Rear Differential Carrier Installation

Using a hexagon wrench (12 mm), temporarily install the differential carrier to the suspension member with 3 new bolts (A).

Install the 2 rear upper differential mount stoppers and 2 rear lower differential mount stoppers. Temporarily install the differential carrier rear to the suspension member with 2 new bolts (B).

Using a hexagon wrench (12 mm) and torque wrench, tighten the 3 bolts (A) to the specified torque.

Torque:

142 N*m{1,450 kgf*cm, 105 ft.*lbf}

Using a torque wrench, tighten the 2 bolts (B) to the specified torque.

Torque:

95 N*m{970 kgf*cm, 70 ft.*lbf}

NOTICE:

Do not tilt the inner tube and rubber parts when fully tightening the differential mount stopper.

Support the rear suspension member along with the differential using a jack.

HINT:

Install the rear suspension member along with the rear differential carrier assembly.

Install the 2 rear suspension member stoppers and 2 differential support member stoppers to the rear suspension member.

Install the rear suspension member along with the rear suspension member stopper lower with the 8 bolts.

Torque:

Bolt (A):

127 N*m{1,300 kgf*cm, 94 ft.*lbf}

Bolt (B):

19 N*m{195 kgf*cm, 14 ft.*lbf}

Install the suspension member brace lower LH with the 4 bolts.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

Install the suspension member brace lower RH with the 4 bolts.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

Install the clamp to the rear suspension member.

Connect the height control sensor connector.

Coat the spline of the inboard joint shaft assembly with gear oil.

Set the shaft snap ring with the opening side facing down.

Align the shaft splines and install the drive shaft assembly with a brass bar and hammer.

NOTICE:

1. Be careful not to damage the drive shaft dust cover, boot and oil seal.
   
2. Move the drive shaft assembly while keeping it level.
   

HINT:

It is possible to determine if the inboard joint shaft is properly engaged (the shaft is in contact with the pinion shaft, and the snap ring is engaged in the pinion gear) based on the sound or feeling when the shaft is driven in.

Install the rear drive shaft assembly to the rear axle carrier.

NOTICE:

Be careful not to damage the drive shaft boot.

Install the rear drive shaft assembly and rear axle assembly.

Install the No. 2 rear upper control arm assembly to the rear axle carrier sub-assembly with a new nut.

Torque:

70 N*m{714 kgf*cm, 52 ft.*lbf}

Temporarily tighten the No. 1 rear upper control arm assembly to the rear axle carrier sub-assembly with the bolt, washer and nut.

HINT:

Install the bolt from the rear side of the vehicle and lightly tighten the bolt.

Temporarily tighten the No. 1 rear suspension arm assembly to the rear axle carrier sub-assembly with the bolt and nut.

HINT:

Install the bolt from the rear side of the vehicle and lightly tighten the bolt.

Temporarily tighten the No. 2 rear suspension arm assembly to the rear axle carrier sub-assembly with the bolt and nut.

HINT:

Install the bolt from the rear side of the vehicle and lightly tighten the bolt.

Install the toe control link sub-assembly to the rear axle carrier sub-assembly with a new nut.

Torque:

70 N*m{714 kgf*cm, 52 ft.*lbf}

Install the speed sensor to the rear axle carrier with the 2 bolts.

Torque:

Bolt (A):

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Bolt (B):

6.0 N*m{61 kgf*cm, 53 in.*lbf}

NOTICE:

1. Be careful not to damage the speed sensor.
   
2. Prevent foreign matter from adhering to the speed sensor.
   
3. Do not twist the sensor wire when installing the speed sensor.
   

Temporarily install the rear shock absorber with coil spring with the bolt and nut.

Install the rear disc brake caliper assembly and No. 1 caliper plates with the 2 bolts.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

NOTICE:

1. Do not twist the rear brake hose when installing the rear disc brake caliper.
   
2. Make sure that there are no foreign objects or damage to the threads.
   
3. Do not overtighten the bolts because the hub carrier is made of aluminum and may be damaged.
   

Install a new axle shaft nut.

Torque:

290 N*m{2,957 kgf*cm, 214 ft.*lbf}

Using a chisel and a hammer, stake the axle shaft nut.

Temporarily tighten the No. 1 rear upper control arm assembly to the rear axle carrier sub-assembly with the bolt, washer and nut.

HINT:

Install the bolt from the rear side of the vehicle and lightly tighten the bolt.

Fully tighten the No. 1 rear suspension arm assembly with the bolt and nut.

Torque:

95 N*m{969 kgf*cm, 70 ft.*lbf}

NOTICE:

Turn the bolt while holding the nut.

Fully tighten the No. 2 rear suspension arm assembly with the bolt and nut.

Torque:

161 N*m{1,642 kgf*cm, 119 ft.*lbf}

NOTICE:

Turn the bolt while holding the nut.

Fully tighten the bolt holding the rear shock absorber with coil spring.

Torque:

110 N*m{1,120 kgf*cm, 81 ft.*lbf}

NOTICE:

Turn the bolt while holding the nut.

Connect the No. 3 parking brake cable assembly to the parking brake equalizer.

Install the No. 3 parking brake cable assembly to the body with the 3 bolts and 2 clamps.

Torque:

Bolt (A):

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Bolt (B):

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the rear suspension member brace LH with the 2 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Remove the SST from the transmission.

SST

09325-40010

Insert the yoke of the intermediate shaft into the transmission.

HINT:

Be careful not to damage the oil seal.

Install the 2 center support bearing washers and center support bearing. (for automatic transmission)

Install the 2 center support bearing washers, center support bearing and 2 center support bearing dampers. (for manual transmission)

Temporarily tighten the 2 bolts.

Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts.

Torque:

74 N*m{750 kgf*cm, 54 ft.*lbf}

Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) as shown in illustration.

Check that the center line of the bracket is perpendicular to the shaft axial direction.

Tighten the 2 bolts.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Stabilize the propeller shaft and differential.

1. Turn the propeller shaft several times by hand to stabilize the center support bearing.
   

Check both the No. 2 and No. 3 joint angles.

1. Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
   

   SST

   09370-50010
   

   HINT:

   The SST should be set directly on the bottom of the shaft.





2. Using SST, measure the installation angle of the differential.
   
   

   
   
   
   

   SST

   09370-50010
   

   HINT:

   Measure the installation angle by placing the SST in the positions shown in the illustration.

3. Calculate the No. 2 joint angle.
   

   No. 2 joint angle:

   A - B = -1°13' to -0°13'
   

   A:

   Intermediate shaft installation angle
   

   B:

   Propeller shaft installation angle
   

4. Calculate the No. 3 joint angle.
   

   No. 3 joint angle:

   B - C = 1°30' to 2°30'
   

   B:

   Propeller shaft installation angle
   

   C:

   Differential installation angle
   

   HINT:

   If the measured angle is not within the specified range, adjust it with the center support bearing washers.

Adjust the No. 2 joint angle .

1. Select the center support bearing washers for adjustment.
   

   Adjustment washer (for manual transmission)

   Thickness mm (in)

   2 (0.078)

   4.5 (0.1772)

   6.5 (0.2559)

   9.0 (0.3543)

   11 (0.4331)

   Adjustment washer (for automatic transmission)

   Thickness mm (in)

   2 (0.078)

   4.5 (0.1772)

   6.5 (0.2559)

   9.0 (0.3543)

   11 (0.4331)

   13.5 (0.5315)

   NOTICE:

   The 2 washers should be the same thickness.

Install the No. 1 heat insulator with the 4 nuts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Install the air guide plate outside RH with the 4 nuts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Install the tail exhaust pipe assembly with the 6 exhaust pipe supports.

Using a vernier caliper, measure the free length of the compression springs.

Minimum length:

38.5 mm (1.516 in.)

Install a new gasket to the rear end of the front exhaust pipe.

NOTICE:

1. Be careful with the installation direction of the gasket.
   

1. Do not reuse the gasket.
   

1. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.
   

   HINT:

   Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

Install 3 new gaskets and front exhaust pipe assembly.

CAUTION:

Do not reuse the gaskets.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install 4 new nuts and 4 bolts.

Torque:

62 N*m{632 kgf*cm, 46 ft.*lbf}

NOTICE:

Do not reuse the nuts.

Install the front center floor brace with the 4 bolts.

Torque:

7.4 N*m{75 kgf*cm, 65 in.*lbf}

Install the rear No. 1 floor panel brace with the 4 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Before installing the heated oxygen sensors, twist the sensor wires counterclockwise 4 turns.

Using the SST, install the heated oxygen sensors to the front exhaust pipe.

SST

09224-00010

Torque:

44 N*m{449 kgf*cm, 33 ft.*lbf}

After installing the sensors, check that the sensor wires are not twisted.
If the sensor wires are twisted, reinstall them.

Install the grommets of the heated oxygen sensors.

Install the stabilizer link assembly LH to the rear No. 2 suspension arm and height control sensor link bracket with the bolt and nut.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Install the rear stabilizer link assembly LH with the nut.

Torque:

89 N*m{908 kgf*cm, 66 ft.*lbf}

NOTICE:

Be sure to hold the stud bolt using a hexagon wrench 6 in order to prevent the bolt from turning.

Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.

Add oil.

Capacity:

1.10 to 1.20 liter (1.17 to 1.27 US qts, 0.97 to 1.05 lmp. qts)

Oil grade:

Toyota genuine differential synthetic gear oil API GL-5 SAE 75W-85 or equivalent

Check the oil level.

Using a hexagon wrench (10 mm), install the differential filler plug with a new gasket.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

NOTICE:

After replacing the oil, recheck the oil level after driving.

Stop the vehicle on a level place.

Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.

Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the inner surface of the differential filler plug opening.

NOTICE:

1. Excessively large or small amounts of oil may cause trouble.
   
2. After replacing oil, recheck the oil level after driving.
   

Check for oil leakage if the oil level is low.

Using a hexagon wrench (10 mm), install the differential filler plug and a new gasket.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Install the No. 2 differential support protector to the rear suspension member brace with the 2 nuts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Fully depress the parking brake pedal and release it to engage the parking brake.

Depress the pedal to the floor again, and release it to disengage the parking brake.

Slowly depress the parking brake pedal to the floor, and count the number of clicks.

Parking brake pedal travel:

7 to 9 notches at 300 N (31 kgf, 67.5 lbf)

Depress the parking brake pedal. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut.

Release the parking brake pedal.

Turn the No. 1 wire adjusting nut until the parking brake pedal travel meets the above specification.

Hold the wire adjusting No. 1 nut using a wrench or equivalent tool and tighten the lock nut.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Count the number of clicks after depressing and releasing the parking brake pedal 3 or 4 times.

Check whether the parking brake drags or not.

When operating the parking brake pedal, check that the parking brake indicator light comes on.

Pull firmly on the parking brake lever.

Release the parking brake lock, and return the parking brake lever to its off position.

Slowly pull the parking brake lever all the way up, and count the number of clicks.

Parking brake lever travel:

4 to 6 notches at 200 N (20 kgf, 45 lbf)

Depress the parking brake lever. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut.

Release the parking brake lever.

Turn the No. 1 wire adjusting nut until the parking brake lever travel meets the above specification.

Hold the No. 1 wire adjusting nut using a wrench or equivalent tool and tighten the lock nut.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Count the number of clicks after depressing and releasing the parking brake lever 3 or 4 times.

Check whether the parking brake drags or not.

When operating the parking brake lever, check that the parking brake indicator light comes on.