Rear Differential Side Gear Shaft Oil Seal (For 2Ad-Fhv) Replacement

Remove the 2 nuts and No. 2 differential support protector from the suspension member brace.

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

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

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

Torque:

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

Remove the No. 1 floor under cover and No. 2 floor under cover.

Remove the 4 bolts and rear No. 1 floor panel brace.

Remove the 4 bolts and front center floor brace.

Using SST, remove the air fuel ratio sensor.

SST

09224-00010

Remove the 2 bolts and 2 compression springs.

Remove the 2 bolts, 2 compression springs, front exhaust pipe assembly and 2 gaskets.

Remove the tail exhaust pipe assembly.

Remove the 2 bolts and rear suspension member brace LH.

Remove the 3 bolts and disengage the 2 clamps and No. 3 parking brake cable assembly LH.

Separate the No. 3 parking brake cable assembly LH from the parking brake equalizer.

Remove the bolt and nut, and separate the load sensing valve sensor bracket and stabilizer link assembly.

Using SST and a hammer, release the staked part of the axle shaft nut.

SST

09930-00010

NOTICE:

Release the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

While depressing the brake pedal, remove the axle shaft nut.

Remove the 2 bolts, and disconnect the rear disc brake caliper assembly.

NOTICE:

Use wire or equivalent to prevent the brake caliper from hanging down by the flexible hose.

Remove the No.1 caliper plates from the brake caliper.

Remove the 2 bolts, and separate the speed sensor from the axle carrier.

NOTICE:

1. Be careful not to damage the speed sensor.
   
2. Prevent foreign matter from adhering to the speed sensor.
   

Remove the nut from the No. 2 upper control arm assembly rear.

Using SST, separate the No. 2 upper control arm assembly rear from the rear axle carrier sub-assembly.

SST

09628-00011

NOTICE:

1. Use caution not to damage the rear axle carrier because it is made of aluminum and may be damaged easily.
   
2. Do not damage the ball joint dust cover.
   
3. Make sure that the SST is securely positioned on the rear axle carrier spacer.
   
4. If the rear axle carrier spacer has come off, replace the rear axle carrier with a new one.
   
5. Make sure that the string of the SST is securely tied to the vehicle.
   

Jack up the rear axle assembly so that the bolt on the No. 1 upper control arm assembly rear can be removed.

HINT:

Place a wooden block between the jack and rear axle carrier to prevent damage to the rear axle carrier.

Remove the bolt, washer and nut, and separate the No. 1 upper control arm assembly rear from the rear axle carrier sub-assembly.

Remove the bolt and nut, and separate the No. 1 rear suspension arm assembly from the rear axle carrier sub-assembly.

NOTICE:

Turn the bolt while holding the nut.

Remove the bolt and nut, and separate the No. 2 rear suspension arm assembly from the rear axle carrier sub-assembly.

NOTICE:

Turn the bolt while holding the nut.

Remove the nut from the toe control link sub-assembly.

Using SST, separate the toe control link sub-assembly from the rear axle carrier sub-assembly.

SST

09628-00011

NOTICE:

1. Use caution not to damage the rear axle carrier because it is made of aluminum and may be damaged easily.
   
2. Do not damage the ball joint dust cover.
   
3. Make sure that the SST is securely positioned on the rear axle carrier spacer.
   
4. If the rear axle carrier spacer has come off, replace the rear axle carrier with a new one.
   
5. Make sure that the string of the SST is securely tied to the vehicle.
   

Using a plastic hammer, separate the drive shaft from the rear axle assembly.

NOTICE:

1. Be careful not to damage the boot.
   
2. Use wire or equivalent to prevent the rear drive shaft assembly from hanging down.
   

Using SST, remove the rear drive shaft assembly.

SST

09520-01010
09520-24010(09520-32040)

NOTICE:

1. Be careful not to damage the oil seal, inboard joint boot and drive shaft dust cover.
   
2. Be careful not to drop the drive shaft assembly.
   

Using SST, remove the oil seal.

SST

09308-10010

Using SST and a hammer, install a new oil seal.

SST

09223-15030
09950-70010(09951-07200)

Oil seal installation depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Apply MP grease to the oil seal lip.

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 stabilizer link assembly and the load sensing valve sensor bracket to the No. 2 rear suspension arm assembly with the bolt and nut.

Torque:

27 N*m{275 kgf*cm, 20 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.
   

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.
   

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

Install the rear wheels.

Lower the vehicle to the ground. Bounce the vehicle up and down at the corners to stabilize the rear suspension.

Remove the rear wheels.

Jack up the axle carrier, with a wooden block placed between the jack and axle carrier, to apply a load to the suspension so that the rear drive shaft assembly becomes level.

Fully tighten the No. 1 rear upper control arm assembly with the nut.

Torque:

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

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.

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}

Install the tail exhaust pipe assembly with the 4 exhaust pipe supports.

Using vernier calipers, measure the free length of the compression springs.

Minimum length:

38.5 mm (1.516 in.)

Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly by hand.

NOTICE:

1. Be careful with the installation direction of the gasket.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. 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 the front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold converter and front exhaust pipe assembly.

Before installing the air fuel ratio sensor, twist the sensor wire counterclockwise 4 turns.

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST

09224-00010

Torque:

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

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{195 kgf*cm, 14 ft.*lbf}

Install the No. 1 floor under cover and No. 2 floor under cover.

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

Add oil.

Capacity:

1.30 to 1.40 litter (1.37 to 1.48 US qts, 1.14 to 1.23 lmp. qts)

Oil grade:

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

Torque:

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

NOTICE:

After replacing the oil, drive the vehicle and recheck the oil level.

Check the oil level.

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

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 the oil, drive the vehicle and recheck the oil level.
   

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}

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.