . . 27-41
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 27-42
SEALANT AND ADHESIVE . . . . . . . . . . . . 27-42
COMPONENT IDENTIFICATION . . . . . . . . 27-42
GENERAL DESCRIPTION
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REAR AXLE
27-2
.
GENERAL DESCRIPTION
M1271000100207
The rear axle has the following features.
DOJ-type on the differential side and BJ-type on
the hub side constant velocity joints are featured
in the drive shaft.
Large capacity and high rigidity taper-roller type
unit bearing in the wheel bearing is featured.
ABS rotor to detect wheel speed is press-fitted
into the drive shaft.
NOTE: The structure of differential is basically the
same as featured in existing models.
CONSTRUCTION DIAGRAM
SPECIAL TOOLS
M1271000600291
ACX02216
KNUCKLE
REAR HUB
UNIT BEARING
DIFFERENTIAL CARRIER
BJ
DOJ
DRIVE SHAFT
AB
TOOL TOOL NUMBER AND
NAME
SUPERSESSION APPLICATION
MB990767
End yoke holder
MB990767-01 Removal and installation of the
drive shaft nut
MB991897
Ball joint remover
MB991113-01,
MB990635-01 or
General service
tool
Disconnection of ball joint
NOTE: Steering linkage puller
(MB990635 or MB991113)is
also used to disconnect knuckle
and tie rod end ball joint.
MB990909
Working base

Supporting of the differential

carrier
B990767
AC106827
MB990909
SPECIAL TOOLS
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REAR AXLE
27-3
MB990810
Side bearing puller
MB990810-01 Removal of the side bearing
inner race
Removal of the companion
flange
MB991407
Differential rear support
arbor

Removal of the side bearing

inner race
MB990850
End yoke holder

Removal of the self-locking

nut
Adjustment of the drive
pinion turning torque
MD998801
Bearing remover

Removal of the drive pinion rear

bearing inner race
MB991168
Drive pinion oil seal installer

Press-fitting of the drive pinion

oil seal
MB991445
Bushing remover and
installer base

Press-fitting of the drive pinion

rear bearing outer race
(Use together with MB990938)
TOOL TOOL NUMBER AND
NAME
SUPERSESSION APPLICATION
MB990810
MB991407
MB990850
MB991168
SPECIAL TOOLS
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REAR AXLE
27-4
MB991171
Pinion height gauge set
A: MB991169
Drive pinion gauge
attachment
B: MB991170
Cylinder gauge
C: MB990819
Drive pinion gauge

Measurement of the pinion

height
MB991768
Drive pinion gauge set
A: MB991770
Head

MB991534
Cylinder gauge

MB990326
Preload socket
General service
tool
Measurement of the starting
torque of ball bearing
Measurement of the starting
torque of ball bearing
MB990685
Torque wrench
MB990998
Front hub remover and
installer
MB990998-01 or
General service
tool
Measure at the wheel
bearing rotation starting
torque
Wheel bearing backlash
check
MB990802
Bearing installer
MB990802-01 Press-fitting of the drive pinion
rear bearing inner race
MB990727
Drive pinion oil seal installer

Press-fitting of the drive pinion

oil seal
TOOL TOOL NUMBER AND
NAME
SUPERSESSION APPLICATION
MB991171
A
B C
MB991768
A
MB991534
MB990326
MB990685AC
MB990998
MB990802
MB990727
SPECIAL TOOLS
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REAR AXLE
27-5
MD998812
Installer cap

Press-fitting of the side bearing

inner race
MD998829
Installer adapter

MB990925
Bearing and oil seal installer
set
A: MB990926 MB990937
Installer adapter
B: MB990938
Bar
C: MB990939
Brass bar
MB990925-01 or
General service
tool
Press-fitting of oil seal
Inspection of drive gear tooth
contact
Removal of bearing outer
race
For details of each installer,
refer to GROUP 26 Special
Tools P.26-9.
MB991045
Bushing remover and
installer
A: MB991050
Base (B)

Removal of the rear suspension

crossmember bushing
MB991159
Bushing remover and
installer
A: MB991162
Bolt
B: MB991218
Bearing

Removal and press-fitting of the

rear suspension crossmember
bushing
MB991816
Bushing remover and
installer base

MB990955
Oil seal installer

Press-fitting of the rear

suspension crossmember
bushing
TOOL TOOL NUMBER AND
NAME
SUPERSESSION APPLICATION
MB990925
A
B
C
MB991045AB
A
MB991159AB
A
B
MB990955
REAR AXLE DIAGNOSIS
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REAR AXLE
27-6
REAR AXLE DIAGNOSIS
INTRODUCTION
M1271004100102
Noise from the drive shaft or differential may be
caused by defects in the components.
TROUBLESHOOTING STRATEGY
M1271004200109
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
rear axle fault.
1. Gather information from the customer.
2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1271004300214
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Noise while Wheels are Rotating <DRIVE SHAFT>
DIAGNOSIS
STEP 1. Check whether the drive shaft is bent.
Q: Is the drive shaft bent?
YES : Replace the part. Then go to Step 3.
NO : Go to Step 2.
STEP 2. Check the wheel bearing of rear hub
assembly for wear or damage.
Q: Is the wheel bearing damaged or worn?
YES : Replace the part. Then go to Step 3.
NO : Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
SYMPTOMS INSPECTION
PROCEDURE
REFERENCE
PAGE
Drive shaft Noise while wheels are rotating 1
P.27-6
Grease leakage 2
P.27-7
Differential Constant noise 3
P.27-7
Gear noise while driving 4
P.27-8
Gear noise while coasting 5
P.27-9
Bearing noise while driving or coasting 6
P.27-10
Noise while turning 7
P.27-10
Heat 8
P.27-10
Oil leakage 9
P.27-11
REAR AXLE DIAGNOSIS
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REAR AXLE
27-7
INSPECTION PROCEDURE 2: Grease Leakage <DRIVE SHAFT>
DIAGNOSIS
STEP 1. Check the DOJ boot and the BJ boot for
wear or damage.
Q: Is the DOJ boot or the BJ boot worn or damaged?
YES : Replace the part and apply grease (Refer to
P.27-20.). Then go to Step 2.
NO : Go to Step 2.
STEP 2. Retest the system.
Q: Is there grease leakage?
YES : Start over at Step 1.
NO : The procedure is complete.
INSPECTION PROCEDURE 3: Constant Noise <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 5 mm (0.2 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 9.
NO : Go to Step 2.
STEP 2. Check the tooth contact (engagement) of the drive
gear and drive pinion. Refer to GROUP 26, Differential
Carrier Inspection Before Disassembly P.26-41.
Q: Is the tooth contact (engagement) of the drive gear and
drive pinion correct?
YES : Go to Step 3.
NO : Adjust or replace the part. Then go to Step 9.
STEP 3. Check the side bearing for looseness, wear or
damage.
Q: Is the side bearing loosened, worn or damaged?
YES : Adjust or replace the part. Then go to Step 9.
NO : Go to Step 4.
STEP 4. Check the drive pinion bearing for wear or
damage.
Q: Is the drive pinion bearing worn or damaged?
YES : Adjust or replace the part. Then go to Step 9.
NO : Go to Step 5.
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
REAR AXLE DIAGNOSIS
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REAR AXLE
27-8
STEP 5. Check the drive gear and drive pinion for wear.
Q: Is the drive gear or drive pinion worn?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 6.
STEP 6. Check the side gear thrust washer or pinion shaft
for wear.
Q: Is the side gear thrust washer or pinion shaft worn?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.
STEP 7. Check the drive gear and differential case for wear
or damage.
Q: Is the drive gear or differential case worn or damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 8.
STEP 8. Check for foreign material.
Q: Is any foreign material found?
YES : Remove the foreign material and then inspect for
damage. If necessary, replace the part. Then go to
Step 9.
NO : Go to Step 9.
STEP 9. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 4: Gear Noise while Driving <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 5 mm (0.2 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 6.
NO : Go to Step 2.
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
REAR AXLE DIAGNOSIS
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REAR AXLE
27-9
STEP 2. Check the gear engagement.
Q: Is the gear engagement in good condition?
YES : Go to Step 3.
NO : Adjust or replace the part. Then go to Step 6.
STEP 3. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES : Go to Step 4.
NO : Adjust the turning torque. Then go to Step 6.
STEP 4. Check the gear for damage.
Q: Is the gear damaged?
YES : Replace the gear. Then go to Step 6.
NO : Go to Step 5.
STEP 5. Check for foreign material.
Q: Is foreign material found?
YES : Remove the foreign material and then inspect for
damage. If necessary, replace the part. Then go to
Step 6.
NO : Go to Step 6.
STEP 6. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 5: Gear Noise while Coasting <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES : Go to Step 2.
NO : Adjust the turning torque. Then go to Step 3.
STEP 2. Check the gear for damage.
Q: Is the gear damaged?
YES : Replace the gear. Then go to Step 3.
NO : Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
REAR AXLE DIAGNOSIS
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REAR AXLE
27-10
INSPECTION PROCEDURE 6: Bearing Noise while Driving or Coasting <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the drive pinion rear bearing for
cracks or damage.
Q: Is the drive pinion rear bearing cracked or
damaged?
YES : Replace the part. Then go to Step 2.
NO : Go to Step 2.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 7: Noise while Turning < DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the side bearing for wear or
damage.
Q: Is the side bearing worn or damaged?
YES : Replace the part. Then go to Step 3.
NO : Go to step 2.
STEP 2. Check the side gear, pinion gear or
pinion shaft for damage.
Q: Is the side gear, pinion gear or pinion shaft
damaged?
YES : Replace the part. Then go to Step 3.
NO : Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 8: Heat <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 5 mm (0.2 inch) below the
bottom of the filler plug hole?
YES : Check the oil leakage from differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 3.
NO : Go to Step 2.
STEP 2. Check for excessive gear backlash. Refer to
GROUP 26, Differential Carrier Inspection before
Disassembly P.26-41.
Q: Is the gear backlash correct?
YES : Go to Step 3.
NO : Adjust the backlash. Then go to step 3.
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
REAR AXLE DIAGNOSIS
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REAR AXLE
27-11
STEP 3. Retest the system.
Q: Is the heat eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.
INSPECTION PROCEDURE 9: Oil Leakage <DIFFERENTIAL>
DIAGNOSIS
STEP 1. Check the breather hose for clogging.
Q: Is the breather hose clogged?
YES : Clean or replace the part. Then go to Step 5.
NO : Go to step 2.
STEP 2. Check the cover installation.
Q: Is the cover installed correctly?
YES : Go to Step 3.
NO : Repair. Then go to Step 5.
STEP 3. Check the oil seal for wear or damage.
Q: Is the oil seal worn or damaged?
YES : Replace the seal. Then go to Step 5.
NO : Go to Step 4.
STEP 4. Check the oil level.
Remove the filler plug and check the gear oil level.
Q: Is the gear oil level more than 5 mm (0.2 inch) below the
bottom of the filler plug hole?
YES : Refill Hypoid gear oil API classification GL-5 or
higher, SAE viscosity Number 90, 80W. Then go to
Step 5.
NO : Go to Step 5.
STEP 5. Retest the system.
Q: Is there oil leakage?
YES : Start over at Step 1.
NO : The procedure is complete.
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
ON-VEHICLE SERVICE
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REAR AXLE
27-12
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
M1271001200069
1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position.
Move the transfer control lever to the neutral position. Apply
the parking brake. Raise the vehicle on a jack.
3. Turn the companion flange clockwise as far as it will go.
Make the mating mark on the dust cover of the companion
flange and on the differential carrier.
4. Turn the companion flange counterclockwise as far as it will
go, and measure the amount of distance the mating marks
moved.
Limit: 5 mm (0.2 inch)
5. If the backlash exceeds the limit value, remove the
differential carrier assembly and check the following.
Final drive gear backlash
Differential gear backlash
GEAR OIL LEVEL CHECK
M1272001200040
Check that gear oil level is not 5 mm (0.2 inch) below the bot-
tom of filler plug hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W
WHEEL BEARING AXIAL PLAY CHECK
M1271000900258
1. Remove the rear brake assembly and remove the brake disc
while holding it with wires to prevent it from falling.
ACX00962AB
MATING MARKS
ACX00964
ACX01083AB
GEAR OIL
UPPER
LIMIT
LOWER
LIMIT
5 mm
(0.2 in)
REAR AXLE HUB ASSEMBLY
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REAR AXLE
27-13
2. Fit the dial gauge as shown in the diagram and move the
hub in the axial direction to measure the play.
Limit: 0 mm (0 inch)
3. If the play exceeds the limit, replace the rear hub assembly.
REAR AXLE HUB ASSEMBLY
REMOVAL AND INSTALLATION
M1271002000217
ACX01084
Post-installation Operation
Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle ServiceP.36-4.)
ACX01085AC
152 25 Nm
113 18 ft-lb
255 29 Nm
188 21 ft-lb
100 10 Nm
74 7 ft-lb
113 14 Nm
84 10 ft-lb
8
133 14 Nm
98 10 ft-lb
7
11
5
2
1
3
10
4
6
9
N
REMOVAL STEPS
1. HUB CAP
<<A>> >>B<< 2. DRIVE SHAFT NUT
<<B>> 3. REAR BRAKE CALIPER
4. REAR BRAKE DISC
5. PARKING BRAKE SHOE AND
LINING ASSEMBLY (REFER TO
GROUP 36, PARKING BRAKE
DRUM P.36-8.)
6. COMPANION SHAFT AND DRIVE
SHAFT CONNECTION
<<C>> >>A<< 7. LOWER ARM AND KNUCKLE
CONNECTION
8. REAR DRIVE SHAFT ASSEMBLY
9. ABS ROTOR PROTECTOR
10. REAR HUB ASSEMBLY
11. BACKING PLATE
REMOVAL STEPS (Continued)
REAR AXLE HUB ASSEMBLY
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REAR AXLE
27-14
Required Special Tools:
MB990767: End Yoke Holder
MB990998: Front Hub Remover and Installer
MB990326: Preload Socket
REMOVAL SERVICE POINTS
.
<<A>> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
.
<<B>> REAR BRAKE CALIPER REMOVAL
Suspend the rear brake caliper from the body with wire, etc. to
prevent it from falling.
.
<<C>> LOWER ARM AND KNUCKLE DISCONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to remove the lower arm mounting
bolt by compressing the coil spring.
INSTALLATION SERVICE POINTS
.
>>A<< LOWER ARM AND KNUCKLE CONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to install the lower arm mounting
bolt by compressing the coil spring.
.
ACX00972
MB990767
AC
ACX01086AB
WOODEN
BLOCK
ACX01086AB
WOODEN
BLOCK
REAR AXLE HUB ASSEMBLY
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REAR AXLE
27-15
>>B<< DRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.
CAUTION
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
2. Tighten the drive shaft nut fully with special tool MB990767.
3. If the pin hole does not align with another, tighten the drive
shaft nut [less than 284 Nm (209 ft-lb)] and find the nearest
hole then bend the split pin to fit in.
INSPECTION
M1271002100098
WHEEL BEARING ROTATION STARTING
TORQUE CHECK
1. Tighten special tool MB990998 in rear hub assembly to the
specified torque.
2. Hold the rear hub assembly in a vice using of wood blocks.
3. Measure the wheel bearing rotation torque with special tool
MB990326.
Limit: 1.76 Nm (15.6 in-lb)
4. Hub rotation starting torque must be under the limit value
and the hub should rotate smoothly.
WHEEL BEARING AXIAL PLAY CHECK
1. Check the wheel bearing axial play.
Limit: 0 mm (0 inch)
2. If the wheel bearing axial play exceeds the limit value at the
specified torque of [255 29 Nm (188 21ft-lb)], replace
the rear hub assembly.
ACX01087AB
MB990767
WASHER
255 29 Nm
188 21 ft-lb
ACX01088AB
MB990998
MB990998
255 29 Nm
188 21 ft-lb
MB990326
WOODEN BLOCK
ACX01089AB
WOODEN BLOCK
WOODEN
BLOCK
KNUCKLE
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REAR AXLE
27-16
KNUCKLE
REMOVAL AND INSTALLATION
M1271003000146
Required Special Tool:
MB991897:Ball Joint Remover
Pre-removal Operation
Rear Hub Assembly Removal (Refer to P.27-13.)
Post-installation Operation
Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
Rear Hub Assembly Installation (Refer to P.27-13.)
ACX01090AB
231 34 Nm
170 25 ft-lb
67 7 Nm
50 5 ft-lb
150 30 Nm
111 22 ft-lb
3
5
1
4
2
N
N
REMOVAL STEPS
1. VEHICLE SPEED SENSOR
<<A>> 2. KNUCKLE AND TOE-CONTROL
ARM CONNECTION
3. KNUCKLE AND TRAILING ARM
CONNECTION
<<A>> 4. KNUCKLE AND UPPER ARM
CONNECTION
5. KNUCKLE ASSEMBLY
REMOVAL STEPS (Continued)
KNUCKLE
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REAR AXLE
27-17
REMOVAL SERVICE POINT
.
<<A>> KNUCKLE AND TOE-CONTROL ARM/UPPER ARM
DISCONNECTION
CAUTION
Do not remove the nut from ball joint. Loosen it and use
special tool MB991897 to avoid possible damage to ball
joint threads.
Hang special tool MB991897 with cord to prevent it
from falling.
1. Install special tool MB991897 as shown in the figure.
2. Turn the bolt and knob as necessary to make the jaws of
special tool MB991897 parallel, tighten the bolt by hand and
confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make sure the
knob is in the position shown in the figure.
3. Tighten the bolt with a wrench to disconnect the knuckle and
toe-control arm, upper arm.
AC106820AB
CORD
BOLT
MB991897
NUT
BALL JOINT
AC106821
KNOB
PARALLEL
BOLT
GOOD
BAD
AB
DRIVE SHAFT ASSEMBLY
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REAR AXLE
27-18
DRIVE SHAFT ASSEMBLY
REMOVAL AND INSTALLATION
M1271003300073
Required Special Tool:
MB990767: End Yoke Holder
REMOVAL SERVICE POINTS
.
<<A>> DRIVE SHAFT NUT REMOVAL
CAUTION
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
.
ACX01091AB
255 29 Nm
188 21 ft-lb
152 25 Nm
113 18 ft-lb
113 14 Nm
84 10 ft-lb
3
5
4
2
1
N
REMOVAL STEPS
1. CAP
<<A>> >>B<< 2. DRIVE SHAFT NUT
3. COMPANION SHAFT AND DRIVE
SHAFT CONNECTION
<<B>> >>A<< 4. KNUCKLE AND LOWER ARM
CONNECTION
5. REAR DRIVE SHAFT ASSEMBLY
ACX00972
MB990767
AC
DRIVE SHAFT ASSEMBLY
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REAR AXLE
27-19
<<B>> KNUCKLE AND LOWER ARM DISCONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to remove the lower arm mounting
bolt by compressing the coil spring.
INSTALLATION SERVICE POINTS
.
>>A<< KNUCKLE AND LOWER ARM CONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to install the lower arm mounting
bolt by compressing the coil spring.
.
>>B<< DRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.
CAUTION
Do not apply pressure to wheel bearing by the vehicle
weight to avoid possible damage to wheel bearing before
tightening drive shaft nut fully.
2. Tighten the drive shaft nut to the torque specification with
special tool MB990767.
3. If the pin hole does not align with another, tighten the drive
shaft nut [less than 284 Nm (209 ft-lb)] and find the nearest
hole then bend the split pin to fit in.
ACX01086AB
WOODEN
BLOCK
ACX01086AB
WOODEN
BLOCK
ACX01087AB
MB990767
WASHER
255 29 Nm
188 21 ft-lb
DRIVE SHAFT ASSEMBLY
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REAR AXLE
27-20
DISASSEMBLY AND ASSEMBLY
M1271003500099
CAUTION
Never disassemble the BJ assembly except when replacing the BJ boot.
Required Special Tool:
MB990939: Brass Bar
ACX01092 AC
10
13
12
11
2
9
1
6
8
5
7
3
4
10
12
7
3
1
2
11
13
3
7
1
2
2
9
1
6
8
5
7
3
4
2
9
1
7
3
BJ BOOT REPAIR KIT
BJ REPAIR KIT DOJ REPAIR KIT DOJ BOOT REPAIR KIT
N
N
N
N
DISASSEMBLY STEPS
1. DOJ BOOT BAND (LARGE)
2. DOJ BOOT BAND (SMALL)
3. CIRCLIP
4. DOJ OUTER RACE
<<A>> 5. BALLS
<<B>> 6. DOJ CAGE
7. SNAP RING
8. DOJ INNER RACE
<<C>> 9. DOJ BOOT
10. BJ BOOT BAND (LARGE)
11. BJ BOOT BAND (SMALL)
<<C>> 12. BJ BOOT
13. BJ ASSEMBLY
ASSEMBLY STEPS
13. BJ ASSEMBLY
>>A<< 12. BJ BOOT
11. BJ BOOT BAND (SMALL)
10. BJ BOOT BAND (LARGE)
>>A<< 9. DOJ BOOT
>>B<< 6. DOJ CAGE
>>B<< 8. DOJ INNER RACE
7. SNAP RING
5. BALLS
>>C<< 4. DOJ OUTER RACE
3. CIRCLIP
>>D<< 2. DOJ BOOT BAND (SMALL)
>>D<< 1. DOJ BOOT BAND (LARGE)
DRIVE SHAFT ASSEMBLY
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REAR AXLE
27-21
LUIBRICATION POINTS
CAUTION
Do not mix old and new or different types of grease, as a special grease is used in the joint.
DISASSEMBLY SERVICE POINTS
.
<<A>> BALLS REMOVAL
Remove the balls from the DOJ cage.
.
ACX01093AD
GREASE: REPAIR KIT GREASE GREASE: REPAIR KIT GREASE
USED AMOUNT: <BJ> 245 10 g (8.7 0.3 oz)
[INSIDE JOINT: 135 5 g (4.8 0.1 oz), INSIDE BOOT: 110 5 g (3.9 0.2 oz)]
NOTE
THE GREASE IN THE REPAIR KIT SHOULD BE DIVIDED IN HALF FOR USE,
RESPECTIVELY, AT THE JOINT AND INSIDE THE BOOT.
<DOJ> 295 10 g (10.5 0.3 oz)
[INSIDE JOINT: 185 5 g (6.5 0.2 oz), INSIDE BOOT: 110 5 g (3.9 0.2 oz)]
DOJ BJ
ACX01094
DRIVE SHAFT ASSEMBLY
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REAR AXLE
27-22
<<B>> DOJ CAGE REMOVAL
Remove the DOJ cage from the DOJ inner race in the direction
of the BJ.
.
<<C>> DOJ BOOT/BJ BOOT REMOVAL
Wrap plastic tape around the spline part on the DOJ side of the
drive shaft so that DOJ boot/BJ boot are not damaged when
they are removed.
ASSEMBLY SERVICE POINTS
.
>>A<< BJ BOOT/DOJ BOOT INSTALLATION
1. Wrap the tape around the spline of the shaft, then install BJ
boot and DOJ boot in order.
CAUTION
Do not mix old and new or different types of grease, as a
special grease is used in the joint.
2. Fill the inside of BJ and BJ boot with specified grease.
NOTE: The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
Specified grease: Repair kit grease
Used amount: 245 10 g (8.7 0.3 oz) [inside joint: 135
5 g (4.8 0.1 oz), inside boot: 110 5 g (3.9 0.2 oz)]
CAUTION
In order to fill the specified amount of air inside the BJ
boot, keep the bent angle of the drive shaft to O during
the operation.
3. Tighten the boot band.
.
>>B<< DOJ CAGE/DOJ INNER RACE INSTALLATION
1. Install DOJ cage to the drive shaft and put it aside to BJ
assembly side.
2. Align the mating mark of DOJ inner race with that of the
shaft.
ACX01095
ACX02368AB
PLASTIC TAPE
ACX01096
DRIVE SHAFT ASSEMBLY
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REAR AXLE
27-23
3. Tap the inner race with even force to press-fit into the bump
of the shaft with special tool MB990939.
.
>>C<< DOJ OUTER RACE INSTALLATION
CAUTION
The drive shaft joint use special grease. Do not mix old
and new or different types of grease.
Fill the inside of the DOJ outer race and DOJ boot with the
specified grease.
Specified grease: Repair kit grease
Used amount: 295 10 g (10.5 0.3 oz) [inside joint:
185 5 g (6.5 0.2 oz), inside boot: 110 5 g (3.9 0.2
oz)]
.
>>D<< DOJ BOOT/DOJ BOOT BAND INSTALLATION
1. Position the DOJ outer race so that the distance between
the boot bands is at the standard value.
Standard value (A): 110 3 mm (4.3 0.1 inches)
2. Remove part of the DOJ boot from the DOJ outer race to
release the air pressure inside the boot.
ACX01097AB
MB990939
MATING MARK
ACX02369
ACX02370
BOOT BAND (LARGE)
BOOT BAND (SMALL)
A
AB
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-24
DIFFERENTIAL CARRIER ASSEMBLY
REMOVAL AND INSTALLATION
M1272002000124
CAUTION
Since a carbon fiber fortified plastic tube is used in the rear propeller shaft, make sure to refer to
GROUP 25 for removal procedure.
Pre-removal and Post-installation Operation
Differential Gear Oil Draining and Refilling (Refer to P.27-
12.)
AC205391AB
152 25 Nm
113 18 ft-lb
1
4
6
7
3
1
2
3 6
5
8
3
113 14 Nm
84 10 ft-lb
113 14 Nm
84 10 ft-lb
152 25 Nm
113 18 ft-lb
83 12 Nm
61 9 ft-lb
46 8 Nm
34 6 ft-lb
46 8 Nm
34 6 ft-lb
N
N
REMOVAL STEPS

PROPELLER SHAFT (REFER TO

GROUP 25 P.25-5.)
1. DRIVE SHAFT CONNECTION
<<A>> >>A<< 2. KNUCKLE AND LOWER ARM
CONNECTION
3. COMPANION SHAFT
4. TOE CONTROL TOWER BAR
5. BREATHER HOSE CONNECTION
<<B>> 6. DIFFERENTIAL CARRIER
ASSEMBLY

FUEL TANK (REFER TO GROUP

13B P.13B-11.)
7. REAR DIFFERENTIAL MOUNT
MEMBER
8. DYNAMIC DAMPER
REMOVAL STEPS (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-25
REMOVAL SERVICE POINTS
.
<<A>> KNUCKLE AND LOWER ARM DISCONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to remove the lower arm mounting
bolt by compressing the coil spring.
.
<<B>> DIFFERENTIAL CARRIER ASSEMBLY REMOVAL
Support the differential carrier assembly lower part by jacking
to remove the joint bolt and the differential carrier assembly.
INSTALLATION SERVICE POINT
.
>>A<< KNUCKLE AND LOWER ARM CONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to install the lower arm mounting
bolt by compressing the coil spring.
ACX01086AB
WOODEN
BLOCK
ACX01086AB
WOODEN
BLOCK
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-26
REAR SUSPENSION CROSSMEMBER BUSHING
(FOR REAR DIFFERENTIAL MOUNT)
REPLACEMENT
1. Remove the rear differential.
2. Use special tools MB991050, MB991218, MB991162 and
MB991816 to remove the bushing.
NOTE: When removing the bushing, insert special tool
MB991162 from the forward of vehicle and fix the nut with a
wrench.
3. Use special tools MB991816, MB991218, MB991162 and
MB990955 to press-fit the bushing.
NOTE: When installing the bushing, insert special tool
MB991162 from the forward of vehicle and fix the nut with a
wrench. Press-fit the bushing until the bushing end face is
flush with the rear suspension crossmember.
4. Install the rear differential.
AC206040
REAR
SUSPENSION
CROSSMEMBER
MB991050
WRENCH
BUSHING
MB991050
NUT
REAR
SUSPENSION
CROSSMEMBER
MB991162
MB991816
MB991218
AB
AC206041
MB991050
WRENCH
BUSHING
MB991050
NUT
REAR
SUSPENSION
CROSSMEMBER
MB991162
MB991816
MB991218
AB
REAR
SUSPENSION
CROSSMEMBER
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-27
DISASSEMBLY
M1272002200117
CAUTION
Do not disassemble the limited slip differential case assembly.
AC203533AB
1
2
20
22
23
24
30
25 26
7
9
8
17
10
16
15
18
19
21
27
28
29
32
5
13
14
7
8
9
16
15
16
4
13
12
11
14
3
31
N
N
N
N
N
N
N
N
N
DISASSEMBLY STEPS
<<A>>

INSPECTION BEFORE
DISASSEMBLY
1. FILLER PLUG
2. DRAIN PLUG
3. DIFFERENTIAL COVER
4. VENT PLUG
5. BEARING CAP
<<B>> 6. DIFFERENTIAL CASE ASSEMBLY
<<B>> 7. DIFFERENTIAL SIDE SHIM
<<B>> 8. SIDE BEARING OUTER RACE
<<C>> 9. SIDE BEARING INNER RACE
<<D>> 10. DRIVE GEAR
<<E>> 11. LOCK PIN
12. PINION SHAFT
13. PINION GEAR
14. PINION WASHER
15. SIDE GEAR
16. SIDE GEAR SPACER
17. DIFFERENTIAL CASE
<<F>> 18. SELF-LOCKING NUT
19. WASHER
<<G>> 20. DRIVE PINION ASSEMBLY
<<G>> 21. COMPANION FLANGE
22. DRIVE PINION FRONT SHIM (FOR
ADJUSTING PRELOAD OF DRIVE
PINION)
23. DRIVE PINION SPACER
<<H>> 24. DRIVE PINION REAR BEARING
INNER RACE
25. DRIVE PINION REAR SHIM (FOR
ADJUSTING DRIVE PINION
HEIGHT)
26. DRIVE PINION
<<I>> 27. OIL SEAL
<<I>> 28. DRIVE PINION FRONT BEARING
INNER RACE
<<I>> 29. DRIVE PINION FRONT BEARING
OUTER RACE
<<J>> 30. DRIVE PINION REAR BEARING
OUTER RACE
31. OIL SEAL
32. DIFFERENTIAL CARRIER
DISASSEMBLY STEPS (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
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REAR AXLE
27-28
Required Special Tools:
MB990810: Side Bearing Puller
MB991407: Differential Rear Support Arbor
MB990850: End Yoke Holder
MD998801: Bearing Remover
MB990939: Brass Bar
DISASSEMBLY SERVICE POINTS
.
<<A>> INSPECTION BEFORE DISASSEMBLY
Except for the following standard values, inspection procedure
is the same as GROUP 26, inspection before disassembly
P.26-41.
DRIVE GEAR BACKLASH
Standard value: 0.13 0.18 mm (0.005 0.007 inch)
DIFFERENTIAL GEAR BACKLASH
Standard value: 0 0.076 mm (0 0.003 inch)
Limit: 0.07mm (0.007 inch)
.
<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL
SIDE SHIM/SIDE BEARING OUTER RACE REMOVAL
CAUTION
When taking out the differential case assembly, be careful
not to drop and damage the differential side shims or the
side bearing outer races.
Use the wooden handle of a hammer to remove the differential
case assembly, differential side shims and side bearings.
NOTE: Keep the right and left side bearings and side bearing
outer race separated, so that they do not become mixed during
assembly.
.
<<C>> SIDE BEARING INNER RACE REMOVAL
Use special tools MB990810 and MB991407 to pull out the side
bearing inner race.
NOTE: Attach the prongs of special tools to the inner race of
the side bearing through the openings in the differential case.
.
ACX02422
ACX01041AB
MB990810
MB991407
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-29
<<D>> DRIVE GEAR REMOVAL
1. Make mating marks to the differential case and the drive
gear.
2. Loosen the drive gear attaching bolts in a diagonal
sequence to remove the drive gear.
.
<<E>> LOCK PIN REMOVAL
Drive out the lock pin with a punch.
.
<<F>> SELF-LOCKING NUT REMOVAL
Use special tool MB990850 to hold the companion flange, and
then remove the companion flange self-locking nut.
.
<<G>> DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
CAUTION
Do not make mating marks on the contact surfaces of the
companion flange and propeller shaft.
1. Make mating marks to the drive pinion and companion
flange.
ACX01042AB
MATING
MARKS
ACX01048AB
PUNCH
ACX01043AB
MB990850
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-30
2. Use special tool MB990810 to pull out the companion
flange.
.
<<H>> DRIVE PINION REAR BEARING INNER RACE
REMOVAL
Use special tool MD998801 to pull out the front bearing inner
race.
.
<<I>> OIL SEAL/DRIVE PINION FRONT BEARING INNER
RACE/DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion front
bearing outer race.
.
<<J>> DRIVE PINION REAR BEARING OUTER RACE
REMOVAL
Use special tool MB990939 to remove the drive pinion rear
bearing outer race.
ACX01044 AB
MB990810
COMPANION
FLANGE
ACX02423
MD998801
AB
ACX01101AB
DRIVE PINION
FRONT BEARING
OUTER RACE DRIVE PINION
FRONT
BEARING
OUTER RACE
OIL SEAL
DRIVE PONION
REAR BEARING
OUTER RACE
MB990939
ACX01102 AB
MB990939
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-31
ASSEMBLY
M1272002300125
AC203534AB
35 5 Nm
25 4 ft-lb
15
5
23
17
18
20
20
18
17
FINAL DRIVE GEAR SET DIFFERENTIAL GEAR SET
12
32
2
31
15
14 13
19
20
26
25
24
17
18
21
20
27
29
30
18
11
4
1
28
9
8
7
10
3
6 5
26
25
24
23
17
N
N
N
N
N
N
N
N
152 15 Nm
112 10 ft-lb
74 5 Nm
55 3 ft-lb
49 9 Nm
37 6 ft-lb
63 4 Nm
47 2 ft-lb
216 29 Nm
159 22 ft-lb
22
19
16
N
ASSEMBLY STEPS
1. DIFFERENTIAL CARRIER
>>A<< 2. OIL SEAL
>>B<< 3. DRIVE PINION REAR BEARING
OUTER RACE
>>C<< 4. DRIVE PINION FRONT BEARING
OUTER RACE
>>D<<

DRIVE PINION HEIGHT

ADJUSTMENT
5. DRIVE PINION
6. DRIVE PINION REAR SHIM (FOR
ADJUSTING DRIVE PINION
HEIGHT)
7. DRIVE PINION REAR BEARING
INNER RACE
8. DRIVE PINION SPACER
>>E<<

DRIVE PINION TURNING TORQUE

ADJUSTMENT
9. DRIVE PINION FRONT SHIM (FOR
ADJUSTING DRIVE PINION
PRELOAD)
10. DRIVE PINION ASSEMBLY
11. DRIVE PINION FRONT BEARING
INNER RACE
>>E<< 12. OIL SEAL
13. COMPANION FLANGE
14. WASHER
15. SELF-LOCKING NUT
16. DIFFERENTIAL CASE
>>F<<

DIFFERENTIAL GEAR BACKLASH

ADJUSTMENT
17. SIDE GEAR SPACER
18. SIDE GEAR
19. PINION WASHER
20. PINION GEAR
21. PINION SHAFT
>>G<< 22. LOCK PIN
>>H<< 23. DRIVE GEAR
>>I<< 24. SIDE BEARING INNER RACE
25. SIDE BEARING OUTER RACE
26. SIDE BEARING SHIM
27. DIFFERENTIAL CASE ASSEMBLY
>>J<< 28. BEARING CAP
29. VENT PLUG
30. DIFFERENTIAL COVER
31. DRAIN PLUG
32. FILLER PLUG
>>J<<

FINAL DRIVE GEAR BACKLASH

ADJUSTMENT
ASSEMBLY STEPS (Continued)
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-32
Required Special Tools:
MB991168: Drive Pinion Oil Seal Installer
MB990938: Bar
MB991445: Bushing Remover and Installer Base
MB990934: Installer Adapter
MB991770: Head
MB990819: Drive Pinion Gauge
MB990326: Preload Socket
MB990685: Torque Wrench
MB991169: Drive Pinion Gauge
MB991534: Cylinder Gauge
MB990802: Bearing Installer
MB990850: End Yoke Holder
MB990727: Drive Pinion Oil Seal Installer
MD998812: Installer Cap
MD998829: Installer Adapter
MB990810: Side Bearing Puller
MB991407: Differential Rear Support Arbor
LUBRICATION AND ADHESIVE POINTS
ACX01104AC
2 3 mm (0.08 0.12 in)
(BEAD DIAMETER)

TM TM
ADHESIVE:
3M PART NO. 8730,
8731 OR EQUIVALENT
SEMI-DRYING SEALANT:
3M AAD PART NO. 8672, 8679,
8678, 8661, 8663 OR EQUIVALENT
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-33
ASSEMBLY SERVICE POINTS
.
>>A<< OIL SEAL PRESS-FITTING
Use special tool MB991168 to press-fit the oil seal.
.
>>B<< DRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
Use special tools MB990938 and MB991445 to press-fit the
drive pinion rear bearing outer race.
.
>>C<< DRIVE PINION FRONT BEARING OUTER RACE
PRESS-FITTING
Use special tools MB990938 and MB990934 to press-fit the
drive pinion front bearing outer race.
.
ACX01105 AB
MB991168
OIL SEAL
ACX01106AB
MB990938
MB991445
ACX01107AB
MB990938
MB990934
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-34
>>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool
MB990819.
2. Install special tool MB990819, MB991770 and drive pinion
front and rear bearing inner races to the gear carrier as
shown in the illustration.
3. Tighten the nut of special tool MB990819 a little at a time,
while measuring the turning torque of the drive pinion. Then
confirm that the turning torque (without the oil seal) is at the
standard value.
Standard value:
4. Clean the side bearing hub.
5. Place special tool MB991534 between the side bearing hub
of the gear carrier, and position the notch as shown in the
illustration. Then tighten side bearing mounting bolt.
6. Use a thickness gauge to measure the clearance (A)
between special tools MB991169 and MB991534.
7. Remove special tools MB991169 and Mb991534.
BEARING DIVISION TURNING TORQUE
New 1.94 2.25 Nm
17.2 19.9 in-lb
AC000178
MB990819
AB
REPLACE THE
HEAD WITH
MB991770
ACX01055AB
MB990819
AC102911
MB990326
AC
MB990685
ACX01109AB
MB991534
NOTCH
MB991169
THICKNESS
GAUGE
A
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-35
8. Use a micrometer to measure the shown dimensions (B, C)
of special tools MB991169 and MB991534.
9. Install the bearing cap, and then use a cylinder gauge to
measure the inside diameter (D) of the bearing cap.
10.Calculate thickness (F) of the required drive pinion rear
shim twice by the following formula. Select a shim which
most closely matches this thickness.
F = A + B + C 1/2D 86.00 mm (3.385 inches)
11.Fit the selected drive pinion rear shim(s) to the drive pinion,
and press-fit the drive pinion rear bearing inner race by
using special tool MB990802.
.
>>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT/
OIL SEAL INSTALLATION
1. Insert the drive pinion into the gear carrier, and then install
the following parts in sequence from the carrier rear side:
Drive pinion spacer, drive pinion front shim and drive pinion
front bearing inner race, companion flange.
NOTE: Do not install the oil seal.
2. Tighten the companion flange to the specified torque by
using special tool MB990850.
Tightening torque: 216 29 Nm (159 22 ft-lb)
ACX01058AB
MB991534
B
C
ACX01110AB
CYLINDER GAUGE
ACX02428
MB990802
DRIVE PINION
REAR SHIM
AB
ACX01065AB
MB990850
216 29 Nm
159 22 ft-lb
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-36
3. Measure the drive pinion turning torque (without the oil
seal).
Standard value:
4. If the drive pinion turning torque is not within the standard
value, adjust the turning torque by replacing the drive pinion
front shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims to a
minimum by selecting the drive pinion spacers.
Also, select the drive pinion spacer from the following two
types.
5. Remove the companion flange and drive pinion again. Then
insert the drive pinion front bearing inner race into the gear
carrier. Use special tool MB990727 to press-fit the oil seal.
6. Install the drive pinion assembly and companion flange with
the mating marks properly aligned. Tighten the companion
flange self-locking nut to the specified torque using special
tool MB990850.
Tightening torque: 216 29 Nm (159 22 ft-lb)
BEARING DIVISION TURNING TORQUE
New 1.94 2.25 Nm
17.2 19.9 in-lb
HEIGHT OF DRIVE PINION
SPACER mm (in)
IDENTIFICATION COLOR
52.50 (2.067) Yellow
52.84 (2.080) Red
ACX01062AB
MB990326
MB990685
ACX01063 AB
IDENTIFICATION
COLOR
ACX01064 AC
MB990727
ACX01065AB
MB990850
216 29 Nm
159 22 ft-lb
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-37
7. Measure the drive pinion turning torque (with oil seal) to
verify that the drive pinion turning torque complies with the
standard value.
Standard value:
8. If the turning torque is not within the standard value, check
the tightening torque of the companion flange self-locking
nut, and the installation of the oil seal.
.
>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear thrust spacers, pinion
gears, and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE: Do not assemble the thrust block and lock pin yet.
3. Insert a wedge between the side gear and the pinion shaft to
lock the side gear.
4. While locking the side gear with the wedge, measure the
differential gear backlash with a dial indicator on the pinion
gear.
Standard value: 0 0.076 mm (0 0.0030 inch)
Limit: 0.2 mm (0.01 inch)
5. Measure by the same procedure for the other pinion gear.
6. If the backlash exceeds the limit value, replace side bearing
adjustment spacers.
7. If adjustment is not possible, replace the side gears and
pinion gears as a set.
8. Check that the backlash is within the limit value and that the
differential gear turns smoothly.
.
BEARING
DIVISION
COMPANION
FLANGE
LUBRICATION
TURNING
TORQUE
New None (with anti-rust
agent)
2.03 2.34 Nm
18.0 20.7 in-lb
Gear oil applied 2.10 2.40 Nm
18.6 21.2 in-lb
ACX01062AB
MB990326
MB990685
ACX01066
AC102885
WEDGE
SIDE GEAR
SPACER
SIDE GEAR
SPACER
AC
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-38
>>G<< LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the differential case
lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch on both sides.
.
>>H<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the
drive gear by turning the tap (M10 x 1.25). Clean the
threaded holes by applying compressed air.
3. Apply 3M stud locking 4170 or equivalent to the threaded
holes of the drive gear.
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
Tightening torque: 152 15 Nm (112 10 ft-lb)
.
>>I<< SIDE BEARING INNER RACE INSTALLATION
Use special tools MD998812 and MD998829 to press-fit the
side bearing inner races into the differential case.
ACX02429
ACX01068AB TAP
ACX02430
ACX02431AB
MD998812
MD998829
DIFFERENTIAL CARRIER ASSEMBLY
TSB Revision
REAR AXLE
27-39
.
>>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR
BACKLASH ADJUSTMENT
Adjust drive gear backlash as follows:
1. Assemble the differential case with the side bearing outer
race to the gear carrier.
2. Press the differential case to one side to measure the
clearance of the side bearing outer race and the gear carrier.
3. Select two pairs of side bearing spacer. Determine the
thickness by adding 1/2 of the clearance to the pre-load
0.05mm (0.002 inch).
4. Remove the side bearing, using special tools MB990810
and MB991407.
NOTE: Hook the claws of the special tool MB990810 with
the side bearing inner race by using the notches (two areas)
of the differential case side.
5. Assemble the selected side bearing spacers to each side.
6. Use special tool MB990802 to press-fit the side bearing
inner case into the differential case. After installing the outer
race, assemble the differential case to the gear carrier.
7. Align the mating marks of differential carrier and the bearing
cap with each other and tighten to the specified torque.
Tightening torque: 74 5 Nm (55 3 ft-lb)
8. Measure the drive gear backlash.
NOTE: Measure at four points or more on the circumference
of the drive gear.
Standard value: 0.13 0.18 mm (0.005 0.007 inch)
ACX01071
ACX01041AB
MB990810
MB991407
ACX02432
DRIVE
PINION
REAR
SHIM
MB990802
MB990802
AB
ACX01034
SPECIFICATIONS
TSB Revision
REAR AXLE
27-40
9. If the backlash is not within the standard value, move the
side bearing spacer as shown in the illustration to adjust the
backlash.
NOTE: The increment of side bearing spacer must be the
same as the decreased amount.
10.Inspect the tooth condition at the final drive gear and adjust
if required. (Refer to GROUP 26, Inspection Before
Disassembly P.26-41.)
11.Measure the drive gear runout.
Limit: 0.05 mm (0.002 inch)
12.If drive gear runout exceeds the limit, remove the differential
case and then the drive gears, moving them to different
positions and reinstall them.
13.If adjustment is not possible, replace the differential case or
drive gear and drive pinion as a set.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1271004000257
ACX02433AB
WHEN THE BACKLASH IS SMALL
WHEN THE BACKLASH IS LARGE
DECREASED
DECREASED
INCREASED
INCREASED
ACX01036
ITEM SPECIFICATION
Rear axle hub assembly, drive shaft assembly
Backing plate bolt 133 14 Nm (98 10 ft-lb)
Lower arm and knuckle connection nut 152 25 Nm (113 18 ft-lb)
Rear brake caliper bolt 100 10 Nm (74 7 ft-lb)
Rear drive shaft and companion shaft connection nut 113 14 Nm (84 10 ft-lb)
Rear drive shaft nut 255 29 Nm (188 21 ft-lb)
Knuckle
Toe-control arm and knuckle connection nut 67 7 Nm (50 5 ft-lb)
Trailing arm and knuckle connection bolt 231 34 Nm (170 25 ft-lb)
Upper arm and knuckle connection nut 150 30 Nm (111 22 ft-lb)
Differential carrier assembly
Bearing cap bolt 74 5 Nm (55 3 ft-lb)
Differential cover bolt 35 5 Nm (25 4 ft-lb)
Dynamic damper bolt 83 12 Nm (61 9 ft-lb)
Drain plug 63 4 Nm (47 2 ft-lb)
Drive gear bolt 152 15 Nm (112 10 ft-lb)
Drive pinion self-locking nut 216 29 Nm (159 22 ft-lb)
Filler plug 49 9 Nm (37 6 ft-lb)
Lower arm and knuckle connection nut 152 25 Nm (113 18 ft-lb)
SPECIFICATIONS
TSB Revision
REAR AXLE
27-41
GENERAL SPECIFICATIONS
M1271000200107
SERVICE SPECIFICATIONS
M1271000300308
Rear drive shaft and companion shaft connection nut 113 14 Nm (84 10 ft-lb)
Rear differential mount member nut 152 25 Nm (113 18 ft-lb)
Toe-control tower bar bolt and nut 46 8 Nm (34 6 ft-lb)
ITEM SPECIFICATION
ITEM SPECIFICATION
Reduction gear type Hypoid gear
Reduction ratio 4.300
Differential gear type (Type number
of gears)
Side gear Straight bevel gear 2
Pinion gear Straight bevel gear 2
Number of teeth Drive gear 43
Drive pinion 10
Side gear 18
Pinion gear 10
Bearings (Outside diameter Inside
diameter) mm (in)
Side 90.0 55.0
(3.54 2.17)
Front 68.3 30.2
(2.69 1.19)
Rear 79.4 36.5
(3.13 1.44)
ITEM STANDARD VALUE LIMIT
Rear axle total backlash mm (in)

5 (0.2)
Wheel bearing axial play mm (in)

0 (0)
Wheel bearing rotation starting torque Nm (in-lb)

1.76 (15.6)
DOJ boot assembly dimension mm (in) 110 3 (4.3 0.1)

Drive gear backlash mm (in) 0.13 0.18 (0.005 0.007)

Drive gear runout mm (in) 0.05 (0.002)

Differential gear backlash mm (in) 0 0.076 (0 0.003) 0.2 (0.01)

Drive pinion
turning torque
Nm (in-lb)
Without oil seal 1.94 2.25 (17.2 19.9)

With
oil seal
Companion flange (oil seal
contacting area) with anti-rust
agent
2.03 2.34 (18.0 20.7)

Companion flange (oil seal

contacting area) with gear oil
applied
2.10 2.40 (18.6 21.2)

SPECIFICATIONS
TSB Revision
REAR AXLE
27-42
LUBRICANTS
M1271000400145
SEALANT AND ADHESIVE
M1271000500142
COMPONENT IDENTIFICATION
M1271003800045
DRIVE PINION SPACER
ITEM SPECIFIED LUBRICANT QUANTITY
Rear differential gear oil Hypoid gear oil API classification GL-5 or
higher SAE viscosity No. 90, 80 W
Approximately 1.6 dm
3
(1.7 qt)
BJ joint Repair kit grease 245 10 g (8.7 0.3 oz)
DOJ joint Repair kit grease 295 10 g (10.5 0.3 oz)
ITEM SPECIFIED SEALANT AND ADHESIVE
Differential cover 3M AAD Part No. 8672, 8679, 8678, 8661, 8663 or
equivalent
Drive gear and differential case mounting part 3M AAD Part No. 8730, 8731 or equivalent
HEIGHT OF DRIVE PINION SPACER mm (in) IDENTIFICATION COLOR
52.50 (2.067) Yellow
52.84 (2.080) Red