27-1

GROUP 27

REAR AXLE
CONTENTS

GENERAL INFORMATION . . . . . . . . 27-2 AXLE ASSEMBLY . . . . . . . . . . . . . . . 27-9

REMOVAL AND INSTALLATION . . . . . . . . 27-9
SERVICE SPECIFICATIONS. . . . . . . 27-3
AXLE SHAFT ASSEMBLY . . . . . . . . . 27-12
LUBRICANTS . . . . . . . . . . . . . . . . . . 27-4 REMOVAL AND INSTALLATION . . . . . . . . 27-12
DISASSEMBLY AND REASSEMBLY . . . . . 27-14
SEALANT. . . . . . . . . . . . . . . . . . . . . . 27-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-17

SPECIAL TOOLS. . . . . . . . . . . . . . . . 27-4 DIFFERENTIAL CARRIER ASSEMBLY

................................. 27-18
ON-VEHICLE SERVICE. . . . . . . . . . . 27-7 REMOVAL AND INSTALLATION . . . . . . . . 27-18
REAR AXLE TOTAL BACKLASH CHECK . 27-7 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-19
GEAR OIL LEVEL CHECK . . . . . . . . . . . . . 27-8 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-23
GEAR OIL REPLACEMENT . . . . . . . . . . . . 27-8 MECHANICAL TYPE LIMITED SLIP DIFFERENTIAL
AXLE SHAFT AXIAL PLAY CHECK . . . . . . 27-8 DISASSEMBLY AND REASSEMBLY . . . . . 27-30
AXLE SHAFT AXIAL PLAY ADJUSTMENT 27-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-34
LIMITED SLIP DIFFERENTIAL PRELOAD
MEASUREMENT<MECHANICAL TYPE> . 27-8
27-2 REAR AXLE
GENERAL INFORMATION

GENERAL INFORMATION
The rear axle has the following features:
• A banjo type semi-flowting type axle has been
incorporated.
• The wheel bearing is a double taper roller bearing
and is highly resistant to a thrust load.
• ABS rotor for detecting the wheel speed is
press-fitted to the retainer. <Vehicles with ABS>
M1271000100519
• Torque sensitive type mechanical limited slip dif-
ferential has been adopted. <4WD-2500 (vehi-
cles without ABS)>
• Hybrid limited slip differential has been adopted.
<4WD-2500 (vehicles with ABS), 4WD-3200>

REAR AXLE
Item Specification
Axle housing Type Banjo
Axle shaft Type Semi-floating
Shaft outer diameter (bearing part × 40.0 × 34.5 × 736
center part) × length mm
Bearing type Double taper roller
Bearing (OD × ID) mm 80 × 40

DIFFERENTIAL<2WD>
Item Specification
Reduction gear type Hypoid gear
Reduction ratio 4.222 <SOHC>, 3.909 <DOHC>
Differential gear type (Type × Side gear Straight bevel gear × 2
number of gears) Pinion gear Straight bevel gear × 2
Number of teeth Drive gear 38 <SOHC>, 43 <DOHC>
Drive pinion 9 <SOHC>, 11 <DOHC>
Side gear 14
Pinion gear 10
Bearing (Outside diameter × Side 80.0 × 45.2
inside diameter) mm Front 68.3 × 30.2
Rear 90 × 36.5
DIFFERENTIAL <4WD>
Item 2500 (vehicles 2500 (vehicles 3200
without ABS) with ABS)
Reduction gear type Hypoid gear Hypoid gear Hypoid gear
Reduction ratio 4.100 4.100 4.100
Limited slip differential type Mechanical Hybrid (Helical Hybrid (Helical
gear + Viscous gear + Viscous
coupling unit) coupling unit)
Number of teeth Drive gear 41 41 41
Drive pinion 10 10 10
 REAR AXLE
SERVICE SPECIFICATIONS
27-3
Item 2500 (vehicles 2500 (vehicles 3200
without ABS) with ABS)
Bearing (Outside diameter × Side 80.0 × 45.2 80.0 × 45.2 90 × 55
inside diameter) mm Front 68.3 × 30.2 68.3 × 30.2 68.3 × 30.2
Rear 79.4 × 36.5 79.4 × 36.5 90 × 36.5

SERVICE SPECIFICATIONS
M1271000300609

Item Standard value Limit

Rear axle total backlash mm − 5
Axle shaft axial play mm 0 −0.25 −
Limited slip differential preload <mechanical type> N⋅ m 25 or more −
Axle shaft retainer press-fitting force N Initial press-fitting −
force 29,400 or
more
Final press-fitting −
force 98,000 −
107,800
Clearance between axial shaft retainer and snap ring mm 0 −0.166 −
Drive gear backlash mm 2WD 0.07 −0.13 −
4WD 0.08 −0.18 −
Drive gear runout mm − 0.05
Differential gear backlash mm 0.01 −0.250 0.2
Drive pinion Without Bearing (oil seal contacting area) with 0.59 −0.88 −
turning torque oil seal anti-rust agent
N⋅ m Bearing (oil seal contacting area) with 0.39 −0.49 −
gear oil applied
With oil Companion flange (oil seal contacting 0.84 −1.12 −
seal area) with anti-rust agent
Companion flange (oil seal contacting 0.64 −0.73 −
area) with gear oil applied
Difference in thickness between left and right friction disc and 0 −0.05 −
friction plate combination mm
Clearance between differential case and spring plate mm 0.06 −0.20 −
Clearance in side gear axial direction mm 0.05 −0.20 −
Difference between left and right dimensions from pressure ring rear 0 −0.05 −
face to thrust washer end face mm
Limited slip differential When a new clutch plate is used 39 −74 −
starting torque When re-installed current clutch plate 25 −74 −
<mechanical type> N⋅ m
Friction plate and friction disc warping (flatness) mm − 0.08
Friction disc and spring plate wear (difference in the thickness of the − 0.1
friction surface and the projections) mm
27-4 REAR AXLE
LUBRICANTS

LUBRICANTS
M1271000400350

Item Specified lubricant Quantity

Rear differential gear oil Hypoid gear oil API classification GL-5 2WD 1.5 L
or higher 4WD-2500 2.6 L
Above 10° C: SAE 90 (vehicles with
Below 10° C: SAE 80W ABS)
4WD-3200 3.2 L
DIA QUEEN LSD gear oil or CASTROL 4WD-2500 2.6 L
HYPOY LS (Hypoid gear oil API (vehicles without
classification GL-5) ABS)

SEALANT
M1271000500335

Item Specified sealant Remark

Axle shaft bearing case Three Bond 1217 or equivalent Semi-drying sealant
Axle housing (differential carrier
mounting part)
Drive gear and differential case 3M Stud Locking 4170 or equivalent Anaerobic sealant
mounting part

SPECIAL TOOLS
M1271000600644

Tool Number Name Use

B MB990590 Rear axle shaft oil • Removal of axle shaft (use
A: MB990212 seal remover together with MB990241,
B: MB990211 A: Adapter MB990211)
B: Slide hammer • Removal of axle housing oil
A MB990590 seal

MB990241 Rear axle shaft Removal of axle shaft (use

puller together with MB990211)

MB990241

MB990925 Bearing and oil • Installation of axle housing oil

A: MB990926 −MB990937 seal installer set seal
C B: MB990938 A:Installer adapter • Press-fitting of bearing outer
C: MB990939 B: Bar race
B A MB990925 C: Brass bar • Press fitting of oil seal
• Press-fitting of drive pinion
front bearing outer race
For details of each installer,
refer to GROUP 26 −Special
Tools P.26-5.
 REAR AXLE
SPECIAL TOOLS
27-5
Tool Number Name Use
MB991552 Axle shaft bearing Removal of the axle shaft
and case remover bearing and bearing case

MB991522

MB990560 Rear axle shaft Removal of bearing inner race

bearing remover

MB990560

MB990799 Ball joint remover Removal of bearing case,

and installer A bearing outer race
Press-fitting of bearing inner
race
MB990799 Press-fitting of retainer

MB990890 or MB990891 Rear suspension Press-fitting of bearing outer

bushing base race

MB990890

MB991367 Special spanner Removal and adjustment of the

side bearing nut

B991367

MB991385 Pin

B991385

MB990810 Side bearing puller Removal of the side bearing

inner race

MB990810

MB990811 Side bearing puller Removal of the side bearing

cap inner race <2500>

MB990811

MB991407 Differential rear Removal of the side bearing

support arbor inner race <3200>

MB991407
27-6 REAR AXLE
SPECIAL TOOLS

Tool Number Name Use

MB990850 End yoke holder Removal of the companion
flange

MB990850

MD998801 Bearing remover Removal of the drive pinion rear

bearing inner race

A
C MB991171 Pinion height Measurement of the pinion
A: MB990819 gauge set height
B: MB991170 A: Pinion gauge
B
C: MB991169 B: Cylinder gauge
A
C
MB991171 C: Drive pinion
gauge
attachment
MB991534 Cylinder gauge

MB991534

MB990326 Preload socket Measurement of drive pinion

turning torque

MB990326

MB990685 Torque wrench

MB991168 Differential oil seal Press-fitting of the drive pinion

installer oil seal

MB991168
 REAR AXLE
ON-VEHICLE SERVICE
27-7
Tool Number Name Use
MB990802 Bearing installer Press-fitting of the drive pinion
rear bearing inner race

MB990802

MB990728 Side and rear Installation of side bearing inner

bearing inner race race
installer

MB990728

MB990988 Side gear holding Measurement of clutch plate

tool set preload <Vehicles with
mechanical LSD>

MB990988

Tool Number Name O D mm

MB990551 Box -
Box
MB990989 Base -
MB990990 Tool A 25
C MB990991 Tool B 28
AB
MB990992 Tool C 31
Base
Tool
AC502729 AB

ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK 3. Turn the companion flange clockwise as far as it
M1271001200274 will go. Make the mating mark on the dust cover of
1. Park the vehicle on a flat, level surface. the companion flange and on the differential
2. Move the transmission control lever to the neutral carrier.
position or the selector lever to the "N" position.
Then place the transfer sift lever to the "2H"
position. Apply the parking brake. Raise the
vehicle on a jack.

Mating marks

ACX00964

4. Turn the companion flange counterclockwise as

far as it will go, and measure the amount of
ACX00962 AB
distance the mating marks moved.
Limit: 5 mm
27-8 REAR AXLE
ON-VEHICLE SERVICE

5. If the backlash exceeds the limit value, remove AXLE SHAFT AXIAL PLAY CHECK
the differential carrier assembly and check the M1271001300088

following.
• Final drive gear backlash
• Differential gear backlash

GEAR OIL LEVEL CHECK

M1272001200318

Gear oil
AC004839 AB

Upper 1. Measure the axle shaft axial play by using a dial

limit indicator.
Lower
limit Standard value: 0 −0.25 mm
8 mm
2. If not within specifications, replace the axle shaft
AC505405 AB assembly.
1. Check that gear oil level is not 8 mm below the
bottom of filler plug hole.
AXLE SHAFT AXIAL PLAY ADJUSTMENT
M1271001400085
2. Tighten the filler plug to the specified torque. The axle shaft axial play is preset at factory. It can
Tightening torque: 50 ± 10 N⋅ m not be adjusted.

GEAR OIL REPLACEMENT LIMITED SLIP DIFFERENTIAL PRELOAD

M1272004600122 MEASUREMENT<MECHANICAL TYPE>
1. Remove the filler plug. M1273000900027

2. Remove the drain plug and drain oil. 1. Park the vehicle on a flat, level surface.
3. Tighten the drain plug to the specified torque. 2. Move the transmission control lever to the neutral
position or the selector lever to the "N" position.
Tightening torque: 60 ± 10 N⋅ m
Then place the transfer sift lever to the "2H"
4. Add the oil until the level comes to the lower position.
portion of the filler plug hole. 3. Disconnect the propeller shaft from the
Specified gear oil <except 4WD-2500 (vehi- differential.
cles without ABS)>: 4. With the parking brake fully released, jack up one
Hypoid gear oil API classification GL-5 or rear wheel so that the other is still on the ground.
higher
Above 10° C: SAE 90
Below 10° C: SAE 80W
Specified gear oil <4WD-2500 (vehicles with-
out ABS)>:
DIA QUEEN LSD gear oil or CASTROL HYPOY
LS (Hypoid gear oil API classification GL-5)
5. Tighten the filler plug to the specified torque.
Tightening torque: 50 ± 10 N⋅ m
AC501139

5. Measure the differential preload in the forward

direction.
Standard value: 25 N⋅ m or more
NOTE: If the differential preload is not within the
standard value, disassemble the limited slip differ-
ential to check parts.
 REAR AXLE
AXLE ASSEMBLY
27-9
AXLE ASSEMBLY
REMOVAL AND INSTALLATION
M1271001700268

CAUTION
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Brake Fluid Filling and Air Bleeding (Refer to GROUP
35A, On-vehicle Service P.35A-9.)
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service P.36-4.)

<2WD> 15 ± 2 N·m
9
14

16 13
6

2
1

54 ± 5 N·m
6
10

52 ± 7 N·m *
4
15

22 ± 3 N·m *

3 11 108 ± 10 N·m
12
AC500808 AB
27-10 REAR AXLE
AXLE ASSEMBLY

<4WD>
14
13

4
3
6 8
16 9 9.8 ± 2.0 N·m
7

2
1

103 ± 5 N·m
10
6 5
15 ± 2 N·m

22 ± 3 N·m *
11 108 ± 10 N·m

6 12
AC501162 AB

Removal steps REMOVAL SERVICE POINTS

1. Brake drum
<<A>> PROPELLER SHAFT REMOVAL
2. Shoe and lining assembly (Refer to
GROUP 35A, Rear Drum Brake CAUTION
P.35A-30, P.35A-31.) Suspend the propeller shaft from the body with
3. Parking brake calbe attaching bolt wire, etc. to prevent it from falling.
4. Parking brake calbe connection
5. Rear wheel speed sensor <Vehicles Mating marks
with ABS>
6. Brake hose and brake tube
connection
7. Bolt <4WD: 2500 Club Cab>
8. Breather hose connection <4WD>
9. Spring support <Vehicles with Load
Sensing Proportioning Valve>
<<A>> >>A<< 10. Propeller shaft connection
<<B>> 11. Shock absorber connection AC003833 AB
12. U bolt seat
13. U bolt Place mating marks on the companion flange and
14. Bump stopper flange yoke. Disconnect the propeller shaft from the
15. Shackle assembly companion flange.
<<C>> 16. Axle assembly
 REAR AXLE
AXLE ASSEMBLY
27-11
<<B>> SHOCK ABSORBER INSTALLATION SERVICE POINT
DISCONNECTION >>A<< PROPELLER SHAFT INSTALLA-
TION

Mating marks

AC004846 AB

Support the axle housing with a jack before removing AC003833 AB

the shock absorber lower mounting nut. Align the mating marks on the flange yoke and the
companion flange to install the propeller shaft.
<<C>> AXLE ASSEMBLY REMOVAL
WARNING
Secure the axle assembly to the jack or
equivalent. The axle assembly is heavy and
unstable and may fall causing damage to the
assembly, surrounding equipment, or injur-
ing the installer.
Take out the axle assembly from the rear of the vehi-
cle.
27-12 REAR AXLE
AXLE SHAFT ASSEMBLY

AXLE SHAFT ASSEMBLY

REMOVAL AND INSTALLATION
M1271002500171

CAUTION
For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed sensor
with tools during servicing work.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Brake Fluid Filling and Bleeding (Refer to GROUP 35A,
On-vehicle Service P.35A-9.)
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service P.36-4.)

AC501171 AC501171

Apply to entire inside diameter of Sealant: Three Bond 1217 or

oil seal lip equivalent
15 ± 1 N·m 6

8N

54 ± 5 N·m 1
5
<4WD>

3
2
<2WD> 4

3 4
AC500811 AB

Removal steps Removal steps (Continued)

1. Brake drum 5. Rear wheel speed sensor <Vehicles
2. Shoe and lining assembly (Refer to with ABS>
GROUP 35A, Rear Drum Brake 6. Brake tube connection
P.35A-30, P.35A-31.) • Axle shaft axial play adjustment
3. Parking brake calbe attaching bolt <<A>> 7. Axle shaft assembly
4. Parking brake calbe connection <<B>> >>A<< 7. Oil seal
 REAR AXLE
AXLE SHAFT ASSEMBLY
27-13
REMOVAL SERVICE POINTS Use the following special tools with hook attached to
remove the oil seal.
<<A>> AXLE SHAFT ASSEMBLY
• Slide hammer (MB990211)
REMOVAL • Adapter (MB990212)

INSTALLATION SERVICE POINT

MB990241 >>A<< OIL SEAL INSTALLATION
MB990211 MB990930

AC500818AB

Pull the rear axle shaft from axle housing. If the rear
MB990938
axle shaft is hard to remove, use the following spe-
cial tools.
AC500820AB
• Slide hammer (MB990211)
• Rear axle shaft puller (MB990241) Drive the new oil seal into the rear axle housing end
by using the following special tools.
• Installation adapter (MB990930)
<<B>> OIL SEAL REMOVAL • Bar (MB990938)

MB990211

MB990212

AC500819AB
27-14 REAR AXLE
AXLE SHAFT ASSEMBLY

DISASSEMBLY AND REASSEMBLY

M1271002700153

AC501172
Apply to entire inside diameter of oil
seal lip and bearing inner race.
1N
2
N 3
10
12
7
5 9
N 11
4

8
AC500971 AB

Disassembly steps DISASSEMBLY SERVICE POINTS

1. Snap ring
<<A>> RETAINER REMOVAL
2. ABS rotor <Vehicle with ABS>
<<A>> 3. Retainer
<<B>> 4. Axle shaft
5. Bearing case
6. Backing plate
<<C>> 7. Outer bearing inner race Backing
8. Hub bolt plate
9. Dust cover
10. Inner bearing inner race Retainer
11. Oil seal bolt
<<D>> 12. Bearing outer race
Reassembly steps AC004855AB

>>A<< 12. Bearing outer race

>>B<< 11. Oil seal
1. Remove one retainer bolt from the backing plate.
>>C<< 10. Inner bearing inner race Grinder
>>C<< 7. Outer bearing inner race
9. Dust cover
8. Hub bolt
6. Backing plate
5. Bearing case
4. Axle shaft
>>D<< 3. Retainer
>>D<< 2. ABS rotor <Vehicle with ABS> Gummed
>>E<< 1. cloth tape
Snap ring
AC004867 AB

2. Apply gummed cloth tape around the edge of the

bearing case for protection.
 REAR AXLE
AXLE SHAFT ASSEMBLY
27-15
CAUTION <<B>> AXLE SHAFT REMOVAL
Be careful not to damage the bearing case and
MB991552
the axle shaft. Plate Washer
3. As shown in the figure, hold the axle shaft. Using
a grinder, shave off a point of its circumference Hanger Nut
locally until the wall thickness become as follows:
• 1.0 −1.5 mm for axle shaft side
• 2.0 mm for bearing side Nut
CAUTION Bearing
Be careful not to damage the bearing case and Bolt Washer
case
the axle shaft. AC103785 AB

Grinder 1. Secure special tool axle shaft bearing and case

remover (MB991552) to the bearing case bolts
with the nuts and adjust the height of the hanger.
Then install the washers, plate and nuts in that
Bearing order.
case
NOTE: The washers are used to eliminate the dif-
ference in height of the bearing case so that the
Retainer plate and the bearing case are parallel.
AC004868AB CAUTION
The hanger and plate should be placed so that
4. Fix the axle shaft and shave off the remaining 2.0 they are parallel.
mm on the side of the retainer bearing. 2. Place the end of the bolt against the center of the
CAUTION axle shaft, and then tighten the bolt to remove the
Be careful not to damage the axle shaft. axle shaft from the bearing case assembly.

<<C>> OUTER BEARING INNER RACE

REMOVAL

Bearing inner
race
MB990560

AC004869AB

5. Cut in with a chisel the place where the retainer

ring has been shaven and remove the retainer
AC500968 AB
ring.
Install special tool rear axle shaft bearing remover
(MB990560) as shown in the illustration, and then
use a press to remove the outer bearing inner race
from the axle shaft.
27-16 REAR AXLE
AXLE SHAFT ASSEMBLY

<<D>> BEARING OUTER RACE 2. Use the following special tools, press-fit the oil
REMOVAL seal into the bearing case until it is flush with the
face of the bearing case.
• Installer adapter (MB990936)
• Bar (MB990938)
MB990799 3. Apply multipurpose grease to the lips of the oil
seal.

Bearing outer >>C<< INNER BEARING INNER

race RACE/OUTER BEARING INNER RACE
INSTALLATION
AC004873 AB

Reinstall the outer bearing inner race that was

removed previously. Use special tool ball joint Axle shaft
remover and installer A (MB990799) and a press to
Outer bearing
remove the bearing outer race.
inner race

REASSEMBLY SERVICE POINTS Inner bearing

inner race
>>A<< BEARING OUTER RACE INSTAL- Bearing case
MB990799
LATION
AC501191AB

1. Apply multipurpose grease to the roller surface

and ends of the bearing.
MB990890 or
MB990891 2. Pass the axle shaft through the bearing case and
the inner bearing inner race and outer bearing
inner race.
CAUTION
Both the inner bearing inner race and outer bear-
ing inner race should be press-fitted together.
AC004875AB
3. Use special tool ball joint remover and installer A
Use special tool rear suspension bushing base (MB990799) to press-fit the inner bearing inner
(MB990890 or MB990891) to press-fit the bearing race and outer bearing inner race to the axle
outer race to the bearing case. shaft.

>>B<< OIL SEAL INSTALLATION >>D<< RETAINER/ABS ROTOR

INSTALLATION
MB990938
ABS rotor

MB990936

AC004896 AB
Retainer
1. Apply multipurpose grease to the outside of the oil AC500972AB
seal.
1. Press-fit the ABS rotor to the retainer until it will
contact the retainer edge part.
 REAR AXLE
AXLE SHAFT ASSEMBLY
27-17
1. After installing the snap ring, measure clearance
(A) between the snap ring and the retainer with a
feeler gauge. Check that it is within the standard
value.
Standard value (A): 0 −0.166 mm
2. If the clearance exceeds the standard value,
Retainer change the snap ring so that the clearance is at
MB990799 the standard value.
Thickness of snap ring Identification colour
AC501192AB
mm
2. Use special tool ball joint remover and installer A 2.17 −
(MB990799) to press-fit the retainer with ABS
rotor to the axle shaft. Check that the press-fitting 2.01 Yellow
force is at the standard value. 1.85 Blue
3. If the initial press-fitting force is less that the 1.69 Purple
standard value, replace the axle shaft. 1.53 Red
Standard value:
Example:
Initial press-fitting force 29,400 or more Clearance 2.0 mm
N Standard value 0 −0.166 mm
Final press-fitting force N 98,000 −107,800 Thickness of snap ring 2.01 mm

>>E<< SNAP RING INSTALLATION INSPECTION

M1271002800138
• Check the dust cover for deformation and dam-
A
age.
Snap ring • Check the inner and outer bearings for seizure,
discoloration and rough raceway surface.
• Check the axle shaft for cracks, wear and dam-
age.

Retainer ring

AC501193 AB
27-18 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL AND INSTALLATION
M1272002000469

Pre-removal Operation Post-installation Operation

• Differential Gear Oil Draining • Axle Shaft Assembly Installation (Refer to P.27-12.)
• Axle Shaft Assembly Removal (Refer to P.27-12.) • Differential Gear Oil Filling (Refer to P.27-8.)

Sealant:
Three Bond 1217 or equivalent

50 ± 10 N·m
54 ± 5 N·m <2WD>,
6
4
103 ± 5 N·m <4WD>

5N

1 3N
27 ± 2 N·m <2WD>,
47 ± 7 N·m <4WD>
2 60 ± 10 N·m
AC502381AB

Removal steps REMOVAL SERVICE POINTS

<<A>> >>A<< 1. Propeller shaft
<<A>> PROPELLER SHAFT REMOVAL
2. Drain plug
3. Packing CAUTION
4. Filler plug Suspend the propeller shaft from the body with
5. Gasket wire, etc. to avoid spilling transmission fluid and
<<B>> 6. Differential case assembly to avoid injury from falling propeller shaft when
not secured.

Mating marks

AC003833 AB

Make the mating marks on the flange yoke of the

propeller shaft and the companion flange of the dif-
ferential case.
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-19
<<B>> DIFFERENTIAL CARRIER INSTALLATION SERVICE POINT
REMOVAL >>A<< PROPELLER SHAFT INSTALLA-
CAUTION TION
Use care not to strike the companion flange.
Mating marks

AC003833 AB

AC502392 Align the mating marks on the flange yoke and the
Remove the attaching nuts. Strike the lower part of companion flange to install the propeller shaft.
differential carrier assembly with a piece of wood
several times to loosen the assembly. Remove the DISASSEMBLY
M1272002200270
assembly.
CAUTION
Do not disassemble the limited slip differential case assembly.

<Conventional differential>

5
2 1 6 4
1312
9
10 11
8 7
14
6 5
29 3
11
12 13 2
10
N 25 27
17
1
23
21 22
19 20 28
<Limited slip differential>
3
N 16 26 18
24 1 5 6 4
7
2
6 5
2

15 1
15 <Hybrid type>
<Mechanical type>
AC502382 AB

Disassembly steps Disassembly steps (Continued)

<<A>> • Inspection before disassembly 5. Differential side bearing outer race
1. Lock plate <<D>> 6. Differential side bearing inner race
<<B>> 2. Side bearing unit <<E>> 7. Drive gear
3. Bearing cap <<F>> 8. Lock pin
<<C>> 4. Differential case assembly 9. Pinion shaft
27-20 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

Disassembly steps (Continued) NOTE: Keep the right and left side bearings and side
10. Pinion gear bearing nuts separate, so that they do not become
11. Pinion washer mixed at the time of assembly.
12. Side gear
13. Side gear spacer
14. Differential case <<C>> DIFFERENTIAL CASE ASSEMBLY
15. Limited slip differential case assembly REMOVAL
<<G>> 16. Self-locking nut
CAUTION
17. Washer
<<H>> 18. Drive pinion assembly
When taking out the differential case assembly,
19. Drive pinion front shim (For adjusting be careful not to drop and damage the differential
preload of drive pinion) side shims or the side bearing outer races.
20. Drive pinion spacer
<<I>> 21. Drive pinion rear bearing inner race
22. Drive pinion rear shim (for adjusting
drive pinion height)
23. Drive pinion
<<H>> 24. Companion flange
<<J>> 25. Oil seal
<<J>> 26. Drive pinion front bearing inner race
<<J>> 27. Drive pinion front bearing outer race
<<K>> 28. Drive pinion rear bearing outer race
29. Differential carrier ACX02422

Use the wooden handle of a hammer to remove the

DISASSEMBLY SERVICE POINTS differential case assembly, differential side shims and
<<A>> INSPECTION BEFORE DISASSEM- side bearings.
BLY NOTE: Keep the right and left side bearings and side
Except for the following standard values, inspection bearing outer race separated, so that they do not
procedure is the same as GROUP 26, inspection become mixed at the time of assembly.
before disassembly P.26-36.
Drive gear backlash <<D>> SIDE BEARING INNER RACE
Standard value: REMOVAL
<2WD> 0.07 −0.13 mm
<4WD> 0.08 −0.18 mm MB990810

<<B>> SIDE BEARING NUT REMOVAL

MB990811
MB991367 <2500>
MB991407
MB991385 <3200>

AC203814 AE

Use the following special tools to pull out the side

bearing inner race.
AC004921AB
• Side bearing puller (MB990810)
• Side bearing puller cup (MB990811) <2500>
Use the following special tools, remove the side • Differential support bush arbor (MB991407)
bearing nut. <3200>
• Special spanner (MB991367)
NOTE: Attach the prongs of special tools to the inner
• Pin (MB991385)
race of the side bearing through the openings in the
differential case.
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-21
<<E>> DRIVE GEAR REMOVAL Use special tool end yoke holder (MB990850) to hold
the companion flange, and then remove the compan-
ion flange self-locking nut.

<<H>> DRIVE PINION

ASSEMBLY/COMPANION FLANGE
Mating REMOVAL
marks
CAUTION
Do not make mating marks on the contact sur-
faces of the companion flange and propeller
ACX01042AB
shaft.
1. Make mating marks to the differential case and 1. Make mating marks to the drive pinion and
the drive gear. companion flange.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear. MB990810

<<F>> LOCK PIN REMOVAL

Companion
flange

Punch AC102894 AD

2. Use special tool side bearing puller (MB990810)

to pull out the companion flange.

<<I>> DRIVE PINION REAR BEARING

ACX01048AB

Drive out the lock pin with a punch.

INNER RACE REMOVAL
<<G>> SELF-LOCKING NUT REMOVAL

MD998801

MB990850

AC104970AC

Use special tool remover (MD998801) to pull out the

ACX01043AB
front bearing inner race.
27-22 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

<<J>> OIL SEAL/DRIVE PINION FRONT

BEARING INNER RACE/DRIVE PINION <<K>> DRIVE PINION REAR BEARING
FRONT BEARING OUTER RACE OUTER RACE REMOVAL
REMOVAL
MB990939 MB990939

Drive pinion rear

bearing outer
Drive pinion front race
bearing outer race
Drive pinion front
bearing inner ACX01102 AB
race
Oil seal
ACX01101AB Use special tool brass bar (MB990939) to remove
Use special tool brass bar (MB990939) to remove the drive pinion rear bearing outer race.
the drive pinion front bearing outer race.
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-23
REASSEMBLY
M1272002300330

<Conventional differential>
18 ± 3 N·m
25
28 29 24
1718
26
21
2019
74 ± 4 N·m 22 23
15
24 25
1 27
19 28
20 18 17
N8 3
13
216 ± 29 N·m 18 ± 3 N·m
4
6 5 29
9 10 2 84 ± 5 N·m
27
N 14 7 11
12 18 ± 3 N·m
<Limited differential>

29 25 24 26
28 23
16
24 25
23 28
4 21 18 ± 3 N·m
22
14
29
16
<Hybrid type>
16 84 ± 5 N·m <2500>
AC502387 AC502388 <Mechanical type> 152 ± 15 N·m <3200>
Final drive gear kit Pinion shaft kit
18 20 <Mechanical type> <Hybrid type>
17

16
20 16
17
18 AC502389 AC502390 AC502391
Differential gear kit Limited slip differential kit Limited slip differential kit
AC503071AB

Reassembly steps Reassembly steps (Continued)

1. Differential carrier 10. Drive pinion spacer
>>A<< 2. Drive pinion rear bearing outer race 11. Drive pinion assembly
>>B<< 3. Drive pinion front bearing outer race 12. Companion flange
>>C<< • Drive pinion height adjustment 13. Washer
4. Drive pinion 14. Self-locking nut
5. Drive pinion rear shim (for adjusting 15. Differential case
drive pinion height) 16. Limited slip differential case assembly
6. Drive pinion rear bearing inner race 17. Side gear spacer
>>D<< • Drive pinion preload adjustment 18. Side gear
7. Drive pinion front bearing inner race 19. Pinion washer
>>E<< 8. Oil seal 20. Pinion gear
9. Drive pinion front shim (for adjusting >>E<< • Differential gear backlash adjustment
drive pinion preload) 21. Pinion shaft
>>F<< 22. Lock pin
27-24 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

Reassembly steps (Continued) Reassembly steps (Continued)

>>G<< 23. Drive gear
>>H<< 24. Differential side bearing inner race
25. Differential side bearing outer race
26. Differential case assembly
>>I<< 27. Bearing cap
>>J<< • Drive gear backlash adjustment
28. Side bearing unit
29. Lock plate
LUBRICATION AND ADHESIVE POINTS

<Conventional differential>

<Limited slip differential>

Adhesive:
3M Stud Locking 4170 or equivalent
AC503087AB

REASSEMBLY SERVICE POINTS

>>A<< DRIVE PINION REAR BEARING >>B<< DRIVE PINION FRONT BEARING
OUTER RACE PRESS-FITTING OUTER RACE PRESS-FITTING

MB990938
MB990938
MB990934
MB990936
<2WD>
MB990937
<4WD>

ACX01107AB
AC102907AF

Use the followingr special tools to press-fit the drive Use the followingr special tools to press-fit the drive
pinion rear bearing outer races into the gear carrier. pinion front bearing outer race.
• Bar (MB990938) • Bar (MB990938)
• Installer adapter (MB990936, MB990937) • Installer adapter (MB990934)
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-25
• Torque wrench (MB990685)
>>C<< DRIVE PINION HEIGHT Standard value:
ADJUSTMENT Bearing type Bearing Turning torque
Adjust the drive pinion height by the following proce- lubrication
dures:
New None (with 0.59 −0.88 N⋅ m
anti-rust agent)
New or reuse Gear oil applied 0.39 −0.49 N⋅ m
Drive pinion
MB990820
attachment NOTE: Because special tool preload socket
<2WD>
MB991169 (MB990326) cannot be turned one turn, turn it
<4WD> several times within the range that it can be
turned; then, after fitting to the bearing, measure
MB990819
the turning torque.
Washer ( )

AC004937AB 4. Clean the side bearing hub.

1. Apply multipurpose grease to the washer of MB991170 Notch

special tool pinion gauge (MB990819). <2500>
MB991534
2. Install the following special tools and drive pinion <3200>
front and rear bearing inner races to the gear
carrier as shown in the illustration.
• Pinion {MB990820 (MB990819)}
A
• Drive pinion gauge attachment (MB991169)
• Pinion gauge (MB990819) Thickness
MB990820 <2WD> gauge
MB990819 MB991169 <4WD> ACX01109AE

5. Place the following special tools between the side

bearing hub of the gear carrier, and position the
notch as shown in the illustration. Then tighten
side bearing mounting bolt.
• Cylinder gauge (MB991170) <2500>
• Cylinder gauge (MB991534) <3200>
• Pinion {MB990820 (MB990819)} <2WD>
ACX01055 AB • Drive pinion gauge attachment (MB991169)
<4WD>
MB990685 MB990326 6. Use a thickness gauge to measure the clearance
(A) between the special tools.
7. Remove the special tools.
MB990819

ACX01056AB

3. Tighten the nut of special tool a little at a time B

while measuring the turning torque of the drive
pinion by using the following special tools. Then
confirm that the turning torque (without oil seal) is
at the standard value.
• Preload socket (MB990326)
AC102913 AC
8. Use a micrometer to measure the shown
dimensions (B, C) of special tools.
27-26 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

MB990850

D
Cylinder gauge

AC102914 AC AC201179 AB

9. Install the bearing cap, and then use a cylinder 2. Tighten the companion flange to the specified
gauge to measure the inside diameter (D) of the torque by using special tool end yoke holder
bearing cap. (MB990850).
10.Calculate thickness (F) of the required drive Tightening torque: 216 ± 29 N⋅ m
pinion rear shim twice by the following formula.
Select a shim which most closely matches this MB990326
thickness. MB990685

F = A + B + C −1/2D −100.00 mm <2WD-2500>

F = A + B + C −1/2D −115.00 mm <4WD-2500>
F = A + B + C −1/2D −120.00 mm <4WD-3200>

ACX01062AB
Drive pinion
rear shim MB990802 3. Use the following special tools to measure the
drive pinion turning torque (without oil seal).
• Preload socket (MB990326)
• Torque wrench (MB990685)
ACX02428 AE Standard value:

11.Fit the selected drive pinion rear shim(s) to the Bearing type Bearing Turning torque
drive pinion, and press-fit the drive pinion rear lubrication
bearing inner race by using special tool bearing New None (with 0.59 −0.88 N⋅ m
installer (MB990802). anti-rust agent)
New or reuse Gear oil applied 0.39 −0.49 N⋅ m
>>D<< DRIVE PINION PRELOAD
ADJUSTMENT
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. A
NOTE: Do not install the oil seal. Identifi-
cation
colour

ACX01063 AE

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.
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-27
NOTE: When selecting the drive pinion front
shims, if the number of shims is large, reduce the MB990326
MB990685
number of shims to a minimum by selecting the
drive pinion spacers.
Also, select the drive pinion spacer from the fol-
lowing two types.
Height of drive pinion spacer Identification
(A) mm colour
2500 56.67 −
ACX01062AB
57.01 White
3200 52.50 Yellow 7. Use special tools to measure the drive pinion
turning torque (with oil seal) to verify that the drive
52.84 Red pinion turning torque complies with the standard
value.
Standard value:
Bearing Companion Turning torque
MB991168 division flange
lubrication
New None (with 0.84 −1.12 N⋅ m
anti-rust agent)
Gear oil applied 0.64 −0.73 N⋅ m

ACX01064 AD
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
differential oil seal installer (MB991168) to
press-fit the oil seal.
MB990850
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.
>>E<< DIFFERENTIAL GEAR BACKLASH
ADJUSTMENT
Adjust the differential gear backlash by the following
procedure:

AC201179 AB

6. Install the drive pinion assembly and companion

flange with mating marks properly aligned.
Tighten the companion flange self-locking nut to
the specified torque using special tool end yoke
holder (MB990850).
Tightening torque: 216 ± 29 N⋅ m
ACX01066
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.
27-28 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

Wedge

Side gear
thrust
Side gear spacer
thrust spacer ACX01035 AB Tap ACX01068AB

3. Insert a wedge between the side gear and the 2. Remove the adhesive adhered to the threaded
pinion shaft to lock the side gear. holes of the drive gear by turning the tap (M10 x
4. While locking the side gear with the wedge, 1.25) <2500>, (M12 × 1.25) <3200>. Clean the
measure the differential gear backlash with a dial threaded holes by applying compressed air.
indicator on the pinion gear.
Standard value: 0.01 −0.250 mm
5. Measure by the same procedure for the other
pinion gear.
Limit: 0.2 mm
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. ACX02430

8. Check that the backlash is within the limit value

3. Apply specified adhesive to the threaded holes of
and that the differential gear turns smoothly.
the drive gear.
>>F<< LOCK PIN INSTALLATION Specified adhesive: 3M Stud Locking 4170 or
1. Align the pinion shaft lock pin hole with the equivalent
differential case lock pin hole, and drive in the lock 4. Install the drive gear onto the differential case with
pin. the mating marks properly aligned. Tighten the
bolts to the specified torque in a diagonal
sequence.
Tightening torque:
84 ± 5 N⋅ m <2500>
152 ± 15 N⋅ m <3200>

>>H<< SIDE BEARING INNER RACE

INSTALLATION
ACX02429
Piece of
Piece of metal
2. Stake the lock pin with a punch on both sides. metal

>>G<< DRIVE GEAR INSTALLATION

1. Clean the drive gear attaching bolts.
MB990728

AC102942 AC
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-29
Use special tool side and rear bearing inner race 0.07 −0.13 mm <2WD>
installer (MB990728) to press-fit the side bearing 0.08 −0.18 mm <4WD>
inner races into the differential case.
When backlash is
insufficient
>>I<< BEARING CAP INSTALLATION
Loosen Loosen

Tighten Tighten

When backlash is
excessive AC004947AB

74 ± 4 N·m 3. Using special tools, adjust the backlash to

AC004945 AB
standard value by moving the side bearing nut as
shown.
Align the mating marks on the gear carrier and the NOTE: First loosen the side bearing nut then
bearing cap, and then tighten the bearing cap. tighten the side bearing nut the same amount as
when it was loosened.
>>J<< DRIVE GEAR BACKLASH
ADJUSTMENT MB991367

Adjust drive gear backlash as follows:

MB991367

MB991385

MB991385

AC004948 AB

4. Using special tools, apply the preload, turn down

both right and left side bearing nuts on half the
AC004921AB
distance between centers of two neighboring
1. Using the following special tools, temporarily holes.
tighten the side bearing nut to just before
preloading of the side bearing. MB092153 MB092154
• Special spanner (MB991367)
• Pin (MB991385)

AC004949 AB

5. Choose and install the lock plate (two kinds).

6. Check the final drive gear tooth contact. If poor
AC004946 AB contact is evident, make adjustment. (Refer to
GROUP 26, Inspection Before Disassembly
2. Measure the drive gear backlash. P.26-36.)
Standard value:
27-30 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

8. When drive gear runout exceeds the limit, remove

the differential case and then the drive gears,
moving them to different positions and reinstall
them.
9. If adjustment is not possible, replace the
differential case or drive gear and drive pinion as
a set.

MECHANICAL TYPE LIMITED SLIP

AC004950 AB DIFFERENTIAL DISASSEMBLY AND
7. Measure the drive gear runout. REASSEMBLY
M1273001400036
Limit: 0.05 mm

20
19
18
17
16
1 15
14
21 11
10
9
8
7
6
11 13 5
4
10 11 3
12 2
13

11 12
Differential gear set
AC501066AC

Disassembly steps Disassembly steps (Continued)

>>C<< • Differential preload inspection for 20. Thrust washer
limited slip differential ..>>A<< 21. Differential case (B)
<<A>> >>B<< 1. Screw
2. Differential case (A) DISASSEMBLY SERVICE POINT
3. Thrust washer
<<A>> SCREW REMOVAL
4. Spring plate
5. Friction plate
6. Friction disc
7. Friction plate
8. Friction disc
9. Pressure ring
10. Side gear
11. Differential pinion gear
12. Differential pinion shaft
13. Side gear
14. Pressure ring Mating marks
15. Friction disc AC501067 AB
16. Friction plate
17. Friction disc 1. Check the mating marks.
18. Friction plate
19. Spring plate
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-31
NOTE: The mating marks are represented by one
of the following methods.
.
• Engraving by a punch or electric pen.
• Identical arabic numerals.
2. Loosen the mounting screws for differential case
(A) and (B) evenly step by step.
3. Separate differential case (B) and differential case
(A), and take out the parts inside. Do not confuse
the left and right spring plates, spring discs, AC501069 AB
friction plates and friction discs for further
reassembly. 2. Place the spring plates together as shown in the
illustration, and use a micrometer to measure the
thickness. Place the parts together in the
REASSEMBLY SERVICE POINTS
combination that gives the least difference in
>>A<< DIFFERENTIAL CASE (B) INSTAL- thickness between the two sets.
LATIION NOTE: If replacing with new parts, the thickness
Before assembly, use the following method to adjust of the spring plates should be 1.75 mm.
the clearance between the spring plates and differ-
ential cases (for adjustment of the clutch plate friction
force), and to adjust the end play of the side gear
when installing the internal components into the dif-
ferential case.
+ +

A AC501070 AB

3. Assemble the pressure ring's internal components

(differential pinion shaft and pressure ring) and
the friction discs and friction plates, and then as
AC501068 AB shown in the figure, measure the overall width.
4. Calculate the total value (A) of the thickness of the
1. Arrange the two (each) friction discs and friction spring plates plus the value measured in (3)
plates for each side, one on top of another, as above.
shown in the figure, combining them so that the
difference in thickness between the left and the Differential Differential
case A case B
right is the standard value.
Standard value: 0 −0.05 mm
NOTE: Two types of replacement parts are availa-
ble: D C
.
Friction disc (with thicknesses of 1.6 mm and 1.7
mm)
Friction plate (with thicknesses of 1.75 mm and E
AC501071 AB
1.85 mm)
5. Obtain the dimension (B) between the spring plate
contact surfaces when differential cases (A) and
(B) are combined.
(B = C + D −E)
27-32 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

6. Change the thickness of the friction disc so that

the clearance (B - A) between the differential case
and the spring plate becomes the standard value.
Standard value: 0.06 −0.20 mm
7. Remove the spring plates, friction plates and
friction disc.

F Thrust Thrust
washer washer
AC501072 AC

12.Install the thrust washer as shown in the figure,

and then select a thrust washer so that the
difference between the left and right dimensions
Thrust Thrust from the pressure ring rear face to the thrust
washer washer washer end face is the standard value.
AC501072 AB Standard value: 0 −0.05 mm
8. Measure the dimension (F) from the thrust washer NOTE: Measure the distance while squeezing the
end surface to end surface. V-shaped groove manually.
13.If the distance is not within the standard value,
Differential Differential
replace the thrust washers.
case A case B
NOTE: Three types of replacement parts are
available: 1.50 mm, 1.60 mm and 1.70 mm.
Friction plate Pressure ring
H
D C

AC501071 AC

9. Obtain the dimension (G) between the thrust

washer contact surfaces when differential cases
(A) and (B) are combined. Spring plate Friction disc
AC501073 AB
(G = C + D + H)
14.Apply specified gear oil to each part, and then
NOTE: Dimension (B) is the distance between the
insert each part into differential case (B) in the
spring plate contact surfaces when differential
order shown in the illustration.
cases (A) and (B) are combined.
10.Check that the clearance (G - F) in the side gear Gear oil: DIA QUEEN LSD gear oil or CAS-
axial direction is within the standard value range. TROL HYPOY LS (Hypoid gear oil API classi-
fication GL-5)
Standard value: 0.05 −0.20 mm
NOTE: Be particularly sure to apply oil to the con-
11.If the clearance is not within the standard value tact surfaces and sliding surfaces.
range, replace the thrust washers.
NOTE: .
• Select washers in such as way that the clear-
ances between the left and right pressure
rings and the thrust washers remain the same
as each other.
• Three types of replacement parts are availa-
ble: 1.50 mm, 1.60 mm and 1.70 mm.
 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-33
>>B<< SCREW INSTALLATION 2. If the starting torque is not within the standard
value, disassemble the differential case assembly
and repair or replace the parts.
M
F

D
Mating marks
AC501067 AB

1. Align the mating marks (the same numeral on D

each case) of differential case (A) and differential
case (B). E J
2. Tighten the screw so that the cases are in close I G
contact. D,N O

NOTE: If, even though the screw is tightened, the

end surfaces of case (A) and case (B) do not
come into close contact, probably the thrust
washer and spring plate are not fit correctly into
the groove, so reassemble. N
H F
K K
>>C<<DIFFERENTIAL PRELOAD
INSPECTION FOR LIMITED SLIP
DIFFERENTIAL J
L H
G
AC501075 AB
MB990992
3. Inspect the contact and sliding surfaces listed
below, and repair any nicks and burrs by using an
oil stone.
D.The sliding surfaces of the thrust washer and the
case.
E.The spring contacting surface of the differential
MB990989 case and spring plate.
AC501074 AB
F.The contact surfaces of the outer circumference of
1. After assembly, in order to check the frictional the pressure ring and the inner circumference of the
force of the clutch plate, use the special tools to differential case.
measure the starting torque. G.The sliding surfaces of the hole in the pressure
• Tool C (MB990992) ring and the outer circumference of the side gear.
• Base (MB990989) H.The projection on the outer circumference of the
pressure ring.
Standard value:
I.The spherical surface of the differential pinion gear
<When a new clutch plate is used>:
and the inner diameter of the pressure ring.
39 −74 N⋅ m
J.The V-shaped groove in the pressure ring, and the
<When the current clutch plate is reused>:
V-shaped part in the pinion shaft.
25 −74 N⋅ m
K.The outer diameter of the pinion shaft and the hole
NOTE: Measure the starting torque after rotating of the differential pinion gear.
slightly. When measuring the torque, do so at the L.The outer circumference groove of the side gear.
beginning of movement. M.The inner circumference groove of the differential
case.
N.The sliding surface of the thrust block.
27-34 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

O.The sliding part of the thrust block. NOTE: The strong contact on the inner circumfer-
ence of the friction surface is because of the spring
INSPECTION plate; this wear is not abnormal.
M1273001500033

DIFFERENTIAL CASE COMPONENT WARPING OF THE FRICTION PLATE AND

SLIDING SURFACE INSPECTION FRICTION DISC
1. Clean the disassembled parts with cleaning oil
and dry them with compressed air.
Friction plate
A B

Friction plate Spring plate B

A A

AC501077
B
Using a dial indicator, measure the amount of warp-
ing (the flatness) of the friction plate and the friction
Pressure ring disc on a surface plate by turning the friction plate or
disc.
Limit: Max. 0.08 mm
C
WEAR OF THE FRICTION DISC AND
AC501076 AB SPRING PLATE
2. Check the following items for each plate and disc
and for the pressure ring.
A.The friction surfaces of the friction plate, friction
disc, spring plate.If there are any signs of seizure,
severe friction, or colour change from the heat, it will
adversely affect the locking performance; replace the
part with a new one.
NOTE: The strong contact on the inner circumfer-
ence of the friction surfaces is because of the spring
plate; this wear is not abnormal. AC501078
B.Inside and outside projections of friction disc, fric-
1. Measure the thickness of the friction surfaces (A)
tion plate and spring plate. Replace any cracked or
and projections (B) of the friction disc and spring
damaged parts.
plate in several places. Then check that the
C.The friction surface of the friction disc and pres-
differences between A and B are within the limit.
sure ring. If there are nicks or scratches, repair the
part by first grinding with an oil stone and then polish- Limit: 0.1 mm
ing with rubbing compound on a surface plate. 2. If the parts are worn beyond the allowable limit,
replace them with new parts.