27-1

GROUP 27

CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 27-2 REMOVAL AND INSTALLATION . . . . . . . . 27-21

SPECIAL TOOLS. . . . . . . . . . . . . . . . 27-2 DRIVE SHAFT ASSEMBLY . . . . . . . . 27-23

REMOVAL AND INSTALLATION . . . . . . . . 27-23
REAR AXLE DIAGNOSIS . . . . . . . . . 27-5 DISASSEMBLY AND ASSEMBLY . . . . . . . 27-25
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 27-5
TROUBLESHOOTING STRATEGY . . . . . . 27-5 DIFFERENTIAL CARRIER ASSEMBLY
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 27-5 ................................. 27-30
SYMPTOM PROCEDURES . . . . . . . . . . . . 27-6 REMOVAL AND INSTALLATION . . . . . . . . 27-30
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-32
ON-VEHICLE SERVICE. . . . . . . . . . . 27-16 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 27-36
REAR AXLE TOTAL BACKLASH CHECK . 27-16
GEAR OIL LEVEL CHECK . . . . . . . . . . . . . 27-17 SPECIFICATIONS . . . . . . . . . . . . . . . 27-45
WHEEL BEARING AXIAL PLAY CHECK . . 27-17 FASTENER TIGHTENING SPECIFICATIONS
...................................... 27-45
REAR AXLE HUB ASSEMBLY . . . . . 27-18 GENERAL SPECIFICATIONS . . . . . . . . . . 27-45
REMOVAL AND INSTALLATION . . . . . . . . 27-18 SERVICE SPECIFICATIONS . . . . . . . . . . . 27-46
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 27-20 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 27-46
SEALANT AND ADHESIVE . . . . . . . . . . . . 27-46
KNUCKLE . . . . . . . . . . . . . . . . . . . . . 27-21 COMPONENT IDENTIFICATION . . . . . . . . 27-46
27-2 REAR AXLE
GENERAL DESCRIPTION

.
GENERAL DESCRIPTION
M1271000100092
The rear axle has the following features. • The hybrid LSD which benefit driving on muddy
• DOJ-type on the differential side and BJ-type on and rough roads are featured as an option.
the hub side constant velocity joints are featured • ABS rotor to detect wheel speed is press-fitted
in the drive shaft. into the drive shaft.
• Large capacity and high rigidity taper-roller type NOTE: The structure of normal differential and hybrid
unit bearing in the wheel bearing is featured. LSD is basically the same as featured in existing
models.
CONSTRUCTION DIAGRAM

DIFFERENTIAL CARRIER

KNUCKLE

BJ
REAR HUB

UNIT BEARING

DOJ
DRIVE SHAFT

ACX02216 AB

SPECIAL TOOLS
M1271000600097

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB990767 MB990767-01 Removal and installation of the
End yoke holder drive shaft nut

MB990767

MB991113 or MB990635 MB991113-01, Disconnection of ball joint

Steering linkage puller MB990635-01 or
General service
tool
MB990635

MB990909 − Supporting of the differential

Working base carrier

MB990909

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 REAR AXLE
SPECIAL TOOLS
27-3
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MB990810 MB990810-01 • Removal of the side bearing
Side bearing puller inner race
• Removal of the companion
flange
MB990810

MB991407 − Removal of the side bearing

Differential rear support inner race
arbor

MB991407

MB990850 − • Removal of the self-locking

End yoke holder nut
• Adjustment of the drive
pinion turning torque
MB990850

MD998801 − Removal of the drive pinion rear

Bearing remover bearing inner race

MB991168 − Press-fitting of the drive pinion

Drive pinion oil seal installer oil seal

MB991168

MB991445 − Press-fitting of the drive pinion

Bushing remover and rear bearing outer race
installer base (Use together with MB990938)

MB991171 − Measurement of the pinion

Pinion height gauge set height
A: MB991170
A Cylinder gauge
B
MB991171 B: MB990819
AC000177
Drive pinion gauge
MB991768 −
Drive pinion gauge set
A A: MB991170
Head
MB991768

MB991534 −
Cylinder gauge

MB991534

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27-4 REAR AXLE
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB990326 General service Measurement of the starting
Preload socket tool torque of ball bearing

MB990326

MB990998 MB990998-01 or • Measure at the wheel

Front hub remover and General service bearing rotation starting
installer tool torque
• Wheel bearing backlash
MB990998 check

MB990802 MB990802-01 Press-fitting of the drive pinion

Bearing installer rear bearing inner race

MB990802

MB990727 − Press-fitting of the drive pinion

Drive pinion oil seal installer oil seal

MB990727

MD998812 − Press-fitting of the side bearing

Installer cap inner race

MD998829 −
Installer adapter

MB990925 MB990925-01 or • Press-fitting of oil seal

A Bearing and oil seal installer General service • Inspection of drive gear tooth
C set tool contact
A: MB990926 − MB990937 • Removal of bearing outer
B MB990925 Installer adapter race
B: MB990938 For details of each installer,
Bar refer to GROUP 26 − Special
C: MB990939 ToolsP.26-11.
Brass bar

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-5
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 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
rear axle fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.

SYMPTOM CHART
M1271004300106

SYMPTOMS INSPECTION REFERENCE

PROCEDURE PAGE
Drive shaft Noise while wheels are rotating 1 P.27-6
Grease leakage 2 P.27-6
Differential Constant noise 3 P.27-7
(Conventional Gear noise while driving 4 P.27-8
differential)
Gear noise while coasting 5 P.27-9
Bearing noise while driving or coasting 6 P.27-9
Noise while turning 7 P.27-10
Heat 8 P.27-10
Oil leakage 9 P.27-11
Differential (Limited- Abnormal noise during driving or shifting 10 P.27-11
slip differential) Abnormal noise when cornering 11 P.27-12
Gear noise 12 P.27-12
Gear oil leakage 13 P.27-14
Seizure 14 P.27-14
Breakdown 15 P.27-15
Limited slip differential does not function 16 P.27-16
(on snow, mud, ice, etc.).

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27-6 REAR AXLE
REAR AXLE DIAGNOSIS

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise while Wheels are Rotating <DRIVE SHAFT>

DIAGNOSIS STEP 2. Check the wheel bearing of rear hub

assembly for wear or damage.
STEP 1. Check whether the drive shaft is bent. Q: Is the wheel bearing damaged or worn?
Q: Is the drive shaft bent? YES : Replace the part. Then go to Step 3.
YES : Replace the part. Then go to Step 3. NO : Go to Step 3.
NO : Go to Step 2.
STEP 3. Check symptoms.
Q: Is the abnormal noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 2: Grease Leakage <DRIVE SHAFT>

DIAGNOSIS STEP 2. Check symptoms.

Q: Is there grease leakage?
STEP 1. Check the DOJ boot and the BJ boot for YES : Start over at Step 1.
wear or damage. NO : Diagnosis is complete.
Q: Is the DOJ boot or the BJ boot worn or damaged?
YES : Replace the part and apply grease (Refer to
P.27-25.). Then go to Step 2.
NO : Go to Step 2.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-7

INSPECTION PROCEDURE 3: Constant Noise <CONVENTIONAL DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the oil level.

Remove the filler plug and check the gear oil level.

GEAR OIL
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 differencial carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 9.
LOWER
LIMIT 5 mm NO : Go to Step 2.
(0.2 in)
ACX01083AB

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.

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.

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27-8 REAR AXLE
REAR AXLE DIAGNOSIS

STEP 7. Check the drive gear and differential case for

strain, and the gear for damage.
Q: Is the drive gear or differential case strained or
damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 8.

STEP 8. Check for the engagement of foreign material.

Q: Is the foreign material found?
YES : Remove the foreign material and then inspect. If
necessary, replace the part. Then go to Step 9.
NO : Go to Step 9.

STEP 9. Check symptoms.

Q: Is the abnormal noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 4: Gear Noise while Driving <CONVENTIONAL DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the oil level.

Remove the filler plug and check the gear oil level.

GEAR OIL
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 differencial carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 6.
LOWER
LIMIT 5 mm NO : Go to Step 2.
(0.2 in)
ACX01083AB

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.
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 REAR AXLE
REAR AXLE DIAGNOSIS
27-9

STEP 5. Check for foreign material.

Q: Is foreign material found?
YES : Remove the foreign material and then inspect. If
necessary, replace the part. Then go to Step 6.
NO : Go to Step 6.

STEP 6. Check symptoms.

Q: Is the abnormal noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 5: Gear Noise while Coasting <CONVENTIONAL DIFFERENTIAL>

DIAGNOSIS STEP 2. Check the gear for damage.

Q: Is the gear damaged?
STEP 1. Check the drive pinion turning torque. YES : Replace the gear. Then go to Step 3.
Q: Is the drive pinion turning torque correct? NO : Go to Step 3.
YES : Go to Step 2.
NO : Adjust the turning torque. Then go to Step 3. STEP 3. Check symptoms.
Q: Is the abnormal noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 6: Bearing Noise while Driving or Coasting <CONVENTIONAL

DIFFERENTIAL>

DIAGNOSIS STEP 2. Check symptoms.

Q: Is the abnormal noise eliminated?
STEP 1. Check the drive pinion rear bearing for YES : Diagnosis is complete.
cracks or damage. NO : Start over at Step 1.
Q: Is the drive pinion rear bearing cracked or
damaged?
YES : Replace the part. Then go to Step 2.
NO : Go to Step 2.

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27-10 REAR AXLE
REAR AXLE DIAGNOSIS

INSPECTION PROCEDURE 7: Noise while Turning <CONVENTIONAL DIFFERENTIAL>

DIAGNOSIS STEP 2. Check the side gear, pinion gear or

pinion shaft for damage.
STEP 1. Check the side bearing for wear or Q: Is the side gear, pinion gear or pinion shaft
damage. damaged?
Q: Is the side bearing worn or damaged? YES : Replace the part. Then go to Step 3.
YES : Replace the part. Then go to Step 3. NO : Go to Step 3.
NO : Go to step 2.
STEP 3. Check symptoms.
Q: Is the abnormal noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 8: Heat <CONVENTIONAL DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the oil level.

Remove the filler plug and check the gear oil level.

GEAR OIL
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 differencial carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 3.
LOWER
LIMIT 5 mm NO : Go to Step 2.
(0.2 in)
ACX01083AB

STEP 2. Check the gear backlash (excessive). 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.

STEP 3. Check symptoms.

Q: Is the heat eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-11

INSPECTION PROCEDURE 9: Oil Leakage <CONVENTIONAL 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 damaged.

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.

GEAR OIL
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
UPPER
LIMIT Step 5.
NO : Go to Step 5.
LOWER
LIMIT 5 mm
(0.2 in)
ACX01083AB

STEP 5. Check symptoms.

Q: Is there oil leakage?
YES : Start over at Step 1.
NO : Diagnosis is complete.

INSPECTION PROCEDURE 10: Abnormal Noise during Driving or Shifting <LIMITED-SLIP

DIFFERENTIAL>

NOTE: In addition to a malfunction of the differential carrier components, abnormal noise can also be caused
by the universal joint of the propeller shaft, the drive shafts, the wheel bearings, etc. Before disassembling
any parts, take all possibilities into consideration and confirm the source of the noise.
DIAGNOSIS tightening nut?
YES : Tighten to 216 ± 29 N⋅m (159 ± 22 ft-lb).
Then go to Step 3.
STEP 1. Check for looseness in the companion NO : Go to Step 2.
flange tightening nut.
Q: Is there looseness in the companion flange

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27-12 REAR AXLE
REAR AXLE DIAGNOSIS

STEP 2. Check the drive gear backlash STEP 3. Check symptoms.

(excessive). Q: Is the abnormal noise eliminated?
Q: Is the gear backlash correct? YES : Diagnosis is complete.
YES : Go to Step 3. NO : Start over at Step 1.
NO : Adjust the backlash. Then go to step 3.

INSPECTION PROCEDURE 11: Abnormal Noise when Cornering <LIMITED-SLIP DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check that Hypoid gear oil API classification GL-5

or higher, SAE viscosity Number 90, 80W is being used.
Q: Is the Hypoid gear oil API classification GL-5 or higher,
SAE viscosity Number 90, 80W being used?
YES : Go to Step 2.
NO : Replace the oil. Then go to Step 4.

STEP 2. Check the oil level.

(1) Remove the filler plug and check the gear oil level.

GEAR OIL
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 differencial carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 4.
LOWER
LIMIT 5 mm NO : Go to Step 3.
(0.2 in)
ACX01083AB

STEP 3. Check the limited slip differential case assembly

for damage.
Q: Is the limited slip differential case assembly damaged?
YES : Replace the part. Then go to Step 4.
NO : Go to step 4.

STEP 4. Check symptoms.

Q: Is the abnormal noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 12: Gear Noise <LIMITED-SLIP DIFFERENTIAL>

NOTE: Noise from the engine, muffler vibration, transmission, propeller shaft, wheel bearings, tires, body,
etc., is easily mistaken as being caused by malfunction in the differential carrier components. Be extremely
careful and attentive when test driving, etc.
Test methods to confirm the source of the abnormal noise include: coasting, acceleration, constant speed
driving, raising the rear wheels, etc. Use the method most appropriate to the circumstances.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-13
DIAGNOSIS

STEP 1. Check that Hypoid gear oil API classification GL-5

or higher, SAE viscosity Number 90, 80W is being used.
Q: Is the Hypoid gear oil API classification GL-5 or higher,
SAE viscosity Number 90, 80W being used?
YES : Go to Step 2.
NO : Replace the oil. Then go to Step 9.

STEP 2. Check the oil level.

Remove the filler plug and check the gear oil level.

GEAR OIL
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 differencial carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher, SAE viscosity Number
90, 80W. Then go to Step 9.
LOWER
LIMIT 5 mm NO : Go to Step 3.
(0.2 in)
ACX01083AB

STEP 3. Check the tooth contact (engagement) of the drive

gear. Refer to GROUP 26, Differential Carrier − Inspection
before Disassembly P.26-41.
Q: Is the tooth contact (engagement) of the drive gear
correct?
YES : Go to Step 4.
NO : Adjust or replace the part. Then go to Step 9.

STEP 4. Check the drive gear backlash.

Q: Is the drive gear backlash correct?
YES : Go to Step 5.
NO : Adjust the backlash. Then go to Step 9.

STEP 5. Check the drive pinion turning torque.

Q: Is the drive pinion turning torque correct?
YES : Go to Step 6.
NO : Adjust the turning torque. Then go to Step 9.

STEP 6. Check the drive gear and drive pinion for tooth
damage or breakage.
Q: Are the drive gear and drive pinion for tooth damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.

STEP 7. Check the drive pinion bearing and side bearing

for seizure, damage or breakage.
Q: Are the drive pinion bearing and side bearing damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 8.

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27-14 REAR AXLE
REAR AXLE DIAGNOSIS

STEP 8. Check the limited slip differential case assembly

for damage.
Q: Is the limited slip differential case assembly damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 9.

STEP 9. Check symptoms.

Q: Is the gear noise eliminated?
YES : Diagnosis is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 13: Gear Oil Leakage <LIMITED-SLIP DIFFERENTIAL>

DIAGNOSIS STEP 3. Check for looseness in the companion

flange tightening nut.
STEP 1. Check for looseness in the filler or drain Q: Is the companion flange tightening nut loose?
plug. YES : Tighten to 216 ± 29N⋅m (159 ± 22 ft-lb).
Q: Is the filler or drain plug loose? Then go to Step 5.
YES : Tighten the filler plug to 49 ± 9 N⋅m (36 ± 7 NO : Go to Step 4.
ft-lb) or tighten the drain plug to 63 ± 4 N⋅m
(47 ± 2 ft-lb). Then go to Step 5. STEP 4. Check the oil seal for wear, damage or
NO : Go to Step 2. foreign material.
Q: Is the oil seal worn, damaged or does it contain
STEP 2. Check the breather hose for clogging or foreign material?
damage. YES : Replace the seal. Then go to Step 5.
Q: Is the breather hose clogged or damaged? NO : Go to Step 5.
YES : Clean or replace the part. Then go to Step
5. STEP 5. Check symptoms.
NO : Go to Step 3.
Q: Is there oil leakage?
YES : Start over at Step 1.
NO : Diagnosis is complete.

INSPECTION PROCEDURE 14: Seizure <LIMITED-SLIP DIFFERENTIAL>

NOTE: In the event of seizure, disassemble and replace the parts involved. Be sure to check all components
for any irregularities and repair or replace as necessary.
DIAGNOSIS

STEP 1. Check that Hypoid gear oil API classification GL-5

or higher, SAE viscosity Number 90, 80W is being used.
Q: Is Hypoid gear oil API classification GL-5 or higher, SAE
viscosity Number 90, 80W being used?
YES : Go to Step 2.
NO : Replace the oil. Then go to Step 6.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-15

STEP 2. Check the oil level.

Remove the filler plug and check the gear oil level.

GEAR OIL
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 differencial carrier, and
repair if necessary. Then, refill with Hypoid gear oil
UPPER
LIMIT API classification GL-5 or higher, SAE viscosity
Number 90, 80W. Then go to Step 6.
LOWER
LIMIT 5 mm NO : Go to Step 3.
(0.2 in)
ACX01083AB

STEP 3. Check the drive gear backlash (low).

Q: Is the drive gear backlash correct?
YES : Go to Step 4.
NO : Adjust the backlash. Then go to Step 6.

STEP 4. Check the drive pinion turning torque (excessive).

Q: Is the drive pinion turning torque correct?
YES : Go to Step 5.
NO : Adjust it. Then go to Step 6.

STEP 5. Check the side bearing preload (excessive).

Q: Are the side bearing cap mounting bolts tightened to 74
± 5 N⋅m (55 ± 3 ft-lb)?
YES : Go to Step 6.
NO : Tighten them to 74 ± 5 N⋅m (55 ± 3 ft-lb). Then go to
Step 6.

STEP 6. Check symptoms.

Q: Does the seizure still occur?
YES : Start over at Step 1.
NO : Diagnosis is complete.

INSPECTION PROCEDURE 15: Breakdown <LIMITED-SLIP DIFFERENTIAL>

NOTE: In addition to disassembling and replacing the failed parts, be sure to check all components for
irregularities and repair or replace as necessary.
DIAGNOSIS STEP 2. Check the drive gear backlash. Refer to
GROUP 26, Differential Carrier − Inspection
STEP 1. Check for looseness of the drive gear before Disassembly P.26-41 and refer to P.27-32.
tightening bolt. Q: Is the drive gear backlash correct?
Q: Are the drive gear tightening bolts loose? YES : Go to Step 3.
YES : Tighten to 152 ± 15N⋅m (112 ± 10 ft-lb) and NO : Adjust the backlash. Then go to Step 5.
apply 3MäStud Locking 4170 or equivalent.
Then go to Step 5.
NO : Go to Step 2.

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27-16 REAR AXLE
ON-VEHICLE SERVICE

STEP 3. Check the drive pinion turning torque STEP 4. Check the side bearing preload (low).
(low). Refer to P.27-36. Q: Are the side bearing cap mounting bolts tightened
Q: Is the drive pinion turning torque correct? to 74 ± 5 N⋅m (55 ± 3 ft-lb)?
YES : Go to Step 4. YES : Go to Step 5.
NO : Adjust it. Then go to Step 5. NO : Tighten them to 74 ± 5 N⋅m (55 ± 3 ft-lb).
Then go to Step 5.

STEP 5. Check symptoms.

Q: Is there damage?
YES : Start over at Step 1.
NO : Diagnosis is complete.

INSPECTION PROCEDURE 16: Limited Slip Differential does not Function (on Snow, Mud, Ice, etc.)
<LIMITED-SLIP DIFFERENTIAL>

DIAGNOSIS STEP 2. Check symptoms.

Q: Does the limited slip differential function?
STEP 1. Check the limited slip device for YES : Diagnosis is complete.
damage. NO : Start over at Step 1.
Q: Is the limited slip device damaged?
YES : Replace the damaged part. Then go to Step
2.
NO : Go to Step 2.

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.
MATING MARKS Make the mating mark on the dust cover of the companion
flange and on the differential carrier.

ACX00962AB

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 REAR AXLE
ON-VEHICLE SERVICE
27-17
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
ACX00964

GEAR OIL LEVEL CHECK

M1272001200040
Check that gear oil level is not 5 mm (0.2 inch) below the
bottom of filler plug hole.
GEAR OIL
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W
UPPER
LIMIT
LOWER
LIMIT 5 mm
(0.2 in)
ACX01083AB

WHEEL BEARING AXIAL PLAY CHECK

M1271000900106
1. Remove the rear brake assembly and remove the brake disc
while holding it with wires to prevent it from falling.
2. Fit the dial gauge as shown in the diagram and move 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.

ACX01084

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27-18 REAR AXLE
REAR AXLE HUB ASSEMBLY

REAR AXLE HUB ASSEMBLY

REMOVAL AND INSTALLATION
M1271002000079

Post-installation Operation
Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle ServiceP.36-4.)
113 ± 14 N·m
6 84 ± 10 ft-lb

10
88 ± 10 N·m 4
65 ± 7 ft-lb 3
9 255 ± 29 N·m
188 ± 21 ft-lb

2
81 ± 6 N·m
60 ± 4 ft-lb N
5

152 ± 25 N·m
113 ± 18 ft-lb
11
7 ACX01085 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. HUB CAP 7. LOWER ARM AND KNUCKLE
<<C>> >>A<<
<<A>> >>B<< 2. DRIVE SHAFT NUT CONNECTION
<<B>> 3. REAR BRAKE CALIPER 8. REAR DRIVE SHAFT ASSEMBLY
4. REAR BRAKE DISC 9. ABS ROTOR PROTECTOR
5. PARKING BRAKE SHOE AND 10. REAR HUB ASSEMBLY
LINING ASSEMBLY (REFER TO 11. BACKING PLATE
GROUP 36, PARKING BRAKE
DRUMP.36-8.)
6. COMPANION SHAFT AND DRIVE
SHAFT CONNECTION

Required Special Tools: • MB990998: Front Hub Remover and Installer

• MB990767: End Yoke Holder • MB990326: Preload Socket

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 REAR AXLE
REAR AXLE HUB ASSEMBLY
27-19
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.

MB990767

ACX00972 AC

<<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
illustration and use the floor jack to remove the lower arm
mounting bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

INSTALLATION SERVICE POINTS

.

>>A<< LOWER ARM AND KNUCKLE CONNECTION

Position a wooden block to the lower arm as shown in the
illustration and use the floor jack to install the lower arm
mounting bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

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27-20 REAR AXLE
REAR AXLE HUB ASSEMBLY

>>B<< DRIVE SHAFT NUT INSTALLATION

1. Assemble the drive shaft washer in the illustrated direction.
WASHER
MB990767 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
255 ± 29 N·m shaft nut [less than 284 N⋅m (209 ft-lb)] and find the nearest
188 ± 21 ft-lb hole then bend the split pin to fit in.
ACX01087AB

INSPECTION
M1271002100098

WHEEL BEARING ROTATION STARTING

TORQUE CHECK
1. Tighten special tool MB990998 in rear hub assembly to the
MB990998 specified torque.
MB990998 MB990326
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 N⋅m (15.6 in-lb)
4. Hub rotation starting torque must be under the limit value
and the hub should rotate smoothly.
255 ± 29 N·m WOODEN BLOCK
188 ± 21 ft-lb ACX01088AB

WHEEL BEARING AXIAL PLAY CHECK

1. Check the wheel bearing axial play.
WOODEN BLOCK Limit: 0 mm (0 inch)
2. If the wheel bearing axial play exceeds the limit value at the
specified torque of [255 ± 29 N⋅m (188 ± 21ft-lb)], replace
the rear hub assembly.

WOODEN
BLOCK ACX01089AB

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 REAR AXLE
KNUCKLE
27-21
KNUCKLE
REMOVAL AND INSTALLATION
M1271003000094

Pre-removal Operation Post-installation Operation

Rear Hub Assembly Removal (Refer to P.27-18.) • Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
• Rear Hub Assembly Installation (Refer to P.27-18.)

4
150 ± 30 N·m
111 ± 22 ft-lb

67 ± 7 N·m N
50 ± 5 ft-lb
2 N
1
231 ± 34 N·m
170 ± 25 ft-lb

3
ACX01090 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. VEHICLE SPEED SENSOR 4. KNUCKLE AND UPPER ARM
<<A>>
2. KNUCKLE AND TOE-CONTROL CONNECTION
<<A>> 5. KNUCKLE ASSEMBLY
ARM CONNECTION
3. KNUCKLE AND TRAILING ARM
CONNECTION

Required Special Tool:

MB991113 or MB990635: Steering Linkage Puller

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27-22 REAR AXLE
KNUCKLE

REMOVAL SERVICE POINT

.

<<A>> KNUCKLE AND TOE-CONTROL ARM/UPPER ARM

DISCONNECTION
CAUTION
• Use special tool MB991113 or MB990635 to loosen the
nut from the ball joint instead of removing it.
MB991113 OR
MB990635 • Hang special tool MB991113 or MB990635 with ropes to
prevent it from falling.
BALL JOINT
CORD

NUT ACX00715AC

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-23
DRIVE SHAFT ASSEMBLY
REMOVAL AND INSTALLATION
M1271003300040

113 ± 14 N·m
84 ± 10 ft-lb 255 ± 29 N·m
188 ± 21 ft-lb

N
3

2
1

152 ± 25 N·m
113 ± 18 ft-lb
4 ACX01091 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. CAP 4. KNUCKLE AND LOWER ARM
<<B>> >>A<<
<<A>> >>B<< 2. DRIVE SHAFT NUT CONNECTION
3. COMPANION SHAFT AND DRIVE 5. REAR DRIVE SHAFT ASSEMBLY
SHAFT CONNECTION

Required Special Tool:

MB990767: End Yoke Holder

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27-24 REAR AXLE
DRIVE SHAFT ASSEMBLY

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.

MB990767

ACX00972 AC

<<B>> KNUCKLE AND LOWER ARM DISCONNECTION

Position a wooden block to the lower arm as shown in the
illustration and use the floor jack to remove the lower arm
mounting bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

INSTALLATION SERVICE POINTS

.

>>A<< KNUCKLE AND LOWER ARM CONNECTION

Position a wooden block to the lower arm as shown in the
illustration and use the floor jack to install the lower arm
mounting bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-25
>>B<< DRIVE SHAFT NUT INSTALLATION
1. Assemble the drive shaft washer in the illustrated direction.
WASHER
MB990767 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
255 ± 29 N·m shaft nut [less than 284 N⋅m (209 ft-lb)] and find the nearest
188 ± 21 ft-lb hole then bend the split pin to fit in.
ACX01087AB

DISASSEMBLY AND ASSEMBLY

M1271003500044

CAUTION
Never disassemble the BJ assembly except when replacing the BJ boot.

10 N
13
12
11 N

10
12

7
N 2
9

11 N 1 6
2 8
1 3 5
7
3 4
BJ BOOT REPAIR KIT

13 5 9 1
7 7
3
4 3
2
9
1 2
6
8
2 3
1
7

BJ REPAIR KIT DOJ REPAIR KIT DOJ BOOT REPAIR KIT

ACX01092 AC

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27-26 REAR AXLE
DRIVE SHAFT ASSEMBLY

DISASSEMBLY STEPS ASSEMBLY STEPS

1. DOJ BOOT BAND (LARGE) 13. BJ ASSEMBLY
2. DOJ BOOT BAND (SMALL) >>A<< 12. BJ BOOT
3. CIRCLIP 11. BJ BOOT BAND (SMALL)
4. DOJ OUTER RACE 10. BJ BOOT BAND (LARGE)
<<A>> 5. BALLS >>A<< 9. DOJ BOOT
<<B>> 6. DOJ CAGE >>B<< 6. DOJ CAGE
7. SNAP RING >>B<< 8. DOJ INNER RACE
8. DOJ INNER RACE 7. SNAP RING
<<C>> 9. DOJ BOOT 5. BALLS
10. BJ BOOT BAND (LARGE) >>C<< 4. DOJ OUTER RACE
11. BJ BOOT BAND (SMALL) 3. CIRCLIP
<<C>> 12. BJ BOOT >>D<< 2. DOJ BOOT BAND (SMALL)
13. BJ ASSEMBLY >>D<< 1. DOJ BOOT BAND (LARGE)

Required Special Tool:

MB990939: Brass Bar

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-27
LUIBRICATION POINTS
CAUTION
Do not mix old and new or different types of grease, as a special grease is used in the joint.

DOJ BJ

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)]
<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)]
NOTE
THE GREASE IN THE REPAIR KIT SHOULD BE DIVIDED IN HALF FOR USE,
RESPECTIVELY, AT THE JOINT AND INSIDE THE BOOT.
ACX01093AD

DISASSEMBLY SERVICE POINTS

.

<<A>> BALLS REMOVAL

Remove the balls from the DOJ cage.

ACX01094

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27-28 REAR AXLE
DRIVE SHAFT ASSEMBLY

<<B>> DOJ CAGE REMOVAL

Remove the DOJ cage from the DOJ inner race in the direction
of the BJ.

ACX01095

<<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.
PLASTIC TAPE

ACX02368AB

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
ACX01096 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.

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-29
3. Tap the inner race with even force to press-fit into the bump
of the shaft with special tool MB990939.

MATING MARK

MB990939

ACX01097AB

>>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.
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: 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)]

ACX02369

>>D<< DOJ BOOT/DOJ BOOT BAND INSTALLATION

1. Position the DOJ outer race so that the distance between
A 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.

BOOT BAND (SMALL)

BOOT BAND (LARGE)
ACX02370 AB

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27-30 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL AND INSTALLATION
M1272002000049

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-
17.)

7
1 152 ± 25 N·m
113 ± 18 ft-lb

5
3 6

4
113 ± 14 N·m
3 84 ± 10 ft-lb

46 ± 8 N·m
34 ± 6 ft-lb

113 ± 14 N·m
84 ± 10 ft-lb
46 ± 8 N·m
34 ± 6 ft-lb
6

152 ± 25 N·m
113 ± 18 ft-lb
3 2

8
83 ± 12 N·m 1
61 ± 9 ft-lb
AC101787 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

• PROPELLER SHAFT (REFER TO 6. DIFFERENTIAL CARRIER
<<B>>
GROUP 25P.25-5.) ASSEMBLY
1. DRIVE SHAFT CONNECTION • FUEL TANK (REFER TO GROUP
2. KNUCKLE AND LOWER ARM 13BP.13B-10.)
<<A>> >>A<< 7. REAR DIFFERENTIAL MOUNT
CONNECTION
3. COMPANION SHAFT MEMBER
4. TOE CONTROL TOWER BAR 8. DYNAMIC DAMPER
5. BREATHER HOSE CONNECTION

REMOVAL SERVICE POINTS

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-31
.

<<A>> KNUCKLE AND LOWER ARM DISCONNECTION

Position a wooden block to the lower arm as shown in the
illustration and use the floor jack to remove the lower arm
mounting bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

<<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
illustration and use the floor jack to install the lower arm
mounting bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

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27-32 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

DISASSEMBLY
M1272002200043

CAUTION
Do not disassemble the limited slip differential case assembly.

<CONVENTIONAL DIFFERENTIAL>
7 8
16 N 4
9
16 15
13
11
12
14
13 15 17 3
10
14 16
8
5 9
7
33
26 27
N 29 30 N 31 N
25 N
N 28 24
22 23
20 21 <LIMITED SLIP DIFFERENTIAL>
N 19
32 N 7
8 6
9
10
N
18
2 8
9
1 7

ACX01100 AB

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

• INSPECTION BEFORE <<F>> 19. SELF-LOCKING NUT
<<A>> 20. WASHER
DISASSEMBLY
1. FILLER PLUG <<G>> 21. DRIVE PINION ASSEMBLY
2. DRAIN PLUG <<G>> 22. COMPANION FLANGE
3. DIFFERENTIAL COVER 23. DRIVE PINION FRONT SHIM (FOR
4. VENT PLUG ADJUSTING PRELOAD OF DRIVE
5. BEARING CAP PINION)
<<B>> 6. DIFFERENTIAL CASE ASSEMBLY 24. DRIVE PINION SPACER
<<B>> 7. DIFFERENTIAL SIDE SHIM 25. DRIVE PINION REAR BEARING
<<H>>
<<B>> 8. SIDE BEARING OUTER RACE INNER RACE
<<C>> 9. SIDE BEARING INNER RACE 26. DRIVE PINION REAR SHIM (FOR
<<D>> 10. DRIVE GEAR ADJUSTING DRIVE PINION
<<E>> 11. LOCK PIN HEIGHT)
12. PINION SHAFT 27. DRIVE PINION
13. PINION GEAR <<I>> 28. OIL SEAL
14. PINION WASHER 29. DRIVE PINION FRONT BEARING
<<I>>
15. SIDE GEAR INNER RACE
16. SIDE GEAR THRUST SPACER 30. DRIVE PINION FRONT BEARING
<<I>>
17. DIFFERENTIAL CASE OUTER RACE
18. LIMITED SLIP DIFFERENTIAL CASE 31. DRIVE PINION REAR BEARING
<<J>>
ASSEMBLY OUTER RACE

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-33
DISASSEMBLY STEPS (Continued)
32. OIL SEAL
33. DIFFERENTIAL CARRIER

Required Special Tools: • MB990850: End Yoke Holder

• MB990810: Side Bearing Puller • MD998801: Bearing Remover
• MB991407: Differential Rear Support Arbor • 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)
.

<<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 at the
time of assembly.

ACX02422

<<C>> SIDE BEARING INNER RACE REMOVAL

MB990810
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.
MB991407

ACX01041AB

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27-34 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

<<D>> DRIVE GEAR REMOVAL

1. Make mating marks to the differential case and the drive
gear.
2. Loosen the drive gear attaching bolts in diagonal sequence
to remove the drive gear.

MATING
MARKS

ACX01042AB

<<E>> LOCK PIN REMOVAL

Drive out the lock pin with a punch.

PUNCH

ACX01048AB

<<F>> SELF-LOCKING NUT REMOVAL

Use special tool MB990850 to hold the companion flange, and
then remove the companion flange self-locking nut.

MB990850

ACX01043AB

<<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.

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-35
MB990810 2. Use special tool MB990810 to pull out the companion
flange.

COMPANION
FLANGE

ACX01044 AB

<<H>> DRIVE PINION REAR BEARING INNER RACE

REMOVAL
Use special tool MD998801 to pull out the front bearing inner
race.

MD998801

ACX02423 AB

<<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
MB990939
bearing outer race.

DRIVE PONION
REAR BEARING
DRIVE PINION OUTER RACE
FRONT BEARING
OUTER RACE DRIVE PINION
FRONT
BEARING
OIL SEAL OUTER RACE
ACX01101AB

<<J>> DRIVE PINION REAR BEARING OUTER RACE

REMOVAL
Use special tool MB990939 to remove the drive pinion rear
bearing outer race.
MB990939

ACX01102 AB

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27-36 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

ASSEMBLY
M1272002300040

<CONVENTIONAL DIFFERENTIAL>
N 30 28
27 26 35 ± 5 N·m
25 19 25 ± 4 ft-lb
18 21 23
22 20
74 ± 5 N·m 19 24
55 ± 3 ft-lb 21 18 16
20 25 31
29 26
1 6 5 27
N 4 3N
N 11 7N
14 13 8
9 152 ± 15 N·m
216 ± 29 N·m 10 112 ± 10 ft-lb
159 ± 22 ft-lb
N 15 N N <LIMITED SLIP DIFFERENTIAL>
2N
12 32 63 ± 4 N·m 49 ± 9 N·m
47 ± 2 ft-lb 33 37 ± 6 ft-lb
27 28
26
25
24 21 24
5 19 18 17 25
15 26
27
18
19
21
FINAL DRIVE GEAR SET DIFFERENTIAL GEAR SET 152 ± 15 N·m
112 ± 10 ft-lb ACX01103 AB

ASSEMBLY STEPS ASSEMBLY STEPS (Continued)

1. DIFFERENTIAL CARRIER 13. COMPANION FLANGE
>>A<< 2. OIL SEAL 14. WASHER
15. SELF-LOCKING NUT
>>B<< 3. DRIVE PINION REAR BEARING 16. DIFFERENTIAL CASE
OUTER RACE
4. DRIVE PINION FRONT BEARING 17. LIMITED SLIP DIFFERENTIAL CASE
>>C<< ASSEMBLY
OUTER RACE
DIFFERENTIAL GEAR BACKLASH
>>D<< • DRIVE PINION HEIGHT >>F<< •
ADJUSTMENT ADJUSTMENT
5. DRIVE PINION 18. SIDE GEAR THRUST SPACER
6. DRIVE PINION REAR SHIM (FOR 19. SIDE GEAR
ADJUSTING DRIVE PINION 20. PINION WASHER
HEIGHT) 21. PINION GEAR
7. DRIVE PINION REAR BEARING 22. PINION SHAFT
INNER RACE >>G<< 23. LOCK PIN
8. DRIVE PINION SPACER >>H<< 24. DRIVE GEAR
>>I<< 25. SIDE BEARING INNER RACE
>>E<< • DRIVE PINION TURNING TORQUE 26. SIDE BEARING OUTER RACE
ADJUSTMENT
9. DRIVE PINION FRONT SHIM (FOR 27. SIDE BEARING SHIM
ADJUSTING DRIVE PINION 28. DIFFERENTIAL CASE ASSEMBLY
PRELOAD) >>J<< 29. BEARING CAP
10. DRIVE PINION ASSEMBLY 30. VENT PLUG
11. DRIVE PINION FRONT BEARING 31. DIFFERENTIAL COVER
INNER RACE 32. DRAIN PLUG
>>E<< 12. OIL SEAL

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-37
ASSEMBLY STEPS (Continued)
33. FILLER PLUG
>>J<< • FINAL DRIVE GEAR BACKLASH
ADJUSTMENT

Required Special Tools: • MB990727: Drive Pinion Oil Seal Installer

• MB990938: Bar • MD998812: Installer Cap
• MB991445: Bushing Remover and Installer Base • MD998829: Installer Adapter
• MB990934: Installer Adapter • MB990810: Side Bearing Puller
• MB990850: End Yoke Holder • MB991407: Differential Rear Support Arbor
• MB990326: Preload Socket • MB990802: Bearing Installer

LUBRICATION AND ADHESIVE POINTS

2 – 3 mm (0.08 – 0.12 in)

(BEAD DIAMETER)

ADHESIVE: SEMI-DRYING SEALANT:

3M TM STUD LOCKING 3870, 3MTM AAD PART NO. 8672, 8679,
3871 OR EQUIVALENT 8678, 8661, 8663 OR EQUIVALENT

ACX01104 AB

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27-38 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL PRESS-FITTING

Use special tool MB991168 to press-fit the oil seal.
MB991168

OIL SEAL ACX01105 AB

>>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.
MB990938
MB991445

ACX01106AB

>>C<< DRIVE PINION FRONT BEARING OUTER RACE

PRESS-FITTING
Use special tools MB990938 and MB990934 to press-fit the
MB990938 drive pinion front bearing outer race.
MB990934

ACX01107AB

>>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.
REPLACE THE
2. Install special tool MB990819, MB991770 and drive pinion
HEAD WITH
MB991770 front and rear bearing inner races to the gear carrier as
shown in the illustration.

MB990819

AC000178 AB

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-39
3. Tighten the nut of special tool MB990819 a little at a time
MB990819
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:

BEARING DIVISION TURNING TORQUE

New 1.94 − 2.25 N⋅m
17.2 − 19.9 in-lb
ACX01055 AB

4. Clean the side bearing hub.

MB990326

MB990819

ACX01056AB

NOTCH 5. Place special tool MB991534 between the side bearing hub
MB991534
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.
A

MB991169 THICKNESS
GAUGE ACX01109AB

8. Use a micrometer to measure the shown dimensions (B, C)

of special tools MB991169 and MB991534.
MB991534 C

ACX01058AB

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DIFFERENTIAL CARRIER ASSEMBLY

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.
CYLINDER GAUGE
F = A + B + C − 1/2D − 86.00 mm (3.385 inches)

ACX01110AB

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.
DRIVE PINION
REAR SHIM
MB990802

ACX02428 AB

>>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
216 ± 29 N•m
159 ± 22 ft-lb using special tool MB990850.
MB990850 Tightening torque: 216 ± 29 N⋅m (159 ± 22 ft-lb)

ACX01065AB

3. Measure the drive pinion turning torque (without the oil

MB990685
MB990326 seal).
Standard value:

BEARING DIVISION TURNING TORQUE

New 1.94 − 2.25 N⋅m
17.2 − 19.9 in-lb

ACX01062AB

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-41
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.

HEIGHT OF DRIVE IDENTIFICATION COLOR

PINION SPACER mm (in)
52.50 (2.067) Yellow
52.84 (2.080) Red

IDENTIFICATION
COLOR

ACX01063 AB

5. Remove the companion flange and drive pinion again. Then

insert the drive pinion front bearing inner race into the gear
MB990727
carrier. Use special tool MB990727 to press-fit the oil seal.

ACX01064 AC

6. Install the drive pinion assembly and companion flange with

216 ± 29 N•m
159 ± 22 ft-lb mating marks properly aligned. Tighten the companion
MB990850 flange self-locking nut to the specified torque using special
tool MB990850.
Tightening torque: 216 ± 29 N⋅m (159 ± 22 ft-lb)

ACX01065AB

7. Measure the drive pinion turning torque (with oil seal) to

MB990685
MB990326 verify that the drive pinion turning torque complies with the
standard value.
Standard value:

BEARING COMPANION TURNING

DIVISION FLANGE TORQUE
LUBRICATION
New None (with anti-rust 2.03 − 2.34 N⋅m
ACX01062AB agent) 18.0 − 20.7 in-lb
Gear oil applied 2.10 − 2.40 N⋅m
18.6 − 21.2 in-lb

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27-42 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

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.

ACX01066

3. Insert a wedge between the side gear and the pinion shaft to
WEDGE 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)
SIDE GEAR 5. Measure by the same procedure for the other pinion gear.
SIDE GEAR THRUST
SPACER
Limit: 0.2 mm (0.01 inch)
THRUST
SPACER ACX01035 AB 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.
.

>>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.

ACX02429

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DIFFERENTIAL CARRIER ASSEMBLY
27-43
>>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.

TAP ACX01068AB

3. Apply 3Mä 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 N⋅m (112 ± 10 ft-lb)

ACX02430

>>I<< SIDE BEARING INNER RACE INSTALLATION

Use special tools MD998812 and MD998829 to press-fit the
side bearing inner races into the differential case.

MD998812
MD998829

ACX02431AB

>>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 the side bearing spacer with the
thickness derived from the sum of the clearance and a half
of pre-load, 0.05mm (0.002 inch).

ACX01071

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27-44 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

MB990810
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)
MB991407
of the differential case side.
5. Assemble the selected side bearing spacers to each side.

ACX01041AB

MB990802 6. Use special tool MB990802 to press-fit the side bearing

DRIVE
PINION inner case into the differential case. After installing the outer
REAR race, assemble the differential case to the gear carrier.
SHIM 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 N⋅m (55 ± 3 ft-lb)

MB990802

ACX02432 AB

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)

ACX01034

9. If the backlash is not within the standard value, move the

WHEN THE BACKLASH IS SMALL
side bearing spacer as shown in the illustration to adjust the
DECREASED INCREASED 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
INCREASED DECREASED Disassembly P.26-41.)
WHEN THE BACKLASH IS LARGE
ACX02433AB

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.

ACX01036

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 REAR AXLE
SPECIFICATIONS
27-45
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS M1271004000097

ITEMS SPECIFICATIONS
Rear axle hub assembly, drive shaft assembly
Backing plate bolt 81 ± 6 N⋅m (60 ± 4 ft-lb)
Lower arm and knuckle connection nut 152 ± 25 N⋅m (113 ± 18 ft-lb)
Rear brake caliper bolt 88 ± 10 N⋅m (65 ± 7 ft-lb)
Rear drive shaft and companion shaft connection nut 113 ± 14 N⋅m (84 ± 10 ft-lb)
Rear drive shaft nut 255 ± 29 N⋅m (188 ± 21 ft-lb)
Knuckle
Toe-control arm and knuckle connection nut 67 ± 7 N⋅m (50 ± 5 ft-lb)
Trailing arm and knuckle connection bolt 231 ± 34 N⋅m (170 ± 25 ft-lb)
Upper arm and knuckle connection nut 150 ± 30 N⋅m (111 ± 22 ft-lb)
Differential carrier assembly
Bearing cap bolt 74 ± 5 N⋅m (55 ± 3 ft-lb)
Differential cover bolt 35 ± 5 N⋅m (25 ± 4 ft-lb)
Dynamic damper bolt 83 ± 12 N⋅m (61 ± 9 ft-lb)
Drain plug 63 ± 4 N⋅m (47 ± 2 ft-lb)
Drive gear bolt 152 ± 15 N⋅m (112 ± 10 ft-lb)
Drive pinion self-locking nut 216 ± 29 N⋅m (159 ± 22 ft-lb)
Filler plug 49 ± 9 N⋅m (37 ± 6 ft-lb)
Lower arm and knuckle connection nut 152 ± 25 N⋅m (113 ± 18 ft-lb)
Rear drive shaft and companion shaft connection nut 113 ± 14 N⋅m (84 ± 10 ft-lb)
Rear differential mount member nut 152 ± 25 N⋅m (113 ± 18 ft-lb)
Toe-control tower bar bolt and nut 46 ± 8 N⋅m (34 ± 6 ft-lb)

GENERAL SPECIFICATIONS M1271000200044

ITEMS NORMAL DIFFERENTIAL HYBRID LSD

Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 4.636 4.636 <PART TIME 4WD>
4.300 <ACTIVE-TRAC 4WD II>
LSD type − Torque sensing + VCU
Differential gear type (Type × Side gear Straight bevel gear × 2 Helical gear × 2
number of gears) Pinion gear Straight bevel gear × 2 Long pinion × 4
Short pinion × 4
Number of Drive gear 49 43 <PART TIME 4WD>
teeth 49 <ACTIVE-TRAC 4WD II>
Drive pinion 10 10
Side gear 18 22
Pinion gear 10 7

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27-46 REAR AXLE
SPECIFICATIONS

ITEMS NORMAL DIFFERENTIAL HYBRID LSD

Bearings (Outside diameter Side 90.0 × 55.0 90.0 × 55.0
× Inside diameter) mm (in) (3.54 × 2.17) (3.54 × 2.17)
Front 68.3 × 30.2 68.3 × 30.2
(2.69 × 1.19) (2.69 × 1.19)
Rear 79.4 × 36.5 79.4 × 36.5
(3.13 × 1.44) (3.13 × 1.44)

SERVICE SPECIFICATIONS M1271000300096

ITEMS 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 N⋅m (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 Without oil seal 1.94 − 2.25 (17.2 − 19.9) −
turning torque
With Companion flange (oil seal 2.03 − 2.34 (18.0 − 20.7) −
N⋅m (in-lb) oil seal contacting area) with anti-rust
agent
Companion flange (oil seal 2.10 − 2.40 (18.6 − 21.2) −
contacting area) with gear oil
applied

LUBRICANTS M1271000400048

ITEMS SPECIFIED LUBRICANTS QUANTITY

Rear differential gear oil Hypoid gear oil API classification GL-5 or Approximately 1.6 dm3 (1.7 qt)
higher SAE viscosity No. 90, 80 W
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)

SEALANT AND ADHESIVE

ITEMS SPECIFIED SEALANT AND ADHESIVE
Differential cover 3Mä AAD Part No. 8672, 8679, 8678, 8661, 8663 or
equivalent
Drive gear and differential case mounting part 3Mä Stud Locking 8730, 8731 or equivalent

COMPONENT IDENTIFICATION M1271003800045

DRIVE PINION SPACER

HEIGHT OF DRIVE PINION SPACER mm (in) IDENTIFICATION COLOR
52.50 (2.067) Yellow
52.84 (2.080) Red

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