REAR AXLE &

REAR SUSPENSION GI

SECTION RA MA

EM

LC

EC

CONTENTS FE

PRECAUTIONS AND PREPARATION............................2 Inspection.....................................................................9 CL

Precautions ..................................................................2 Installation - 2WD and 4WD models without
Special Service Tools ..................................................2 ABS - ...........................................................................9
Commercial Service Tools ...........................................3 Installation - 4WD models with ABS - .......................11
MT
REAR AXLE AND REAR SUSPENSION........................4 REAR SUSPENSION.....................................................13
ON-VEHICLE SERVICE ..................................................5 Shock Absorber .........................................................14 TF
Rear Axle and Rear Suspension Parts .......................5 Leaf Spring ................................................................14
Rear Wheel Bearing ....................................................5 SERVICE DATA AND SPECIFICATIONS (SDS) ..........16
REAR AXLE.....................................................................6 General Specifications...............................................16 PD
Components.................................................................6 Inspection and Adjustment ........................................16
Removal.......................................................................7
FA

BR

ST

RS

BT

HA

EL

IDX
 PRECAUTIONS AND PREPARATION

Precautions
I When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
I Use flare nut wrench when removing or installing brake
tubes.
I After installing removed suspension parts, check wheel
alignment and adjust if necessary.
I Always torque brake lines when installing.
SBR820BA

Special Service Tools

Tool number
Description
Tool name
KV40101000 Removing rear axle shaft
Axle stand

NT159

ST36230000 Removing rear axle shaft

Sliding hammer

NT126

ST38020000 Removing wheel bearing lock nut

Bearing lock nut wrench

NT160

KV40106500 Removing wheel bearing and ABS sensor rotor

Rear axle shaft bearing
puller

NT683

ST37840000 Installing rear axle shaft

Rear axle shaft guide

NT162

GG94310000 Removing and installing brake piping

Flare nut torque
wrench

NT406 a: 10 mm (0.39 in)

RA-2
 PRECAUTIONS AND PREPARATION

Commercial Service Tools

Tool name Description GI
q
1 Flare nut crowfoot Removing and installing each brake piping
q
2 Torque wrench MA

EM
NT360 a: 10 mm (0.39 in)
Rear axle oil seal drift Installing oil seal
LC

EC
a: 74 mm (2.91 in) dia.
NT115 b: 68 mm (2.68 in) dia.
Rear axle oil seal drift Installing oil seal FE

CL
a: 54.5 mm (2.146 in) dia.
NT115 b: 34.5 mm (1.358 in) dia.
MT

TF

PD

FA

BR

ST

RS

BT

HA

EL

IDX

RA-3
 REAR AXLE AND REAR SUSPENSION

2WD

SRA795A

4WD

SRA796A

RA-4
 ON-VEHICLE SERVICE

Rear Axle and Rear Suspension Parts

Check rear axle and rear suspension parts for excessive play, wear
or damage. GI
I Shake each rear wheel to check for excessive play.
MA

EM

SMA525A
LC
I Retighten all nuts and bolts to the specified torque.
: Refer to REAR SUSPENSION, RA-13.
EC

FE

CL

SRA839 MT
I Check shock absorber for oil leakage or other damage.
I Check shock absorber bushing for excessive wear or other TF
damage.

PD

FA

SRA734

Rear Wheel Bearing

BR
I Check that wheel bearings operate smoothly.
I Check axial end play.
Axial end play: ST
Refer to SDS, RA-16.

RS

BT
SRA006-A

HA

EL

IDX

RA-5
 REAR AXLE

Components

SRA797A

SRA798A

RA-6
 REAR AXLE

Removal
I Before removing the rear axle, disconnect the ABS wheel
sensor from the assembly. Then move it away from the GI
axle. Failure to do so may result in damage to the sensor
wires and the sensor becoming inoperative.
I Wheel bearing does not require maintenance.
MA
I If growling noise is emitted from wheel bearing during
operation, replace wheel bearing assembly.
I If the wheel bearing assembly is removed, it must be renewed.
EM
The old assembly must not be re-used.
LC
1. Disconnect parking brake cable and brake tube.
2. Remove nuts securing wheel bearing cage with baffle plate.
EC

FE

CL

SRA002 MT
3. Draw out axle shaft with Tool.
When drawing out axle shaft, be careful not to damage oil seal. TF
4. Remove case shim and case seal.
— 2WD and 4WD models without ABS —
5. Remove O-ring. — 4WD models with ABS — PD
6. Remove oil seal.
Do not reuse oil seal once it is removed.
Always install new one. FA

SRA003-A

7. Remove ABS sensor rotor. — 4WD models with ABS —

BR

ST

RS

BT
SRA799A

8. Unbend lock washer with a screwdriver.

HA

EL

IDX

SRA104

RA-7
 REAR AXLE
Removal (Cont’d)
9. Remove bearing lock nut with Tool.

SRA728-A

10. Remove wheel bearing together with bearing cage and baffle
plate from axle shaft.

SRA800A

11. Remove grease seal in bearing cage with suitable bar.

12. Remove wheel bearing outer race with a brass drift.
— 2WD and 4WD models without ABS —

SRA595C

13. Remove wheel bearing assembly. — 4WD models with ABS —

SRA801A

RA-8
 REAR AXLE

Inspection
AXLE SHAFT GI
I Check axle shaft for straightness, cracks, damage, wear or
distortion. Replace if necessary.
MA
WHEEL BEARING
I Make sure wheel bearing rolls freely and is free from noise,
cracks, pitting or wear.
EM

AXLE CASE LC
I Check axle case for yield, deformation or cracks. Replace if
necessary.
EC

FE

CL

MT
Installation — 2WD and 4WD models without
ABS — TF
1. Install wheel bearing outer race with a brass drift.
2. Install a new grease seal in bearing cage. PD
After installing new grease seal, coat sealing lip with multi-
purpose grease.
FA

SRA010

3. Install bearing spacer with chamfer side facing axle shaft

flange. BR

ST

RS

BT
SRA510

4. Install wheel bearing inner race with a brass drift.

5. Coat each bearing cone with multi-purpose grease.
HA
Specified amount of grease:
8 - 12 g (0.28 - 0.42 oz) EL

IDX

SRA011

RA-9
 REAR AXLE
Installation — 2WD and 4WD models without
ABS — (Cont’d)
6. Install plain washer and a new wheel bearing lock washer.
7. Tighten wheel bearing lock nut.
Fit wheel bearing lock washer lip in wheel bearing lock nut
groove correctly by tightening lock nut. Be sure to bend it up.

SRA730

8. Install a new oil seal with suitable tool.

After installing new oil seal, coat sealing lip with multi-purpose
grease.

SRA731

9. Apply recess of axle case end with multi-purpose grease.

10. Apply gear oil to the spline of axle shaft. Coat seal surface of
axle shaft with multi-purpose grease (as shown left).

SRA652A

11. Adjust axial end play.

a. Select end shims.
Standard thickness: 1.5 mm (0.059 in)
Axle case end shim: Refer to SDS, RA-16.
Do not insert end shims between case seal and bearing cage.

SRA653A

b. Insert axle shaft with Tool as a guide.

When inserting axle shaft, be careful not to damage oil seal.
c. Measure end play of axle shaft.
Axial end play:
Servicing one side axle
0.02 - 0.15 mm (0.0008 - 0.0059 in)
Servicing both side axles
On first axle (right or left)
0.30 - 0.90 mm (0.0118 - 0.0354 in)
On second axle
0.02 - 0.15 mm (0.0008 - 0.0059 in)
SRA012-A

RA-10
 REAR AXLE
Installation — 2WD and 4WD models without
ABS — (Cont’d)
d. If axial end play is not within the specified limit, reselect axle
case end shims. GI
While adjusting axial end play, be careful not to damage oil
seal.
MA

EM

SRA006-A
LC
Installation — 4WD models with ABS —
1. Press new wheel bearing until it bottoms end face of bearing EC
cage.
Maximum load P:
78 kN (8 ton, 8.8 US ton, 7.9 Imp ton) FE
Always press outer race of wheel bearing during installation.

CL

SRA288A MT
2. Press new grease seal until it bottoms end face of bearing
cage. TF
After installing new grease seal, coat sealing lip with multi-
purpose grease.
PD

FA

SRA289A

3. Press axle shaft into inner race of wheel bearing.

Maximum load P: BR
47.1 kN (4.8 ton, 5.3 US ton, 4.72 Imp ton)
Be careful not to damage or deform grease seal.
ST

RS

BT
SRA761A

4. Install plain washer and a new wheel bearing lock washer.

5. Tighten wheel bearing lock nut to specified torque.
HA
: 245 - 294 N⋅m (25 - 30 kg-m, 181 - 217 ft-lb)
Fit wheel bearing lock washer lip in wheel bearing lock nut EL
groove correctly by tightening lock nut. Be sure to bend it up.

IDX

SRA762A

RA-11
 REAR AXLE
Installation — 4WD models with ABS —
(Cont’d)
6. Check wheel bearing preload.
a. Turn bearing cage (with respect to axle shaft) two or three
times. It must turn smoothly.
b. Attach spring gauge to bearing cage bolt (as shown at left) and
pull it at a speed of 10 rpm to measure preload.
Spring gauge indication:
6.9 - 48.1 N (0.7 - 4.9 kg, 1.5 - 10.8 lb)

SRA763A

7. Install new oil seal to rear axle housing using a suitable tool.
After installing new oil seal, coat sealing lip with multi-purpose
grease.
8. Install new O-ring to rear axle housing.

SRA803A

9. Press ABS sensor rotor onto axle shaft until it contacts wheel
bearing lock nut.

SRA802A

10. Position axle shafts in rear axle housing with Tool as a guide.
Be careful not to damage oil seal.

SRA012-A

11. Check axial end play.

a. Check that wheel bearings operate smoothly.
b. Check axial end play.
Axial end play:
0 mm (0 in)

SRA006-A

RA-12
 REAR SUSPENSION

2WD

GI

MA

EM

LC

EC

FE

CL

MT

TF

SRA593CA PD
4WD
FA

BR

ST

RS

BT

HA

EL

IDX

SRA804A

RA-13
 REAR SUSPENSION

Shock Absorber
REMOVAL AND INSTALLATION
I Remove shock absorber by disconnecting upper and lower
end.

SRA701

INSPECTION
I If oil leakage, cracks or deformation occurs, replace shock
absorber assembly.
I If rubber bushings are cracked or deformed, replace rubber
bushings.

Leaf Spring
REMOVAL AND INSTALLATION
1. Disconnect shock absorber lower end, and remove U-bolts.

SRA702

2. Disconnect spring shackle.

SRA704

RA-14
 REAR SUSPENSION
Leaf Spring (Cont’d)
3. Disconnect front pin.

GI

MA

EM

SRA705
LC
INSPECTION
I Check leaf spring for cracks. Replace if necessary. EC
I Check front bracket and pin, shackle, U-bolts and spring pad for
wear, cracks, straightness or damaged threads. Replace if nec-
essary. FE
I Check all bushings for deformation or cracks. Replace if nec-
essary.
[4WD models for Australia: Rear spring front bushing] CL
Make sure that front bushing is properly installed.

SRA535AA MT
INSTALLATION
1. Apply soapsuds to rubber bushing. TF
2. Install spring shackle and front pin, and finger tighten the nuts.
3. Install spring pad and nuts under leaf spring or axle case.
4. Tighten U-bolt mounting nuts diagonally. PD
Tighten U-bolts so that the lengths of all U-bolts under spring
pad are the same.
5. Install shock absorber, and finger tighten the nuts. FA

SRA727

6. Remove stands and bounce the vehicle to stabilize suspension.

(Unladen) BR

ST

RS

BT
SRA703

7. Tighten spring shackle nuts, front pin nuts and shock absorber
nuts.
HA
When installing rubber parts, final tightening must be carried
out under unladen condition* with tires on the ground. EL
* Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.
IDX

SRA754

RA-15
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Rigid axle with semi-elliptic leaf
Suspension type
spring
Shock absorber type Double-acting hydraulic

Inspection and Adjustment

WHEEL BEARING WHEEL BEARING
— 2WD and 4WD models without ABS — 4WD models with ABS
Total end play mm (in) 0.02 - 0.15 (0.0008 - 0.0059) Total end play mm (in) 0 (0)

Thickness Wheel bearing preload at bearing

Part number 6.9 - 48.1 (0.7 - 4.9, 1.5 - 10.8)
mm (in) cage bolt N (kg, lb)
0.05 (0.0020) 43086-P0110
Available rear axle case end 0.07 (0.0028) 43087-P0110
shims 0.10 (0.0039) 43088-P0110
0.15 (0.0059) 43086-B9500
0.20 (0.0079) 43089-P0110
0.50 (0.0197) 43090-P0110
1.00 (0.0394) 43036-01G00

RA-16