27-1

GROUP 27

REAR AXLE
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 27-2 REMOVAL AND INSTALLATION . . . . . . . . 27-16

SPECIAL TOOLS. . . . . . . . . . . . . . . . 27-2 DRIVE SHAFT ASSEMBLY . . . . . . . . 27-18

REMOVAL AND INSTALLATION . . . . . . . . 27-18
REAR AXLE DIAGNOSIS . . . . . . . . . 27-6 DISASSEMBLY AND ASSEMBLY . . . . . . . 27-20
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 27-6
TROUBLESHOOTING STRATEGY . . . . . . 27-6 DIFFERENTIAL CARRIER
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 27-6 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 27-25
SYMPTOM PROCEDURES . . . . . . . . . . . . 27-6 REMOVAL AND INSTALLATION . . . . . . . . 27-25
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-28
ON-VEHICLE SERVICE. . . . . . . . . . . 27-12 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 27-32
REAR AXLE TOTAL BACKLASH CHECK . 27-12
GEAR OIL LEVEL CHECK . . . . . . . . . . . . . 27-12 SPECIFICATIONS . . . . . . . . . . . . . . . 27-41
WHEEL BEARING END PLAY CHECK . . . 27-12 FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 27-41
REAR AXLE HUB ASSEMBLY . . . . . 27-13 GENERAL SPECIFICATIONS . . . . . . . . . . 27-41

REMOVAL AND INSTALLATION . . . . . . . . 27-13 SERVICE SPECIFICATIONS . . . . . . . . . . . 27-42

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 27-15 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 27-42

SEALANT AND ADHESIVE . . . . . . . . . . . . 27-42
KNUCKLE . . . . . . . . . . . . . . . . . . . . . 27-16 COMPONENT IDENTIFICATION . . . . . . . . 27-43
27-2 REAR AXLE
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1271000100207
The rear axle has the following features. • ABS rotor to detect wheel speed is press-fitted
• DOJ-type on the differential side and BJ-type on into the drive shaft.
the hub side constant velocity joints are featured NOTE: The structure of differential is basically the
in the drive shaft. same as featured in existing models.
• Large capacity and high rigidity taper-roller type
unit bearing in the wheel bearing is featured.

CONSTRUCTION DIAGRAM
DIFFERENTIAL CARRIER
KNUCKLE

BJ
REAR HUB

UNIT BEARING

DOJ
DRIVE SHAFT

ACX02216 AB

SPECIAL TOOLS
M1271000600291

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

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

B990767

MB991897 MB991113-01, Disconnection of ball joint

Ball joint remover MB990635-01 or NOTE: Steering linkage puller
General service (MB990635 or MB991113)is
tool also used to disconnect knuckle
AC106827 and tie rod end ball joint.
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 (Use
installer base together with MB990938)

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27-4 REAR AXLE
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
A MB991171 − Measurement of the pinion
Pinion height gauge set height
A: MB991169
B
Drive pinion gauge
C
MB991171 attachment
B: MB991170
Cylinder gauge
C: MB990819
Drive pinion gauge
MB991768 −
Drive pinion gauge set
A A: MB991770
Head
MB991768

MB991534 −
Cylinder gauge

MB991534

MB990326 General service • Measurement of the starting

Preload socket tool torque of ball bearing
• Measurement of the starting
torque of ball bearing
MB990326

MB990685
Torque wrench

MB990685AC

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

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 REAR AXLE
SPECIAL TOOLS
27-5
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
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 Tools P.26-9.
Brass bar
MB991045 − Removal of the rear suspension
Bushing remover and crossmember bushing
installer
A A: MB991050
MB991045AB Base(B)
MB991159 − Removal and press-fitting of the
A Bushing remover and rear suspension crossmember
B installer bushing
A: MB991162
MB991159AB Bolt
B: MB991218
Bearing
MB991816 −
Bushing remover and
installer base

MB990955 − Press-fitting of the rear

Oil seal installer suspension crossmember
bushing

MB990955

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27-6 REAR AXLE
REAR AXLE DIAGNOSIS

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
M1271004300214

SYMPTOM INSPECTION REFERENCE

PROCEDURE PAGE
Drive shaft Noise while wheels are rotating 1 P.27-6
Grease leakage 2 P.27-7
Differential Constant noise 3 P.27-7
Gear noise while driving 4 P.27-8
Gear noise while coasting 5 P.27-9
Bearing noise while driving or coasting 6 P.27-10
Noise while turning 7 P.27-10
Heat 8 P.27-10
Oil leakage 9 P.27-11

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?
YES : Replace the part. Then go to Step 3.
Q: Is the drive shaft bent?
YES : Replace the part. Then go to Step 3. NO : Go to Step 3.
NO : Go to Step 2.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-7

INSPECTION PROCEDURE 2: Grease Leakage <DRIVE SHAFT>

DIAGNOSIS STEP 2. Retest the system.

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 : The procedure is complete.
Q: Is the DOJ boot or the BJ boot worn or damaged?
YES : Replace the part and apply grease (Refer to
P.27-20).. Then go to Step 2.
NO : Go to Step 2.

INSPECTION PROCEDURE 3: Constant Noise <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 differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher; Above −23°C(−10°F):
SAE 90, 85W-90, 80W-90, From −34 to −23°C(−30 to
LOWER
LIMIT 5 mm −10°F): SAE 80W, 80W-90, Below −34°C(−30°F):
(0.2 in) SAE 75W. Then go to Step 9.
ACX01083AB NO : Go to Step 2.

STEP 2. Check the tooth contact (engagement) of the drive

gear and drive pinion. Refer to GROUP 26, Differential
Carrier − Inspection Before Disassembly P.26-43.
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.

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27-8 REAR AXLE
REAR AXLE DIAGNOSIS

STEP 5. Check the drive gear and drive pinion for wear.
Q: Is the drive gear or drive pinion worn?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 6.

STEP 6. Check the side gear thrust washer or pinion shaft

for wear.
Q: Is the side gear thrust washer or pinion shaft worn?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.

STEP 7. Check the drive gear and differential case for wear
or damage.
Q: Is the drive gear or differential case worn or damaged?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 8.

STEP 8. Check for foreign material.

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

STEP 9. Retest the system.

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

INSPECTION PROCEDURE 4: Gear Noise while Driving <DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the oil level.

Remove the filler plug and check the gear oil level.

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 differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher; Above −23°C(−10°F):
SAE 90, 85W-90, 80W-90, From −34 to −23°C(−30 to
LOWER
LIMIT 5 mm −10°F): SAE 80W, 80W-90, Below −34°C(−30°F):
(0.2 in) SAE 75W. Then go to Step 6.
ACX01083AB NO : Go to Step 2.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-9

STEP 2. Check the gear engagement.

Q: Is the gear engagement in good condition?
YES : Go to Step 3.
NO : Adjust or replace the part. Then go to Step 6.

STEP 3. Check the drive pinion turning torque.

Q: Is the drive pinion turning torque correct?
YES : Go to Step 4.
NO : Adjust the turning torque. Then go to Step 6.

STEP 4. Check the gear for damage.

Q: Is the gear damaged?
YES : Replace the gear. Then go to Step 6.
NO : Go to Step 5.

STEP 5. Check for foreign material.

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

STEP 6. Retest the system.

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

INSPECTION PROCEDURE 5: Gear Noise while Coasting <DIFFERENTIAL>

DIAGNOSIS STEP 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.
NO : Go to Step 3.
Q: Is the drive pinion turning torque correct?
YES : Go to Step 2.
NO : Adjust the turning torque. Then go to Step 3. STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.

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27-10 REAR AXLE
REAR AXLE DIAGNOSIS

INSPECTION PROCEDURE 6: Bearing Noise while Driving or Coasting <DIFFERENTIAL>

DIAGNOSIS STEP 2. Retest the system.

Q: Is the abnormal noise eliminated?
STEP 1. Check the drive pinion rear bearing for YES : The procedure 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.

INSPECTION PROCEDURE 7: Noise while Turning < 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?
YES : Replace the part. Then go to Step 3.
Q: Is the side bearing worn or damaged?
YES : Replace the part. Then go to Step 3. NO : Go to Step 3.
NO : Go to step 2.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES : The procedure is complete.
NO : Start over at Step 1.

INSPECTION PROCEDURE 8: Heat <DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the oil level.

Remove the filler plug and check the gear oil level.

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 differential carrier, and
repair if necessary. Then, refill Hypoid gear oil API
UPPER
LIMIT classification GL-5 or higher; Above −23°C(−10°F):
SAE 90, 85W-90, 80W-90, From −34 to −23°C(−30 to
LOWER
LIMIT 5 mm −10°F): SAE 80W, 80W-90, Below −34°C(−30°F):
(0.2 in) SAE 75W. Then go to Step 3.
ACX01083AB NO : Go to Step 2.

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 REAR AXLE
REAR AXLE DIAGNOSIS
27-11

STEP 2. Check for excessive gear backlash. Refer to

GROUP 26, Differential Carrier − Inspection before
Disassembly P.26-43.
Q: Is the gear backlash correct?
YES : Go to Step 3.
NO : Adjust the backlash. Then go to step 3.

STEP 3. Retest the system.

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

INSPECTION PROCEDURE 9: Oil Leakage <DIFFERENTIAL>

DIAGNOSIS

STEP 1. Check the breather hose for clogging.

Q: Is the breather hose clogged?
YES : Clean or replace the part. Then go to Step 5.
NO : Go to step 2.

STEP 2. Check the cover installation.

Q: Is the cover installed correctly?
YES : Go to Step 3.
NO : Repair. Then go to Step 5.

STEP 3. Check the oil seal for wear or damage.

Q: Is the oil seal worn or damaged?
YES : Replace the seal. Then go to Step 5.
NO : Go to Step 4.

STEP 4. Check the oil level.

Remove the filler plug and check the gear oil level.

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; Above −23°C(−10°F): SAE 90, 85W-90,
UPPER
LIMIT 80W-90, From −34 to −23°C(−30 to −10°F): SAE
80W, 80W-90, Below −34°C(−30°F): SAE 75W. Then
LOWER
LIMIT 5 mm go to Step 5.
(0.2 in) NO : Go to Step 5.
ACX01083AB

STEP 5. Retest the system.

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

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27-12 REAR AXLE
ON-VEHICLE SERVICE

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.

ACX00962 AB

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

M1272001200200
Check that gear oil level is not 5 mm (0.2 inch) below the bot-
tom of filler plug hole.
GEAR OIL
Specified gear oil: Hypoid gear oil API classification
GL-5 or higher
Above −23°C(−10°F): SAE 90, 85W-90, 80W-90
UPPER From −34 to −23°C(−30 to −10°F): SAE 80W, 80W-90
LIMIT
Below −34°C(−30°F): SAE 75W
LOWER
LIMIT 5 mm
(0.2 in)
ACX01083AB

WHEEL BEARING END PLAY CHECK

M1271000900258
1. Remove the rear brake assembly and remove the brake disc
while holding it with wires to prevent it from falling.

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 REAR AXLE
REAR AXLE HUB ASSEMBLY
27-13
2. Fit the dial gauge as shown in the diagram and move the
hub in the axial direction to measure the play.
Limit: 0 mm (0 inch)
3. If the play exceeds the limit, replace the rear hub assembly.

ACX01084

REAR AXLE HUB ASSEMBLY

REMOVAL AND INSTALLATION
M1271002000217

Post-installation Operation
Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service P.36-4).

113 ± 14 N·m
6 84 ± 10 ft-lb

10
100 ± 10 N·m 4
74 ± 7 ft-lb 3
9 255 ± 29 N·m
188 ± 21 ft-lb

133 ± 14 N·m 2
98 ± 10 ft-lb
N
5

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

REMOVAL STEPS REMOVAL STEPS (Continued)

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

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27-14 REAR AXLE
REAR AXLE HUB ASSEMBLY

Required Special Tools:

• MB990767: End Yoke Holder • MB990326: Preload Socket
• MB990998: Front Hub Remover and Installer

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.
Use special tool MB990767 to fix the hub and remove the drive
shaft nut.
.

<<B>> DISC BRAKE ASSEMBLY REMOVAL

MB990767
Suspend the disc brake assembly from the body with wire, etc.
to prevent it from falling.
ACX00972 AC

<<C>> LOWER ARM AND KNUCKLE DISCONNECTION

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

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 illus-
tration 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
REAR AXLE HUB ASSEMBLY
27-15
>>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 END PLAY CHECK

1. Check the wheel bearing end play.
WOODEN BLOCK Limit: 0 mm (0 inch)
2. If the wheel bearing end 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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27-16 REAR AXLE
KNUCKLE

KNUCKLE
REMOVAL AND INSTALLATION
M1271003000221

Pre-removal Operation Post-installation Operation

Rear Hub Assembly Removal (Refer to P.27-13). • Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
• Rear Hub Assembly Installation (Refer to P.27-13).

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

Required Special Tool:

MB991897:Ball Joint Remover

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 REAR AXLE
KNUCKLE
27-17
REMOVAL SERVICE POINT
.

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

DISCONNECTION
CAUTION
• Do not remove the nut from ball joint. Loosen it and use
special tool MB991897 to avoid possible damage to ball
joint threads.
• Hang special tool MB991897 with cord to prevent it
from falling.
1. Install special tool MB991897 as shown in the figure.
CORD

BALL JOINT
BOLT

MB991897
NUT
AC106820 AB

2. Turn the bolt and knob as necessary to make the jaws of

special tool MB991897 parallel, tighten the bolt by hand and
BOLT
confirm that the jaws are still parallel.
PARALLEL NOTE: When adjusting the jaws in parallel, make sure the
knob is in the position shown in the figure.
CORRECT
3. Tighten the bolt with a wrench to disconnect the knuckle and
KNOB toe-control arm, upper arm.

WRONG AC106821AC

INSTALLATION SERVICE POINT

.

>>A<< UPPER ARM CONNECTION

If the upper arm ball joint is disengaged from the knuckle,
always renew the upper arm ball joint dust cover and retainer.
(Refer to GROUP 34-Upper ArmP.34-11.)

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27-18 REAR AXLE
DRIVE SHAFT ASSEMBLY

DRIVE SHAFT ASSEMBLY

REMOVAL AND INSTALLATION
M1271003300073

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. HUB CAP <<B>> >>A<< 4. KNUCKLE AND LOWER ARM
<<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

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.
Use special tool MB990767 to fix the hub and remove the drive
shaft nut.

MB990767

ACX00972 AC

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-19
<<B>> KNUCKLE AND LOWER ARM DISCONNECTION
Position a wooden block to the lower arm as shown in the illus-
tration and use the floor jack to remove the lower arm mounting
bolt by compressing the coil spring.

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 illus-
tration and use the floor jack to install the lower arm mounting
bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

>>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 to the torque specification with
special tool MB990767.
255 ± 29 N·m 3. If the pin hole does not align with another, tighten the drive
188 ± 21 ft-lb shaft nut [less than 284 N⋅m (209 ft-lb)] and find the nearest
ACX01087AB
hole then bend the split pin to fit in.

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27-20 REAR AXLE
DRIVE SHAFT ASSEMBLY

DISASSEMBLY AND ASSEMBLY

M1271003500099

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

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)

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-21
Required Special Tool:
MB990939: Brass Bar

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.
ACX01093 AD

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27-22 REAR AXLE
DRIVE SHAFT ASSEMBLY

DISASSEMBLY SERVICE POINTS

.

<<A>> BALLS REMOVAL

Remove the balls from the DOJ cage.

ACX01094

<<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.

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 REAR AXLE
DRIVE SHAFT ASSEMBLY
27-23
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 0 degree
angle 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.
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.
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

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27-24 REAR AXLE
DRIVE SHAFT ASSEMBLY

>>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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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-25
DIFFERENTIAL CARRIER ASSEMBLY
REMOVAL AND INSTALLATION
M1272002000265

CAUTION
Since a carbon fiber fortified plastic tube is used in the rear propeller shaft, make sure to refer to
GROUP 25 for removal procedure.
Pre-removal and Post-installation Operation
Differential Gear Oil Draining and Refilling (Refer to
P.27-12).

113 ± 14 N·m
84 ± 10 ft-lb
7 152 ± 25 N·m
113 ± 18 ft-lb
1

5 3 6

4
3

46 ± 8 N·m
34 ± 6 ft-lb

N
N

46 ± 8 N·m
34 ± 6 ft-lb
6
152 ± 25 N·m
113 ± 18 ft-lb
3 2
113 ± 14 N·m
84 ± 10 ft-lb
8 1
83 ± 12 N·m
61 ± 9 ft-lb
AC205391AB

REMOVAL STEPS REMOVAL STEPS (Continued)

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

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27-26 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

Required Special Tools: • MB991162: Bolt

• MB991050: Base(B) • MD991816:Bearing Remover and installer base
• MB991218: Bearing • MD990955:Oil seal installer

REMOVAL SERVICE POINTS

.

<<A>> KNUCKLE AND LOWER ARM DISCONNECTION

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

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 illus-
tration and use the floor jack to install the lower arm mounting
bolt by compressing the coil spring.

WOODEN
BLOCK

ACX01086 AB

REAR SUSPENSION CROSSMEMBER BUSHING

(FOR REAR DIFFERENTIAL MOUNT)
REPLACEMENT
1. Remove the rear differential.

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-27
2. Use special tools MB991050, MB991218, MB991162 and
MB991050 MB991816 to remove the bushing.
NOTE: When removing the bushing, insert special tool
MB991162 from the forward of vehicle and fix the nut with a
WRENCH
wrench.

REAR
SUSPENSION
CROSSMEMBER
BUSHING
MB991050
MB991218
NUT

MB991162 REAR
SUSPENSION
MB991816
CROSSMEMBER

AC206040 AB

3. Use special tools MB991816, MB991218, MB991162 and

MB991816 MB990955 to press-fit the bushing.
NOTE: When installing the bushing, insert special tool
MB991162 from the forward of vehicle and fix the nut with a
wrench. Press-fit the bushing until the bushing end face is
flush with the rear suspension crossmember.
4. Install the rear differential.
REAR
WRENCH SUSPENSION
CROSSMEMBER

MB991816
MB990955
NUT
MB991162

MB991218 REAR
BUSHING SUSPENSION
CROSSMEMBER

AC206041AC

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27-28 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

DISASSEMBLY
M1272002200236

CAUTION
Do not disassemble the limited slip differential case assembly.

7 8
16 N 4
9
16 15
13
11
12
14
13 15 17 3
10
14 16
8
5 9
7
32
25 26
28 29 30
24
N 27 23
21 22
19 20
N 18
31 N

N
2

1
AC203533 AC

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

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

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-29
Required Special Tools:
• MB990810: Side Bearing Puller • MD998801: Bearing Remover
• MB991407: Differential Rear Support Arbor • MB990939: Brass Bar
• MB990850: End Yoke Holder

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.26-43.
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 − 0.0030 inch)
Limit: 0.2 mm (0.01 inch)
.

<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL

SIDE SHIM/SIDE BEARING OUTER RACE REMOVAL
CAUTION
When taking out the differential case assembly, be careful
not to drop and damage the differential side shims or the
side bearing outer races.
Use the wooden handle of a hammer to remove the differential
case assembly, differential side shims and side bearings.
NOTE: Keep the right and left side bearings and side bearing
outer race separated, so that they do not become mixed during
assembly.

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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27-30 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 a 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
27-31
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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27-32 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

ASSEMBLY
M1272002300266

27 N 29
26 25 35 ± 5 N·m
24 18 25 ± 4 ft-lb
17 20 22
21 19
74 ± 5 N·m 18
55 ± 3 ft-lb 20 23
17 16
19 24 30
28 25
1 6 5 26
4 3
11 7
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
2N
12 31
63 ± 4 N·m 49 ± 9 N·m
47 ± 2 ft-lb 32 37 ± 6 ft-lb

23 20
5 18 17
15

17
18 20
FINAL DRIVE GEAR SET DIFFERENTIAL GEAR SET
AC203534AC

ASSEMBLY STEPS ASSEMBLY STEPS (Continued)

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

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-33
Required Special Tools:
• MB991168: Drive Pinion Oil Seal Installer • MB991534: Cyliner Gauge
• MB990938: Bar • MB990802: Bearing Installer
• MB991445: Bushing Remover and Installer Base • MB990850: End Yoke Holder
• MB990934: Installer Adapter • MB990727: Drive Pinion Oil Seal Installer
• MB991770: Head • MD998812: Installer Cap
• MB990819: Drive Pinion Gauge • MD998829: Installer Adapter
• MB990326: Preload Socket • MB990810: Side Bearing Puller
• MB990685: Torque Wrench • MB991407: Differential Rear Support Arbor
• MB991169: Drive Pinion Gauge

LUBRICATION AND ADHESIVE POINTS

2 – 3 mm (0.08 – 0.12 in)

(BEAD DIAMETER)

ADHESIVE: SEMI-DRYING SEALANT:

3M TM PART NO. 8730, 3MTM AAD PART NO. 8672, 8679,
8731 OR EQUIVALENT 8678, 8661, 8663 OR EQUIVALENT

ACX01104 AC

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27-34 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

ACX01106 AB

>>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:

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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-35
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

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.

MB990685
MB990326

AC102911 AC

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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27-36 REAR AXLE
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)

ACX01110 AB

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
27-37
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.
IDENTIFICATION
Also, select the drive pinion spacer from the following two
COLOR types.
HEIGHT OF DRIVE PINION IDENTIFICATION COLOR
ACX01063 AB
SPACER mm (in)
52.50 (2.067) Yellow
52.84 (2.080) Red

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 the 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

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.
.

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27-38 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY

>>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.
SIDE GEAR
Standard value: 0 − 0.076 mm (0 − 0.0030 inch)
SPACER Limit: 0.2 mm (0.01 inch)
SIDE GEAR 5. Measure by the same procedure for the other pinion gear.
SPACER
AC102885 AC
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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 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-39
>>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 3M stud locking 4170 or equivalent to the threaded

holes of the drive gear.
4. Install the drive gear onto the differential case with the
mating marks properly aligned. Tighten the bolts to the
specified torque in a diagonal sequence.
Tightening torque: 152 ± 15 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 side bearing spacer. Determine the
thickness by adding 1/2 of the clearance to the pre-load
0.05mm (0.002 inch).

ACX01071

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27-40 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.26-43).
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
27-41
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1271004000257

ITEM SPECIFICATION
Rear axle hub assembly, drive shaft assembly
Backing plate bolt 133 ± 14 N⋅m (98 ± 10 ft-lb)
Lower arm and knuckle connection nut 152 ± 25 N⋅m (113 ± 18 ft-lb)
Rear brake caliper bolt 100 ± 10 N⋅m (74 ± 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
M1271000200130

ITEM SPECIFICATION
Reduction gear type Hypoid gear
Reduction ratio 4.300
Differential gear type (Type × number Side gear Straight bevel gear × 2
of gears) Pinion gear Straight bevel gear × 2
Number of teeth Drive gear 43
Drive pinion 10
Side gear 18
Pinion gear 10

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27-42 REAR AXLE
SPECIFICATIONS

ITEM SPECIFICATION
Bearings (Outside diameter × Inside Side 90.0 × 55.0 (3.54 × 2.17)
diameter) mm (in)
Front 68.3 × 30.2 (2.69 × 1.19)

Rear 79.4 × 36.5 (3.13 × 1.44)

SERVICE SPECIFICATIONS
M1271000300308

ITEM STANDARD VALUE LIMIT

Rear axle total backlash mm (in) − 5 (0.2)
Wheel bearing end 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 − 0.0030) 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
M1271000400242

ITEM SPECIFIED LUBRICANT QUANTITY

Rear differential gear oil Hypoid gear oil API classification GL-5 or Approximately 1.6 dm3 (1.7 qt)
higher
• Above −23°C(−10°F): SAE 90, 85W-90,
80W-90
• From −34 to −23°C(−30 to −10°F): SAE
80W, 80W-90
• Below −34°C(−30°F): SAE 75W
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

M1271000500142

ITEM SPECIFIED SEALANT AND ADHESIVE

Differential cover 3M AAD Part No. 8672, 8679, 8678, 8661, 8663 or
equivalent
Drive gear and differential case mounting part 3M AAD Part No. 8730, 8731 or equivalent

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 REAR AXLE
SPECIFICATIONS
27-43
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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NOTES