Group 27 Rear Axle: 1. Wheel Hub and Brake Drum 2. Reduction and Differential 3. Limited Slip Differential

GROUP 27 REAR AXLE
SPECIFICATIONS .............................................................................. 27-2
STRUCTURE AND OPERATION

1. Wheel Hub and Brake Drum ......................................................... 27-2
2. Reduction and Differential ........................................................... 27-3
3. Limited Slip Differential ................................................................ 27-6
TROUBLESHOOTING ....................................................................... 27-8
ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Inspection and Replacement of Axle Oil .................................... 27-10
2. Inspection of Wheel Bearing for Play ..........................................27-11
WHEEL HUB AND BRAKE DRUM .................................................. 27-12
AXLE HOUSING
<REAR AXLE, REAR 2ND AXLE> ............................................... 27-24
<REAR 1ST AXLE>....................................................................... 27-30
REDUCTION AND DIFFERENTIAL

<D10H, D12H>............................................................................... 27-40
<D10HT>........................................................................................ 27-56
DIFFERENTIAL................................................................................. 27-78
27-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Specifications
Item
FS, FV FP-R
Model R10T R10TT R12T
Rear axle
Type Banjo type, full floating
Model D10H D10HT D12H
Type Single-reduction
Reduction Tooth shape Hypoid gear
4.625
Gear ratio 5.142 4.222
5.571
Differential Tooth shape Straight bevel gear
*a AGL-5
Type
*b SAE90
Inter-differ- 0.5
– –
ential {0.5}
Gear oil
Quantity 1.0
Carrier – –
dm3 {L} {1.0}
10 10 14
Housing
{10} {10} {14}
Mass kg Approx.640 Approx.730 Approx.640
*a: Use limited slip differential oil (API GL-5 SAE 90) as gear oil in the model with multiplate limited slip differentials.
*b: Use SAE140-grade oil under high-load conditions such as continuous hill climbing and at the ambient tempera-
ture of 10°C or above.
1. Wheel Hub and Brake Drum
27-2
27
2. Reduction and Differential
<D10H, D12H>
27-3
<D10HT>
27-4
27
1 Companion flange 23 Housing cover sleeve 45 Lock plate
2 Split pin 24 Stopper bolt 46 Differential gear
3 Lock nut 25 Snap ring 47 Differential gear washer
4 Dust cover 26 Companion flange 48 Lock ring
5 Input bearing 27 Split pin 49 Inner bearing
6 Snap ring 28 Lock nut 50 Outer bearing
7 Inter-differential outer gear 29 Washer <P10> 51 Reduction pinion
8 Inter-differential pinion 30 Oil seal 52 Differential carrier
9 Inter-differential pinion washer 31 Through shaft 53 Shim
10 Inter-differential pinion spider 32 Pinion bearing collar 54 Driven helical gear
11 Inter-differential inner gear 33 Bearing retainer 55 Differential carrier cover
12 Inter-differential inner case 34 Pinion pilot bearing 56 Lock nut
13 Oil pump 35 Pinion spider 57 Split pin
14 Shim 36 Pinion washer 58 Inter-differential bushing
15 O-ring 37 Differential pinion 59 Inter-differential gear inner
16 Bearing retainer 38 Side bearing washer
17 Helical outer bearing 39 Lock pawl 60 Input cover
18 Drive helical gear 40 Lock sheet 61 Inter-differential gear outer
19 Helical inner bearing 41 Bearing cap washer
20 Lockout cylinder 42 Differential case 62 Oil seal
21 Differential lock clutch 43 Reduction gear 63 Inter-differential outer case
22 Output bearing 44 Differential case
27-5
3. Limited Slip Differential
• Friction discs and friction plates are fitted alternately and held by springs. The former slides over the spline of dif-
ferential gear, and the latter slides along the grooves in differential case.
3.1 Operating mechanism

• When one wheel spins, a difference in the revolution speed generates between differential gear and differential
cases which causes friction discs and friction plates to revolve relatively to each other.
• This relative revolution produces a friction torque between the friction discs and friction plates.
27-6
27
3.2 Operation during straight driv-
ing
• During straight driving, the right and
left axle shafts rotate at the same
speed, and no friction torque gener-
ates.
TG: Input torque
3.3 Operation when there is a dif-

ference in rotation speed be-
tween right and left wheels
• If one wheel is on a slippery surface
such as mud and the other wheel is
not, the differential function becomes
effective due to differences in resis-
tance of the road surface between
right and left sides. In this state, how-
ever, friction torque TF is generated
between the friction discs and plates.
This torque works in such a manner as
to reduce the differences in rotations
between right and left wheels. That is,
the faster axle shaft is forced to slow
down, and the slower axle shaft is
forced to turn faster.
If one wheel spins due to mud and the
like, a large friction torque generates
because such a spinning makes large
rotational speed difference. According-
ly, a large torque is distributed to the
non-spinning wheel, which makes it
easier for the vehicle to get out of the
mud.
(TG–TF)
High-speed side
2
(spinning side)
(TG+TF)
Low-speed side
2
27-7
TROUBLESHOOTING
Symptoms Power transmission insufficient
Oil leakage from differential carrier and axle housing
Propeller shaft turns but vehicle does not move

Noise when starting and changing speed
Oil leakage from companion flange
Continuous noise while cruising

Intermittent noise while cruising
Oil leakage from axle shaft
Tires drag while cornering

Noise while cornering
Breakage
Seizure
Possible causes
Axle shaft mounting bolt loose O O
Axle housing bent O
Axle shaft bent O
Axle shaft fractured O
Axle shaft slips out of engagement O
Wheel hub and
Oil seal faulty O
axle housing
Air breather cracked, damaged or clogged O
Wheel hub bearing seized O
Wheel hub bearing worn O
Wheel hub bearing rotation faulty O
Wheel hub bearing broken O
Gear oil excessive O
Gear oil insufficient O O
Oil seal faulty O
Sealant faulty O
Side bearing seized O O
Side bearing worn O O
Side bearing rotation faulty O O
Side bearing broken O
Reduction and Side bearing starting torque excessive O O
differential Side bearing starting torque insufficient O O O O
Reduction and differential mounting bolt loose O
Differential carrier and side bearing cap mounting bolts loose O
Differential carrier cracked or damaged O
Reduction gear and differential case mounting bolts loose O O
Reduction gear or reduction pinion broken O O O O
Reduction gear or reduction pinion worn O O
Reduction gear and reduction pinion damaged O
Reduction gear backlash excessive O O
27-8
27
Symptoms Power transmission insufficient
Oil leakage from differential carrier and axle housing
Propeller shaft turns but vehicle does not move

Noise when starting and changing speed
Oil leakage from companion flange
Continuous noise while cruising

Intermittent noise while cruising
Oil leakage from axle shaft
Tires drag while cornering

Noise while cornering
Breakage
Seizure
Possible causes
Reduction gear backlash insufficient O O
Reduction gear tooth contact adjusted incorrectly O
Reduction pinion starting torque excessive O O O
Reduction pinion starting torque insufficient O O
Reduction pinion lock nut loose O O O
Reduction pinion companion flange spline abnormally worn O O
Reduction pinion inner bearing and outer bearing seized O O
Reduction pinion inner bearing or outer bearing worn O O
Reduction pinion inner bearing or outer bearing broken O O
Reduction pinion pilot bearing worn O
Reduction pinion pilot bearing seized or damaged O
Reduction and Pinion spider fractured O
differential Differential gear or differential pinion broken O O O O
Differential gear or differential pinion seized O O
Differential gear or differential pinion worn O O
Differential gear washer worn or damaged O O O
Differential gear backlash excessive O O
Differential gear backlash insufficient O O
Play between differential gear and axle shaft spline excessive O O
Damaged O O O O O
Differential gear splines worn O
Limited
slip differ- Differential gear washer worn or damaged O
ential
Friction plates and friction discs seized O
Differential spider damaged or broken O
27-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection and Replacement of Axle Oil
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Inspection plug
– 110 ± 10 {11 ± 1} –
Drain plug
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Gear oil:
D10H, D10HT *a Normal: Maximum air tempera- 10 dm3 {10 L}
Axle housing ture during operation
below 40°C
D12H 14 dm3 {14 L}
API GL-5
– SAE90
Inter-differential <D10HT> *b Hot areas: Maximum air tempera- 0.5 dm3 {0.5 L}
ture during operation
above 40°C
Carrier <D10HT> API GL-5 1 dm3 {1 L}
SAE140
*a:Use limited slip differential oil (API GL-5 SAE 90) as gear oil in the model with multiplate limited slip differentials.
*b:Use this oil under heavily-loaded, severe conditions such as continuous driving on uphill grades. However, the air
temperature must be above 10°C.
WARNING
• Since there is a risk to burn oneself, let the transmission to
cool down after driving.
[Inspection]
• Remove the inspection plug and check whether the gear oil level
is up to the plug hole.
• If the oil level is low, fill oil through the plug hole until it comes up
to the hole.
[Drain]
• Remove the grease plugs, inspection plug and drain plugs to
drain the gear oil. Check the oil that has been drained from the
following points of view to identify any related abnormalities.
• Oil quantity
• Oil quality
• Whether the oil contains metal pieces or swarf
[Lubrication]
• Through the grease plugs, fill the specified quantity of gear oil.
• Through the inspection plug, fill gear oil up to the plug hole.
27-10
27
2. Inspection of Wheel Bearing for Play
• Jack up the vehicle.
• Try to move the top and bottom of the rear tire by hands in the il-
lustrated directions to inspect the wheel bearing for play.
• If play is found with the feel of hands, repeat the inspection pro-
cedure while having the brake pedal pressed by another person-
nel. When the play is removed by operating the brake pedal, the
symptom indicates that there is play in the wheel bearing, not in
the suspension or other related parts. Then inspect the turning
torque of the wheel bearing and adjust it as required. (See
“WHEEL HUB AND BRAKE DRUM”.)
• If the turning torque of the wheel bearing cannot be adjusted
correctly or the play still remains after the adjustment, replace
the wheel bearing with a new one. (See “WHEEL HUB AND
BRAKE DRUM”.)
27-11
WHEEL HUB AND BRAKE DRUM
Disassembly sequence
1 Brake hose (for spring brake) 12 Outer bearing outer race
2 Brake hose (for service brake) 13 Brake drum (See Gr35.)
3 Nylon tube (for breather) 14 Hub bolt
4 Axle shaft 15 Wheel hub
5 Gasket 16 Inner bearing inner race
6 Lock plate 17 Oil seal retainer
7 Lock nut 18 Rear drum brake (See Gr35.)
8 Lock washer 19 Oil seal
9 Outer bearing inner race
10
11
Oil seal
Inner bearing outer race
*a:: Axle housing
Non-reusable parts
• Plug the brake hoses that have been removed to prevent the ingress of dust and other contaminants.
• Release the wheel park brake before starting disassembly. (See Gr35.)
27-12
27
Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Make sure that the brake lining surface and inner surface of the brake drum of the wheel hub and brake
drum are free from grease to avoid malfunction of brakes.
• Make sure that the rotor and oil seal are not damaged when you install the wheel hub and brake drum on
the axle housing.
• After reassembly, make the initial adjustment of the brake drum-to-shoe clearance. (See Gr35.)
Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
2.5 to 5.5 N·m
Starting torque of wheel hub bearing (tangential force at {0.25 to 0.55 kgf·m}
– – Adjust or replace
hub bolt position with oil seal assembled) (tangential force: 15 to
32 N {1.5 to 3.3 kgf})
Bend at center 0 to 1.0 2.0 Replace
4 Axle shaft Lateral runout at flange
0 to 0.05 0.5 Replace
face

Brake hose (for spring brake) tightening (axle side)
41.7 ± 2.5 {4.25 ± 0.25} –
Brake hose (for service brake) tightening (axle side)
Bolt (axle shaft mounting) 272 {27.7} –
Nut (rear drum brake mounting) 135 {13.8} M14 × 1.5
Bolt (lock plate mounting) 9 ± 2 {0.9 ± 0.2} –
Back-off angle
Lock nut 300 {30} 22.5° (1/16 of a
turn)
Nut (wheel hub and brake drum mounting) 420 {43} –

Lip area of oil seal
Wheel bearing grease As required
Pack space between rollers of bearing inner race
[NLGI No. 2 (Li soap)]
Pack inside of wheel hub 2000 g
Nylon tube contacting surfaces with the elbow of the
Loctite 414 As required
spring chamber
For a wheel
Special tools (Unit: mm)

Mark Tool name and shape Part No. Application
Socket wrench
A MH061536
Removal and installation of lock nut
120
27-13
MH061433
or
Removal of wheel hub and brake
Wheel hub puller MH061458
drum
or
MH062145
Wheel hub inner bearing

installer <R10T>
03723-21000
A B Installation of inner bearing outer race
<R12T>
φ158 φ146 03724-25000
Wheel hub outer bearing

installer
<R10T>
A B 03723-20000 Installation of outer bearing outer
<R12T> race
R10T φ148 φ138 03724-26000
R12T φ148 φ140
Oil seal retainer

installer <R10T>
03723-31001
Installation of inner bearing inner race
<R12T>
03724-23000
A B C D
R10T φ105 φ93 φ91 250
R12T φ107 φ98 φ95 250
Removal of inner bearing inner race

Gear puller MH061102
and oil seal retainer
Oil seal retainer installer

<R10T>
03723-31001
Installation of oil seal retainer
<R12T>
03724-23000
A B C
R10T φ155 φ93 250
R12T φ155 φ98 250
27-14
27
Oil seal installer

<R10T>
A B MH062016
Installation of oil seal
R10T φ70 φ60 <R12T>
MH062015
R12T φ75 φ65
Adapter
A B
Use together with wheel hub puller
φ95 φ91 MH061103
and gear puller listed above.
Oil seal retainer puller

adapter
Removal of inner bearing inner race
03724-16000
A B C and oil seal retainer
19 φ146 240
Removal procedure
Removal: Brake hose
• Disconnect the brake hoses, first at the axle side and then at the
wheel brake side.
Removal: Lock nut
Removal: Wheel hub and brake drum

• If the brake drum has stepped wear and the wear prevents the
wheel hub and brake drum assembly from being removed, the
removal can still be effected by taking the following procedure.
• After removing the wheel hub and brake drum, correct or replace
the brake drum.
27-15
• Remove the dust cover behind the anchor bracket.

• Release the spring brake by applying an air pressure of 640 kPa
{6.5 kgf/cm2} into the spring brake air supply port in the brake
chamber.
• Using a flat-blade screwdriver or equivalent, turn the adjuster on
the expander in the direction of the arrow to increase the clear-
ance between the brake drum and shoe. Then, remove the
wheel hub and brake drum.
• Install the dust cover behind the anchor bracket.
CAUTION
• When using a flat-blade screwdriver to turn the adjuster,
take care not to damage the boots on the expander.
Removal: Inner bearing outer race

• Drive out the inner bearing outer race by tapping evenly at
notches in the wheel hub.
Removal: Outer bearing outer race

• Drive out the outer bearing outer race by tapping it evenly at
notches in the wheel hub.
Removal: Inner bearing inner race and oil seal retainer
27-16
27
Inspection procedure
Inspection: Axle shaft
• Perform the following inspection. If the measurement is out of
the standard value, replace the axle shaft.
(1) Bend at shaft center
• Give the axle shaft one complete turn and read the dial gauge at
this time. The bend is one half of the reading.
(2) Lateral runout at flange face
Inspection: Outer bearing inner race

• Inspect the outer bearing inner race after cleaning the bearing to
remove grease completely.
• If any damage, wear, or poor rotating condition is evident in the
inner race, replace it with a new one.
• The inner race and the outer race should be replaced as a set.
Inspection: Wheel hub

(1) Visual inspection
• Check the disc wheel mounting surface of the wheel hub by
watching and touching. If there is damage or crack on it, replace
the wheel hub.
• Make sure that there is not rust, dust, paint or foreign body on
the disc wheel mounting surface of the wheel hub to prevent the
wheel nut to loosen.
• If any abnormality is found, remove it with sandpaper.
(2) Wear in disc wheel mounting part of wheel hub
• Clean the wheel mounting surface of the wheel hub before in-
spection.
• Place a straight edge on the hub so as to contact to the two hub
bolts on the disc wheel mounting surface.
CAUTION
• Make sure that the straight edge does not run onto the hub
bolt.
• Using feeler gauges to measure the amount of wear at the outer

periphery of the wheel hub.
Measure the amount of wear in the area of every hub bolt.
• If the amount of wear at any point exceeds the following stan-
dard value, inspect the crack check of wheel hub.
Wear standard value: 0.8 mm
27-17
(3) Crack check
• Check if there is not crack on the entire rounded corner on the
root of flange of the wheel hub by magnetic particle or liquid pen-
etrant testing. If crack is found, replace the wheel hub.
• If crack is found on the wheel hub bolt, replace it.
• If there is crack or stepped wear on the wheel hub mounting sur-
face of wheel disc, replace it. (See Gr31.)
Inspection: Inner bearing inner race

• Inspect the inner bearing inner race in the same manner as for
the outer bearing inner race.
(See “ Inspection: Outer bearing inner race”.)
Inspection: Axle housing

• If the lock nut tightening threads (A) are damaged, repair the
damage using a tap to ensure accurate adjustment of starting
torque.
• Replace the axle housing if it apparently has stepped, tapered,
uneven or other abnormal wear or damage in the outer bearing
fitting surface (B).
Installation procedure
Installation: Oil seal
• Install the oil seal evenly along its periphery against the end of
the wheel hub.
Installation: Oil seal retainer

• Install the oil seal retainer until it bottoms out.
27-18
27
Installation: Packing grease in inner bearing inner race
• Insert the grease pump nozzle into the space between rollers of
the inner bearing inner race to pack grease sufficiently.
Installation: Inner bearing inner race

• With the inner bearing inner race press-fitted, ensure that the
clearance between the inner race and the oil seal retainer is as
shown in the illustration.
Installation: Hub bolts

• As for hub bolt, tighten nut at specified torque, and caulk at 4 po-
sitions for prevention of loosening.
Installation: Outer bearing outer race
Installation: Inner bearing outer race
27-19
Installation: Packing of grease to inside of wheel hub
CAUTION
• Wheel bearing seized may be caused unless following
these manners.
• Pack the specific amount of grease measured by measure-
ment cup or etc.
• As shown in the illustrations at the left, fill grease inside of the

hub body in such a manner that grease covers the outer bearing
and inner bearing outer races. Make sure that grease reaches
the outer bearing and inner bearing.
Installation: Packing grease in outer bearing inner race

• Follow the same procedure as for packing the inner bearing in-
ner race with grease.
(See “ Installation: Packing grease in inner bearing inner
race”.)
Adjustment: Wheel hub bearing starting torque

[Adjustment]
• Install the lock washer and lock nut.
• Rotate the wheel hub and brake drum at lease three turns to let
the outer and inner bearings settle in.
• Tighten the lock nut to the specified torque.
• Loosen the lock nut until there is clearance between the lock nut
and lock washer.
• Perform the following work to pull the outer bearing inner race
toward the lock nut side.
• While rotating the wheel hub and brake drum, tap the end of the
axle tube a couple of times.
27-20
27
• Tighten lock nut at specified torque, and after it, return to the
loosening direction as shown at by the amount of 22.5° (1/16
turn).
( : If the result is not satisfactory by tangential measurement,
which will be explained at a later section, repeat the opera-
tion from here.)
• Fit lock plate into place check to ensure that all of the mounting
holes in lock nut and the lock plate are in alignment, and tighten
mounting bolts to the specified torque.
• If the mounting holes of lock nut and lock plate are out of align-
ment, align them by the procedures shown in the following table.
Lock nut hole position How to align lock plate hole
Range A Loosen lock nut and align holes.
Turn over lock plate, loosen lock nut and align
Range B
holes.
Turn over lock plate and align holes. (Hole po-
On line C-C
sition changes from D´ to D.)
• Perform the following work to pull the outer bearing inner race
toward the lock nut side again.
• While rotating the wheel hub and brake drum, tap the end of the
axle tube a couple of times.
[Inspection]
• After adjustment, install a spring balance around the hub bolts to
measure the tangential force.
• If the tangential force meets the specified value, starting torque
will become the standard value.
• If the measured tangential force does not meet the standard val-
ue, re-adjust the starting torque.
• If tangential force deviates from the nominal value, repeat the
operation from the item after.
• If then the result is not satisfactory, replace outer bearings and
inner bearings.
27-21
NOTE
• The starting torque must be measured with the oil seal in-
stalled.
• When taking measurements, ensure that there is no drag
between the brake lining and drum.
Installation: Brake hose

• To install the brake hose, follow the removal procedure in re-
verse. (See “ Removal: Brake hose”.)
• After installing, make sure that the brake hose does not interfere
in the peripheral parts.
CAUTION
• Make sure that the brake hose is not twisted when you in-
stall it.
Installation: Wheel speed sensor harnesses

• Clip the harnesses onto the axle housing, starting from the
wheel brakes and along the housing. Ensure that the harnesses
are free from interference with other parts, looseness, or kinks.
• Bundle the harnesses of the left- and right-hand wheel speed
sensors into a corrugated tube.
• Arrange the corrugated tube such that the white-tape portions of
the tube are aligned with the clips on the housing. With the tube
correctly arranged, face the slit of the corrugated tube down, and
wrap both ends of the tube with black tape (designed for har-
ness bundling) in a half lap pattern.
• Additionally wrap the tube with tape at three locations in the tube
intermediate section of the wheel speed sensor.
27-22
27
M E M O
27-23
AXLE HOUSING <REAR AXLE, REAR 2ND AXLE>
27-24
27
Removal sequence
1 Inspection plug 9 Shim <FS, FV51>
2 Drain plug 10 Spring plate <FS, FV51>
3 Brake hose (for spring brake) 11 Axle housing
4 Brake hose (for service brake)
5
6
Brake hose (for breather)
Connector
*a:: Propeller shaft
Locating pin
7 Reduction and differential (See later section.) : Non-reusable parts
8 Spring seat <FS, FV51>
• The suspension parts around the axle housing must be removed. (See Gr34.)
Installation sequence
Follow the removal sequence in reverse.
NOTE
• Do not let sealant ooze from the mounting surfaces of reduction and differential.

8 Spring seat thickness – 10.0 Replace
10 Spring plate thickness – 2.0 Replace
On board 0 to 0.2 2.5
11 Axle housing bend Replace
Off board 0 4

Inspection plug –
110 ± 10 {11 ± 1}
Drain plug –
Nut (spring seat mounting) 170 ± 20 {17 ± 2} –
Brake hose (for spring brake) mounting (frame side) 39 to 44 {4.0 to 4.5} –
Brake hose (for service brake) mounting (frame side) 69 to 74 {7.0 to 7.5} –
Brake hose (for breather) mounting (frame side) 29 to 39 {3.0 to 4.0} –
P10 120 to 180 {12 to 18}
Nut (propeller shaft mounting) P12 180 to 250 {18 to 26} –
P152 135 to 185 {13.8 to 18.8}
Bolt (reduction and differential mounting) 175 to 237 {17.9 to 24.2} –

Connecting surfaces of reduction and differential assem-
ThreeBond 1215 As required
bly and axle housing

Measuring bar
Measures bend of axle housing: Two
A B C D MH061003
required
30 130 φ3.5 20
27-25
Inspection before removal
Inspection: Companion flange play
• If there is play in the back-and-forth, up and down, right-and-left
and rotated direction, replace all the parts below.
• Inner bearing, outer bearing and pinion pilot bearing
• Pinion collar
• Reduction gear set (reduction pinion and gear)
• Companion flange
Removal procedure
Removal: Brake hoses
• When removing the brake hoses, disconnect them from the
frame side first, and then from the axle housing side.
Removal: Reduction and differential

• Make two jacking bolts (M14 × 1.5 mm) available.
• Install and tighten the bolts evenly into the jacking holes in the
reduction and differential.
• Jack away and remove the reduction and differential from the
axle housing.
• Remove adhered sealant from the mounting surfaces of reduc-
tion differential assembly and axle housing.
27-26
27
Inspection: Spring seat
[Inspection]
(1) Spring seat thickness
• If the measured value is equal to or less than the limit, replace
the spring seat.
• Replace the spring seat if it has cracks, fractures or localized ab-
normal wear.
Replacement of spring seat

[Installation]
• Clean the mounting surfaces of the spring seat and axle hous-
ing.
• Place the spring seat on the axle housing. Thread the bolts from
above.
• Using a feeler gauge, measure the clearance between the axle
housing and spring seat at the four mounting bolts. Insert an ap-
propriate shim pack that achieves the specified clearance L after
shim installation.
Available shim size: 0.2 mm, 0.5 mm, 1.0 mm
• Tighten the nuts to the specified torque while ensuring that there
is no play in the shim pack.
Inspection: Spring plate

[Inspection]
(1) Spring plate thickness
the spring plate.
• Replace the spring plate if it has cracks, fractures or localized
abnormal wear.
Replacement of spring plate

[Removal]
• Remove the spring plate by breaking the weld bead while taking
care not to damage the axle housing.
[Installation]
• Completely drain the gear oil and degrease the area before
welding the spring seat.
27-27
Inspection: Bend of axle housing
(1) On board
• Install axle shaft in axle housing.
• Install on axle shaft.
• Measure clearance A.
• Turn axle shaft 180°.
• Measure clearance B.
• The difference between A and B is the amount of bend of axle
housing.
• If the measurement exceeds the limit, replace the axle housing.
(2) Off board
• Support the axle housing at the outer bearing fitting surfaces on
both ends. Then, measure the height of the locating pin.
• Turn the axle housing 180°.
• Measure the height of the locating pin. The difference between
the two heights is the amount of bend of the axle housing.
• If the difference is equal to or exceeds the limit, replace the axle
housing.
• While turning the axle housing 180°, read the total reading of a
dial gauge installed. A half of the total reading corresponds to
the bend of the axle housing.
Installation: Brake hose
CAUTION
stall it.
27-28
27
M E M O
27-29
AXLE HOUSING <REAR 1ST AXLE>
Removal sequence
1 Grease plug 11 Gasket 21 Reduction and differential
2 Inspection plug 12 Washer <P10> (See later section.)
3 Drain plug 13 Companion flange 22 Spring seat
4 Drain plug 14 Dust cover 23 Shim
5 Brake hose (for spring brake) 15 Oil seal 24 Spring plate
6 Brake hose (for breather) 16 Stopper bolt 25 Axle housing
7 Brake hose (for service brake) 17 Snap ring
8 Connector 18 Housing cover sleeve
*a: Propeller shaft
9 Air hose 19 Output bearing : Locating pin
10 Lockout cylinder 20 Through shaft : Non-reusable parts
(See later section.)
• The suspension parts around the axle housing must be removed. (See Gr34.)
Installation sequence
Follow the removal sequence in reverse.
NOTE
• Do not let sealant ooze from the mounting surfaces of reduction and differential.

11 to 14 N·m
Inter-differential total starting torque (when fully en- {1.1 to 1.4 kgf·m}
– – Adjust
gaged) (tangential force: 122 to
155 N {12.5 to 15.8 kgf}))
19 Play in radial direction of output bearing – 0.2 Replace
20 Through shaft bent 0 to 0.6 1.0 Rectify or replace
22 Spring seat thickness – 10.0 Replace
24 Spring plate thickness – 2.0 Replace
Bend of axle On board 0 to 0.2 2.5
25 Replace
housing Off board 0 4
27-30
27
Inspection plug –
110 ± 10 {11 ± 1}
Drain plug –
Brake hose (for spring brake) mounting (frame side) 39 to 44 {4.0 to 4.5} –
Bolt (spring brake connector mounting) 86 {8.8} –
Bolt (service brake connector mounting) 206 {21} –
Air hose mounting (frame side) 30 to 39 {3 to 4} –
Bolt (lockout cylinder mounting) 78 {8.0} –
Nut (spring seat mounting) 170 ± 20 {17 ± 2} –
P140 (M) 120 to 180 {12 to 18} –
Nut (propeller shaft mounting)
P152 135 to 185 {13.8 to 18.8} –
P10 542 to 733 {55.3 to 74.8} M33 × 1.5
Lock nut (companion flange mounting)
P12 578 to 774 {59.0 to 79.0} M36 × 1.5
Lock nut (stopper bolt mounting) 31 to 38 {3.2 to 3.9} –
Bolt (reduction and differential mounting) 175 to 237 {17.9 to 24.2} –
Brake hose (for breather) mounting (frame side) 29 to 39 {3.0 to 4.0} –
Brake hose (for service brake) mounting (frame side) 69 to 74 {7.0 to 7.5} –

Chassis grease
Lip area of oil seal As required
[NLGI No.1 (Li soap)]
Outer periphery of oil seal ThreeBond 1102 As required
Axle housing mounting surface of reduction and differen-
tial

Oil seal installer
A B MH062622 Installation of oil seal

φ140 φ65
Measuring bar
Measures bend of axle housing: Two
A B C D MH061003
required
30 130 φ3.5 20
Gear puller MH062587 Removal of companion flange
27-31
Inspection: Play of companion flange on front side
• If there is play in the back-and-forth, up-and-down, right-and-left
• Inter differential case set (inter differential inner case and inter
differential outer case)
• Input bearing
Inspection: Play of companion flange on rear side

• If there is play in the back-and-forth, up-and-down, right-and-left
• Through shaft
• Output bearing
Inspection: Inter-differential total starting torque (when fully

engaged)
• With a spring balance installed onto one of the companion
flange bolt holes, measure the tangential force. If the tangential
force meets the specified value, the starting torque will also
meet the specified value.
If the measurement deviates from the standard value, adjust.
Removal procedure
Draining: Gear oil
• Remove the grease plugs, inspection plug and drain plugs to
drain the gear oil.
WARNING
• The gear oil is hot for a while after driving the vehicle. Take
care not to suffer burns.
27-32
27
Removal: Brake hoses
• When removing the brake hoses, disconnect them from the
frame side first, and then from the axle side.
Removal: Air hose

• When removing the air hose, disconnect the frame side first and
then disconnect the axle housing side.
Removal: Companion flange
Removal: Through shaft

• Before removing the through shaft, engage the differential lock
clutch of the reduction and differential by moving it in the direc-
tion of the arrow in the illustration. This will prevent the clutch
from falling when removing the through shaft.
Removal: Reduction and differential

reduction and differential.
• Jack away and remove the reduction and differential from the
axle housing.
• Remove adhered sealant from the mounting surfaces of reduc-
tion differential assembly and axle housing.
27-33
Inspection: Play in radial direction of output bearing
• Install the output bearing to the through shaft.
• Hold the through shaft and measure the play with moving the
output bearing in radial direction.
• If the measured value exceeds the limit, replace the output bear-
ing.
Inspection: Through shaft bent

• Measure the through shaft at the center for bend. If the mea-
surement exceeds the limit, correct or replace the shaft.
• While rotating the through shaft by one revolution, read how
much the dial gauge needle will move. A half of the reading ob-
served represents the bend, if any, of the shaft.
Inspection: Spring seat

[Inspection]
(1) Spring seat thickness
the spring seat.
• Replace the spring seat if it has cracks, fractures or localized ab-
normal wear.
Replacement of spring seat

[Installation]
• Clean the mounting surfaces of the spring seat and axle hous-
ing.
• Place the spring seat on the axle housing. Thread the bolts from
above.
• Using a feeler gauge, measure the clearance between the axle
housing and spring seat at the four mounting bolts. Insert an ap-
propriate shim pack that achieves the specified clearance L after
shim installation.
Available shim size: 0.2 mm, 0.5 mm, 1.0 mm
• Tighten the nuts to the specified torque while ensuring that there
is no play in the shim pack.
27-34
27
Inspection: Spring plate
[Inspection]
(1) Spring plate thickness
the spring plate.
• Replace the spring plate if it has cracks, fractures or localized
abnormal wear.
Replacement of spring plate

[Removal]
• Remove the spring plate by breaking the weld bead while taking
care not to damage the axle housing.
[Installation]
• Completely drain the gear oil and degrease the area before
welding the spring seat.
Inspection: Bend of axle housing

(1) On board
• Install axle shaft in axle housing.
• Install on axle shaft.
• Measure clearance A.
• Turn axle shaft 180°.
• Measure clearance B.
• The difference between A and B is the amount of bend of axle
housing.
• If the measurement exceeds the limit, replace the axle housing.
(2) Off board

• Support the axle housing at the outer bearing fitting surfaces on
both ends. Then, measure the height of the locating pin.
• Turn the axle housing 180°.
• Measure the height of the locating pin. The difference between
the two heights is the amount of bend of the axle housing.
• If the difference is equal to or exceeds the limit, replace the axle
housing.
• While turning the axle housing 180°, read the total reading of a
dial gauge installed. A half of the total reading corresponds to
the bend of the axle housing.
Installation: Stopper bolt, lock nut
• Install the cover sleeve and snap ring onto the axle housing.
Then, screw in the stopper bolt by hand until it is slightly against
the bottom of the groove on the cover sleeve. Back off the bolt
by 1/4 of a turn before securing it with the lock nut.
27-35
• Apply sealant to the outer periphery A of the oil seal before
press-fitting it using .
Installation: Companion flange

[Heating]
• Heat the companion flange following in either of manners below
so that the companion flange becomes 140°C.
<Use of oven>
• Heat the companion flange at the set temperature 140°C for 30
minutes or more.
<Use of ring heater>
• Reheat the companion several times at the set temperature
140°C so that the entire companion flange becomes 140°C.
• Set the thermometer at not flange but boss.
CAUTION
• Heat the companion flange several times because heating
once is not enough thermal expansion for the companion
flange.
<Use of oil bath>

• Heat the gear oil to 140°C and put the companion flange in the
direction as illustrated in the bath.
• Putting it in the bath causes the gear oil to fall. So reheat the oil
to 140°C and heat the companion flange for 20 minutes or more
keeping 140°C.
CAUTION
• Put the companion flange in the bath with facing the boss of
the companion flange upward because facing the boss
downward makes the boss touch the heat source directly
and become 140°C or more.
[Installation]
• Press-fit the headed companion flange onto the through shaft.
WARNING
• Take care not to burn your hand when installing the com-
panion flange onto the through shaft because the compan-
ion flange is heated.
• Install bolts in to prevent from sliding off and hold with

a vise as illustrated.
• Install to the companion flange. Tighten the lock nut to the
lower end of the specified torque range. Then, further tighten the
lock nut within the specified torque range until the pin holes are
aligned. Install the split pin as illustrated. If the pin holes cannot
be aligned by tightening the lock nut within the specified torque
range, replace the lock nut.
27-36
27
WARNING
panion flange onto the through shaft because the compan-
ion flange is heated.
Installation: Air hoses

• To install the air hose, follow the removal procedure in reverse.
(See “ Removal: Air hose”.)
• After installing, make sure that the air hose does not interferes in
the peripheral parts.
CAUTION
• Make sure that the air hose is not twisted when you install
it.
Installation: Brake hoses

CAUTION
stall it.
Work after installation

Inspection: Reduction and differential
• Carry out the same inspections that were performed during re-
moval. If the measurements do not conform to the standard val-
ues, carry out relevant inspections and adjustments again.
(See “ Inspection: Companion flange vertical play”, and “
Inspection: Inter-differential total starting torque (when fully
engaged)”.)
Filling oil: Gear oil

• Fill in the specified quantity of gear oil through the grease and in-
spection plugs.
27-37
Lockout Cylinder
1 Lid
2 O-ring
3 Rod
4 Washer
5 Collar
6 Spring
7 Shift fork
8 O-ring
9 O-ring
10 Piston
11 Housing
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
Repair kit: Lockout cylinder kit

Bolt (lid mounting) 22 {2.2} –

Bolt threads Loctite 262 As required
Outer and inner peripheries of piston Multipurpose type grease
As required
Sliding surface of housing (φ50 mm portion) [NLGI No.2 (Li soap)]
27-38
27
M E M O
27-39
REDUCTION AND DIFFERENTIAL <D10H, D12H>
1 Lock sheet 6 Side bearing outer race 11 Shim
2 Lock pawl 7 Side bearing inner race 12 Differential carrier
3 Adjusting screw 8 Differential (See later section.)
4 Lock plate 9 Pinion (See later section.) : Non-reusable parts
5 Bearing cap 10 O-ring
CAUTION
• Be sure to replace the bearing cap, differential carrier and bolts as a differential carrier set.
• Be sure to replace the reduction gear of the differential and reduction pinion of the pinion as a reduction
gear set.
• Keep side bearings that have been removed separated from each other and ensure that during installation each
one is correctly placed.
• Record the number and thickness of shims to use them as reference at assembly.
27-40
27
Assembly sequence
CAUTION
• The O-ring must be installed without twist or damage.

2.5 to 3.4 N·m
6, 7 Starting torque of side bearing – Adjust
{0.25 to 0.35 kgf·m}
8 Wobble at back face of reduction gear 0 to 0.15 0.2 Replace
8, 9 Backlash between reduction gear and reduction pinion 0.25 to 0.33 0.6 Adjust or replace

Bolt (lock pawl mounting) 27 to 41 {2.8 to 4.2} –
D10H 379 to 513 {38.7 to 52.3}
Bolt (bearing cap mounting) –
D12H 417 to 564 {42.5 to 57.5}
D10H 94 to 141 {9.6 to 14.4}
Bolt (pinion mounting) –
D12H 163 to 220 {16.6 to 22.4}

Pinion pilot bearing mounting surface of differential
carrier
Fitting surface of pinion with differential carrier Gear oil
As required
O-ring (GL-5 SAE80W-90)

Side bearing installer

<D10H>
A B 03724-53000
Installation of side bearing inner race
D10H φ100 φ90.5 <D12H>
03724-54000
D12H φ108 φ95.5
Bearing retainer guide pin

<D10H>
MH061746 Installation of pinion
<D12H> (two pieces are used)
MH062166
A B C D
D10H 23 M14 × 1.5 95 12
D12H 23 M16 × 1.5 95 12
27-41
Bearing retainer
remover
<D10H> Removal of pinion
A B MH062172 (two pieces are used)
68 M14 × 1.5
Work before removal

Alignment marks: Bearing cap and differential carrier
• Put alignment marks on the bearing cap and differential carrier
for correct identification of right and left parts.
Removal procedure
Removal: Side bearing inner race
Removal: Pinion
<D10H>
• Install two at diagonal locations.
• Install and tighten evenly into the jacking holes in the pin-
ion.
• Jack away and remove the pinion from the differential carrier.
<D12H>
• Install two at diagonal locations.
pinion.
27-42
27
Selection: Shim
• Calculate shim thickness by using the following formula based
on the machining error data stamped on pinion and differential
carrier.
• Formula: Shim thickness = 0.5 – a + b + 0.2
a: 1/100 of numeral stamped on outer periphery of flange of dif-
ferential carrier flange
b: Numeral stamped on top of pinion
• Select the shim(s) based on the calculated shim thickness.
Thickness of shims available: 0.1 and 0.2 mm (2 types)
Installation: Pinion
• Apply sealant to the pilot bearing mounting surface of the differ-
ential carrier.
• Apply gear oil to the fitting surfaces of the pinion and differential
carrier.
• Aligning the embossed alignment mark on the bearing retainer
of the pinion assembly with that on the differential carrier, mount
the pinion assembly.
Bearing retainer Differential carrier
mark mark
• Leave for 30 minutes to 2 hours after installation to let the seal-

ant harden.
• Wait at least three hours or, if feasible, 24 hours before running
the vehicle to let the sealant harden.
Inspection: Starting torque of pinion bearing

• The starting torque of the pinion in single unit should be the
standard value.
• With the pinion installed, measure the starting torque of the pin-
ion bearing using a torque wrench installed at the pinion.
• Record the measured starting torque for reference when the
starting torque of the side bearing is calculated.
27-43
Installation: Side bearing inner race

Adjustment: Backlash between reduction gear and reduc-
tion pinion
• Adjust by means of the right- and left-hand adjusting screws, as
long as the side bearing starting torque is not altered.
• When one side bearing nut is loosened, be sure to tighten the
other one by the same amount to prevent the side bearing start-
ing torque from changing.
Inspection: Wobble at back face of reduction gear

• Measure at positions in the table below from the center of the re-
duction gear.
Radius
D10H R200 mm
D12H R270 mm
Inspection: Tooth contact of reduction gear

[Inspection]
• Apply red lead to three to four teeth at three equally spaced
points of the reduction gear.
• Give the reduction gear several turns to check for tooth contact.
Tooth contact off-center to the small end side under no load
comes to the center under load.
• Adjust tooth contact if it is remarkably offset.
27-44
27
[Adjustment]
• Optimize tooth contact by increasing or decreasing shim thick-
ness or adjusting backlash between reduction gear and reduc-
tion pinion (using side bearing nut).
CAUTION
• If teeth are abnormally worn or tooth contact is excessively
concentrated at the large end or small end side, always re-
place both the reduction gear and reduction pinion as a re-
duction gear set.
Tooth contact on reduction gear Adjustment procedure

Concentrated at addendum Advance reduction pinion to reduction gear
(shims are reduced)
Concentrated at dedendum Retard reduction pinion from reduction gear

(shims are added)
Concentrated at large end side Advance reduction gear to reduction pinion center
(less backlash)
Concentrated at small end side Retard reduction gear from reduction pinion center
(more backlash)
27-45
Inspection: Starting torque of side bearing
[Inspection]
• Measure total starting torque of the pinion assembly using a
torque wrench and calculate the starting torque of the side bear-
ing using the following formula. Pinion bearing starting torque is
the value obtained at earlier measurement of pinion bearing
starting torque.
(Total starting torque – Starting torque of the pinion bearing) × Fi-
nal ratio = Starting torque of side bearing
• If the calculated value of side bearing starting torque deviates
from the standard value, adjust.
[Adjustment]
• Adjust by means of the right- and left-hand adjusting screws.
• Always adjust both adjusting screws by the same amount.
• The starting torque must be adjusted without causing the back-
lash between the reduction gear and reduction pinion out of the
standard value.
27-46
27
M E M O
27-47
Pinion
1 Washer <P10> 7 Pinion pilot bearing 13 Inner bearing outer race
2 Companion flange 8 Reduction pinion 14 Bearing retainer
3 Dust cover 9 Inner bearing inner race
4 Oil seal 10 Pinion bearing collar : Non-reusable parts
5 Pinion bearing collar <P10> 11 Outer bearing inner race
6 Lock ring 12 Outer bearing outer race
• Record the height of the pinion bearing collar to use it as reference at assembly.
Assembly sequence
Follow the disassembly sequence in reverse except:
12 → 8 → 7 → 6 → 9 → 10 → 11 → 5
27-48
27
2.5 to 3.4 N·m
{0.25 to 0.35 kgf·m}
D10H
(tangential force: 27 to
When new 38 N {2.8 to 3.9 kgf})
bearing is
used 2.5 to 3.4 N·m
{0.25 to 0.35 kgf·m}
D12H
Starting torque of 29 N {2.2 to 3.0 kgf})
– – Adjust or replace
pinion bearing 2.0 to 2.7 N·m
{0.20 to 0.35 kgf·m}
D10H
When old 30 N {2.2 to 3.1 kgf})
bearing is re-
used 2.0 to 2.7 N·m
{0.20 to 0.35 kgf·m}
D12H
24 N {1.7 to 2.4 kgf})
7 Play in radial direction of pinion pilot bearing – 0.2 Replace

Lock nut (companion flange mounting) 578 to 774 {59.0 to 79.0} –

Lip area of oil seal Chassis grease [NLGI No.1 (Li soap)] As required

Oil seal installer

φ170 φ134
Pinion pilot bearing

installer
<D10H>
A B 03724-50001
Installation of pinion pilot bearing
<D12H>
D10H φ69 φ58.5 MH062165
D12H φ70.5 φ62.5
Pinion inner bearing

installer
<D10H>
A B C MH061004
Installation of outer bearing inner race
<D12H>
D10H φ70 φ58 170 03724-51000
D12H φ85 φ65 180
Pinion outer bearing

installer
<D10H>
A B 03724-55000 Installation of outer bearing outer
<D12H> race
D10H φ129 φ123 03724-56000
D12H φ139 φ132
27-49

installer
<D10H>
A B 03724-56000
Installation of inner bearing outer race
<D12H>
D10H φ139 φ132 03724-33000
D12H φ159 φ149

installer
<D10H>
A B C 03724-51000
Installation of inner bearing inner race
<D12H>
D10H φ85 φ65 180 03724-52000
D12H φ90 φ74 240
Mounting plate MK503727 Installation of lock nut
27-50
27
Inspection: Play in radial direction of pinion pilot bearing
• Hold the pinion and measure the play with moving the pinion pi-
lot bearing in radial direction.
• If the measured value exceeds the limit, replace the pinion pilot
bearing.
Removal procedure
Removal: Reduction pinion

• Drive out the outer bearing outer race by tapping evenly at
notches in bearing retainer.
27-51
Installation: Pinion pilot bearing

• Install the pinion pilot bearing ensuring that it faces correctly as
illustrated.
27-52
27
Installation: Outer bearing inner race
• Install the outer bearing inner race with the pinion assembled
into the bearing retainer.

[Inspection]
• With the lock ring installed, temporarily assemble to apply
the specified load.
• The starting torque must be measured without the oil seal in-
stalled.
• With a spring balance installed, measure the tangential force at
the periphery of the bearing retainer.
• Firmly install before measuring the starting torque.
Diameter of bearing retainer
D10H φ180 mm
D12H φ230 mm
• If the tangential force meets the specified value, the starting
torque will also meet the specified value.
• If the measurement deviates from the specified value, adjust the
tangential force.
[Adjustment]
• Select an appropriate pinion bearing collar from the table below
to bring the tangential force to the standard value.
Thickness of collar
17.475 to 18.075 mm
D10H
(25 sizes in 0.025 mm increments)
17.975 to 18.575 mm
D12H
27-53
• Apply grease to the lip area of the oil seal and install it on the
bearing retainer in the illustrated direction.

[Heating]
<Use of oven>
minutes or more.
CAUTION
flange.
<Use of oil bath>

keeping 140°C.
CAUTION
27-54
27
[Installation]
• Press-fit the headed companion flange onto the reduction pin-
ion.
WARNING
panion flange onto the reduction pinion because the com-
panion flange is heated.

WARNING
panion flange onto the reduction pinion because the com-
panion flange is heated.
27-55
REDUCTION AND DIFFERENTIAL <D10HT>
1 Lock sheet 10 Inter-differential 17 Helical inner bearing
2 Lock pawl (See later section.) inner race
3 Adjusting screw 11 Bearing retainer 18 Helical inner bearing
4 Lock plate 12 O-ring outer race
5 Bearing cap 13 Helical outer bearing 19 Differential carrier cover
6 Side bearing outer race outer race 20 Pinion (See later section.)
7 Side bearing inner race 14 Shim 21 Shim
8 Differential 15 Helical outer bearing 22 Differential carrier
(See later section.) inner race
9 Differential lock clutch 16 Drive helical gear : Locating pin
: Non-reusable parts
CAUTION
• Be sure to replace the bearing cap, differential carrier and bolts as a differential carrier set.
• Be sure to replace the reduction gear of the differential and reduction pinion of the pinion as a reduction
gear set.
• Keep side bearings that have been removed separated from each other and ensure that during installation each
one is correctly placed.
• Record the number and thickness of shims to use them as reference at assembly.
Assembly sequence
CAUTION
• The O-ring must be installed without twist or damage.
27-56
27
2.5 to 3.4 N·m
6, 7 Starting torque of side bearing – Adjust
{0.25 to 0.35 kgf·m}
8 Wobble at back face of reduction gear 0 to 0.15 0.2 Adjust or replace
8, 20 Backlash between reduction gear and reduction pinion 0.30 to 0.41 0.6 Adjust or replace
Clearance between differential lock clutch groove and
9 1.2 to 1.4 2.0 Replace
lockout cylinder shift fork
2.5 to 3.4 N·m
Starting torque of drive helical gear
13, 15 {0.25 to 0.35 kgf·m}
(represented by tangential force at drive helical gear pe- – Adjust
17, 18 (tangential force: 70 to
riphery)
98 N {7.1 to 10 kgf})

Bolt (lock pawl mounting) 27 to 41 {2.8 to 4.2} –
Bolt (bearing cap mounting) 379 to 513 {38.7 to 52.3} –
Bolt (inter-differential mounting) 86 {8.8} –
Bolt (differential carrier cover mounting) 175 to 237 {17.9 to 24.2} –
Bolt (pinion mounting) 94 to 141 {9.6 to 14.4} –

Inter-differential surface where bearing retainer is to be
mounted
Apply in a circle on shim surface corresponding to the pe-
riphery of bearing retainer oil hole, and in a circle on shim
surface corresponding to the periphery of carrier cover oil
hole
Differential carrier cover surface where differential carrier
is to be mounted
Pinion pilot bearing mounting surface of differential carri-
er
Fitting surface of pinion with differential carrier Gear oil
As required
O-ring (GL-5 SAE80W-90)

Side bearing installer
A B 03724-53000 Installation of side bearing inner race

φ100 φ90.5
Bearing retainer guide pin
MH061746 Removal and installation of pinion

(two pieces are used)
A B C D
23 M14 × 1.5 95 12
27-57
Bearing retainer remover
A B Removal of pinion
MH062172
(two pieces are used)
68 M14 × 1.5
Work before removal

Alignment marks: Bearing cap and differential carrier
• Put alignment marks on the bearing cap and differential carrier
for correct identification of right and left parts.
Removal procedure
Removal: Side bearing inner race
Removal: Bearing retainer

• Install and tighten two jacking bolts (M12 × 1.25 mm) evenly into
as many jacking holes in the bearing retainer.
• Jack away and remove the bearing retainer from the differential
gear cover.
Removal: Differential carrier cover

• Install and tighten two jacking bolts (M12 × 1.25 mm) evenly into
as many jacking holes in the differential carrier cover.
• Jack away and remove the differential carrier cover from the dif-
ferential carrier.
27-58
27
Removal: Pinion
• Install at diagonal locations.
• Tighten evenly into the jacking holes in the pinion.
Inspection: Clearance between differential lock clutch
groove and lockout cylinder shift fork
• If the measurement is equal to or exceeds the limit, replace the
defective part(s).
Selection: Shim
• Calculate shim thickness by using the following formula based
on the machining error data stamped on pinion and differential
carrier.
• Formula: Shim thickness = 0.5 – a + b + 0.2
a: 1/100 of numeral stamped on outer periphery of flange of dif-
ferential carrier flange
b: Numeral stamped on top of pinion
• Select the shim(s) based on the calculated shim thickness.
Thickness of shims available: 0.1 and 0.2 mm (2 types)
27-59
Installation: Pinion
• Apply sealant to the pilot bearing mounting surface of the differ-
ential carrier.
• Apply gear oil to the fitting surfaces of the pinion and differential
carrier. Then, install the pinion.
• Leave for 30 minutes to 2 hours after installation to let the seal-
ant harden.
• Wait at least three hours or, if feasible, 24 hours before running
the vehicle to let the sealant harden.

• With the pinion installed, measure the starting torque of the pin-
ion bearing using a torque wrench installed at the pinion.
See “Pinion” later in this manual for the standard value.
• If the measured value deviates from the standard value, make
an adjust.
Inspection: Starting torque of drive helical gear

• With a shim pack measuring the standard thickness (0.5 mm) in-
stalled between the differential carrier cover and bearing retain-
er, measure an initial starting torque of the drive helical gear.
Based on the initial measurement, achieve the specified starting
torque by shimming.
Shim sizes available: 0.1 mm, 0.2 mm
• Secure the bearing retainer to the carrier cover by tightening bolt
(M12 × 35 mm) to the specified torque.
• Install a spring balance to the periphery of the drive helical gear,
and measure the tangential force.
• If the measurement deviates from the standard value, make an
adjustment. If the original bearings are reused after disassem-
bly, a starting torque measuring a minimum of 80% of the speci-
fied starting torque is acceptable. This is because the original
bearings have already settled in by then.
27-60
27
Installation: Shim
• Apply a light coat of sealant in a circle on the shim surface corre-
sponding to the periphery of the bearing retainer oil hole, and in
a circle on the shim surface corresponding to the periphery of
the carrier cover oil hole.
Installation: Side bearing inner race

Adjustment: Backlash between reduction gear and reduc-
tion pinion
• Adjust by means of the right- and left-hand adjusting screws, as
long as the side bearing starting torque is not altered.
• When one side bearing nut is loosened, be sure to tighten the
other one by the same amount to prevent the side bearing start-
ing torque from changing.
Inspection: Wobble at back face of reduction gear

• Measure at a position a radius of 200 mm from the center of the
reduction gear.
27-61
Inspection: Tooth contact of reduction gear
[Inspection]
• Apply red lead to three to four teeth at three equally spaced
points of the reduction gear.
• Give the reduction gear several turns to check for tooth contact.
Tooth contact off-center to the small end side under no load
comes to the center under load.
• Adjust tooth contact if it is remarkably offset.
27-62
27
[Adjustment]
• Optimize tooth contact by increasing or decreasing shim thick-
ness or adjusting backlash between reduction gear and reduc-
tion pinion (using side bearing nut).
CAUTION
• If teeth are abnormally worn or tooth contact is excessively
concentrated at the large end or small end side, always re-
place both the reduction gear and reduction pinion as a re-
duction gear set.
Tooth contact on reduction gear Adjustment procedure

Concentrated at addendum Advance reduction pinion to reduction gear
(shims are reduced)
Concentrated at dedendum Retard reduction pinion from reduction gear

(shims are added)
Concentrated at large end side Advance reduction gear to reduction pinion center
(less backlash)
Concentrated at small end side Retard reduction gear from reduction pinion center
(more backlash)
27-63
Inspection: Starting torque of side bearing
[Inspection]
• Measure total starting torque of the pinion assembly using a
torque wrench and calculate the starting torque of the side bear-
ing using the following formula. Pinion bearing starting torque is
the value obtained at earlier measurement of pinion bearing
starting torque.
(Total starting torque - Starting torque of the pinion bearing) × Fi-
nal ratio = Starting torque of side bearing
• If the calculated value of side bearing starting torque deviates
from the standard value, adjust.
[Adjustment]
• Adjust by means of the right- and left-hand adjusting screws.
• Always adjust both adjusting screws by the same amount.
• The starting torque must be adjusted without causing the back-
lash between the reduction gear and reduction pinion out of the
standard value.
27-64
27
M E M O
27-65
Inter-differential
1 Companion flange 7 Inter-differential inner gear 13 Inter-differential outer case
2 Dust cover 8 Inter-differential pinion washer 14 Snap ring
3 Oil pump 9 Inter-differential pinion 15 Input bearing
4 Inter-differential inner case 10 Inter-differential pinion spider 16 Oil seal
5 Inter-differential bushing 11 Inter-differential outer gear 17 Input cover
6 Inter-differential gear inner 12 Inter-differential gear outer
washer washer : Non-reusable parts
CAUTION
• Be sure to replace the inter-differential inner case and the inter-differential outer case as a inter-differen-
tial case set.
Assembly sequence

Clearance between inter-differential bushing and inter-
5, 7 0.07 to 0.19 0.5 Replace
differential inner gear
Backlash between inter-differential inner gear and
7 – 0.3 Replace
spline of drive helical gear splines
Backlash between inter-differential inner gear and inter-
7, 9 0.19 to 0.25 0.5 Replace
differential pinion
Clearance between inter-differential pinion and inter-dif-
9, 10 0.17 to 0.27 0.5 Replace
ferential pinion spider
Backlash between inter-differential pinion and inter-dif-
9, 11 0.19 to 0.25 0.5 Replace
ferential outer gear
15 Play in radial direction of input bearing – 0.2 Replace
27-66
27
Gear ratio 3.454 1000 to 1342 {102.0 to 137.0} M42 × 1.5
Lock nut (companion flange)
Gear ratio 4.222, 6.666 578 to 774 {59.0 to 79.0} M36 × 1.5
Bolt (inter-differential outer case mounting) 98 {10.0} –

Oil pump surface coming into contact with inter-differen-
ThreeBond 1215 Approx. 5 g
tial inner case
Lip area of oil seal Chassis grease [NLGI No.1 (Li soap)] As required

Oil pump installer
A B C D MH062623 Installation of oil pump

φ70 φ77 φ140 φ204
Oil seal installer

φ114 φ80
Mounting plate MK503727 Installation of lock nut
27-67
Removal procedure
Inspection: Backlash between inter-differential inner gear
and drive helical gear splines
• If the measurement exceeds the limit, replace the defective
part(s).
Inspection: Backlash between inter-differential inner gear

and inter-differential pinion
• If the measurement exceeds the limit, replace the inter-differen-
tial gear inner washer.
Inspection: Backlash between inter-differential pinion and

inter-differential outer gear
• If the measurement exceeds the limit, replace the inter-differen-
tial gear outer washer.
Inspection: Play in radial direction of input bearing

• Install the input bearing on the inter-differential outer case.
• Hold the inter-differential outer case and measure the play with
moving input bearing in radial direction.
• If the measured value exceeds the limit, replace the input bear-
ing.
27-68
27
Installation: Oil pump

• Ensure that the line between the raised locating marks on the oil
pump is at approximately 15° relative to the vertical line as
shown in the illustration.
• Apply sealant onto the surface of the oil pump that comes into
contact with the inter-differential inner case.
• Using , press-fit the oil pump into the inter-differential inner

case and input cover.
• Press-fit until the portion B of is against the end face A of
the inter-differential inner case.
CAUTION
• The press-fitting load must not exceed 98 kN {10000 kgf}.
• With the oil pump installed, carry out the following checks.
• Ensure that the oil pump has been installed evenly around the
inner and outer peripheries and visually presents no abnor-
malities.
• With the pump, the inner case and the input cover standing as
shown in the illustration, measure the gap C between the radi-
al points D. Measure the gap along the entire circumference
of the pump. The gap C must be between 3.5 and 4.1 mm.
27-69
[Heating]
<Use of oven>
minutes or more.
CAUTION
flange.
<Use of oil bath>

keeping 140°C.
CAUTION
[Installation]
• Press-fit the headed companion flange onto the inter-differential
outer case.
WARNING
panion flange onto the inter-differential outer case because
the companion flange is heated.

WARNING
panion flange onto the inter-differential outer case because
the companion flange is heated.
27-70
27
M E M O
27-71
Pinion
1 Driven helical gear 5 Inner bearing inner race 9 Inner bearing outer race
2 Lock ring 6 Pinion bearing collar 10 Bearing retainer
3 Pinion pilot bearing 7 Outer bearing inner race
4 Reduction pinion 8 Outer bearing outer race : Non-reusable parts
• Record the height of the pinion bearing collar to use it as reference at assembly.
Assembly sequence
Service standards
2.5 to 3.4 N·m
{0.25 to 0.35 kgf·m}
When new bearing is used
Starting torque of pinion 38 N {2.8 to 3.9 kgf})
5, 7, 8, 9 – Adjust
bearing 2.0 to 2.7 N·m
When old bearing is re- {0.20 to 0.28 kgf·m}
used (tangential force: 22 to
30 N {2.2 to 3.1 kgf})

Lock nut (driven helical gear mounting) 578 to 774 {59.0 to 79.0} –
27-72
27
Pinion pilot bearing

installer
A B 03724-50001 Installation of pinion pilot bearing

φ69 φ58.5

installer
A B C 03724-51000 Installation of inner bearing inner race
φ85 φ65 180
Pinion bearing installer
A B Installation of outer bearing outer

03724-55000
race
φ129 φ123

installer
A B 03724-56000 Installation of inner bearing outer race
φ139 φ132
Pinion outer bearing in-

staller
A B C 03724-51000 Installation of outer bearing inner race

φ85 φ65 180
27-73
Removal procedure
Removal: Reduction pinion

• Drive out the outer bearing outer race by tapping evenly at

27-74
27
Installation: Pinion pilot bearing

• Install the pinion pilot bearing as shown in the illustration.
27-75
Installation: Outer bearing inner race

[Inspection]
• Apply load A (49 kN {5000 kgf}) onto the driven helical gear, or
tighten the lock nut to the specified torque.
• Firmly lock the driven helical gear. Then, with a tension gauge
installed, measure the tangential force at the periphery of the
bearing retainer.
Diameter of bearing retainer: φ180 mm
• If the measurement deviates from the specified value, adjust the
tangential force.
[Adjustment]
• Select a pinion bearing collar to bring the tangential force to the
standard value.
Thickness of collar
17.475 to 18.075 mm
27-76
27
M E M O
27-77
DIFFERENTIAL
<Without Limited Slip Differential>
1 Reduction gear
2 Differential case LH
3 Differential case RH
4 Differential gear washer
5 Differential gear
6 Differential pinion washer
7 Differential pinion
8 Pinion spider
CAUTION
• Be sure to replace the differential
case as a differential case set.
Assembly sequence
Follow the disassembly sequence in re-
verse.

Backlash between differential gear and axle shaft
5 0.07 to 0.22 0.5 Replace
splines
Backlash between differential gear and differential pin-
5, 7 0.25 to 0.45 0.8 Replace
ion
7, 8 Clearance between differential pinion and pinion spider 0.17 to 0.28 0.5 Replace

Nut (reduction gear and differential case mounting) 559 to 617 {57 to 63} –
Bolt (differential case LH and RH mounting) 343 to 402 {35 to 41} –

Entire bolt Rust preventive As required
Thread area of bolt Loctite 271 As required
27-78
27
Inspection: Backlash between differential gear and axle
shaft splines
defective part(s).
Installation: Differential cases LH and RH
• Apply rust preventive over the entire bolt surface. After applying
it, blow off the excess rust preventive on the bolt using com-
pressed air.
• Apply thread lock cement to the bolt threads.
• Tighten the bolt to the specified torque.
CAUTION
• The bolts must be coated with rust preventive before they
are tightened to the specified torque.
• Do not drive the vehicle for at least an hour after the bolts
have been tightened to let the thread lock cement harden.
• Do not drive the vehicle at full torque for at least four hours
after the bolts have been tightened to let the thread lock ce-
ment harden.
Installation: Differential case and reduction gear

pressed air.
CAUTION
• The bolts must be coated with rust preventive before they
are tightened to the specified torque.
have been tightened to let the thread lock cement harden.
after the bolts have been tightened to let the thread lock ce-
ment harden.
Adjustment after installation

Adjustment: Backlash between differential gear and differ-
ential pinion
differential gear washers.
27-79
DIFFERENTIAL
<With Limited Slip Differential>
1 Reduction gear 6 Spring 11 Differential gear washer
2 Differential case LH 7 Spacer 12 Differential gear
3 Thrust washer 8 Differential gear 13 Differential pinion washer
4 Friction plate 9 Differential case 14 Differential pinion
5 Friction disc 10 Differential case RH 15 Pinion spider
CAUTION
• Be sure to replace the differential case as a differential case set.
Assembly sequence

4 Thickness of friction plate 2.0 ± 0.03 1.9 Replace
5 Thickness of friction disc 2.0 ± 0.03 1.9 Replace
12, 14, Backlash between differential gear and differential pin-
0.20 to 0.28 0.8 Replace
16 ion
12, 16 Backlash between differential gear and axle shaft spline 0.07 to 0.22 0.5 Replace
14, 15 Clearance between differential pinion and pinion spider 0.17 to 0.28 0.5 Replace

Nut (reduction gear and differential case LH mounting) 559 to 617 {57 to 63} –
Bolt (differential case and differential case RH mounting) 225 to 265 {23 to 27} –
27-80
27
Entire bolt Rust preventive As required
Thread area of bolt Loctite 271 As required
Limited slip differential gear oil
Each part As required
API GL-5 SAE90
Inspection: Thrust washer and springs
• If damage, deformation, discoloration from heating, or uneven
wear is evident, replace the faulty part(s).
Inspection: Thickness of friction discs and plates

• On each disc/plate, measurements must be taken at several lo-
cations.
part(s).
Inspection: Backlash between differential gear and axle

shaft splines
part(s).
Adjustment: Backlash between differential gear and differ-

ential pinion
• If the measurement exceeds the limit, replace the thrust washer
and differential gear washer.
27-81
DIFFERENTIAL
Installation: Differential case and differential case RH
• Apply anti-corrosive agent over the entire bolt surface.
• Apply thread-locking compound over the threaded portion of the
bolt.
CAUTION
• The bolts must be coated with anti-corrosive agent before
they are tightened to the specified torque.
have been tightened to harden the thread-locking com-
pound.
after the bolts have been tightened to harden the thread-
locking compound.
Installation: Differential case LH

• Apply the specified gear oil to the friction discs and plates.
• The friction discs and plates must be installed in the correct se-
quence. Face the spring correctly before installation.
• When assembling the differential cases together, ensure that the
alignment marks are aligned.
• Tighten the screws evenly.

• If the differential cases will not fit tightly onto each other by tight-
ening the screws, this may likely be due to the friction discs,
plates or spring incorrectly installed. Reassemble them.
27-82
27
• Ensure that the differential cases are tightly fitted onto each oth-
er without any clearance.
• If clearance is evident, correct in the following manner.
[Correction]
• Observe the clearance while applying load using a press or oth-
er similar tool.
NOTE
• The pressing load must not exceed 20 kN {2000 kgf}.
• Keep pressing the cases together even after the clearance has
disappeared.
CAUTION
• When the clearance has disappeared, stop increasing the
load.
• Fully tighten the screws (× 4).

• Slowly release the pressing load.
• Ensure that there is no clearance between the cases.
27-83
Installation: Reduction gear and limited slip differential
pressed air.
• Tighten the nut to the specified torque.
CAUTION
• The bolts must be coated with anti-corrosive agent before
the nuts are tightened to the specified torque.
have been tightened to harden the thread-locking com-
pound.
after the bolts have been tightened to harden the thread-
locking compound.
27-84

Group 27 Rear Axle: 1. Wheel Hub and Brake Drum 2. Reduction and Differential 3. Limited Slip Differential

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Group 27 Rear Axle: 1. Wheel Hub and Brake Drum 2. Reduction and Differential 3. Limited Slip Differential

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GROUP 27 REAR AXLE

SPECIFICATIONS .............................................................................. 27-2

STRUCTURE AND OPERATION

TROUBLESHOOTING ....................................................................... 27-8

ON-VEHICLE INSPECTION AND ADJUSTMENT

WHEEL HUB AND BRAKE DRUM .................................................. 27-12

REDUCTION AND DIFFERENTIAL

STRUCTURE AND OPERATION

1. Wheel Hub and Brake Drum

3.1 Operating mechanism

3.3 Operation when there is a dif-

Oil leakage from differential carrier and axle housing

Propeller shaft turns but vehicle does not move

Continuous noise while cruising

Tires drag while cornering

Oil leakage from differential carrier and axle housing

Propeller shaft turns but vehicle does not move

Continuous noise while cruising

Tires drag while cornering

Lubricant and/or sealant

Service standards (Unit: mm)

Tightening torque (Unit: N·m {kgf·m})

Lubricant and/or sealant

Special tools (Unit: mm)

Wheel hub inner bearing

Wheel hub outer bearing

Oil seal retainer

Removal of inner bearing inner race

Oil seal retainer installer

Oil seal installer

Oil seal retainer puller

Removal: Lock nut

Removal: Wheel hub and brake drum

• Remove the dust cover behind the anchor bracket.

Removal: Inner bearing outer race

Removal: Outer bearing outer race

Removal: Inner bearing inner race and oil seal retainer

(2) Lateral runout at flange face

Inspection: Outer bearing inner race

Inspection: Wheel hub

• Using feeler gauges to measure the amount of wear at the outer

Inspection: Inner bearing inner race

Inspection: Axle housing

Installation: Oil seal retainer

Installation: Inner bearing inner race

Installation: Hub bolts

Installation: Outer bearing outer race

Installation: Inner bearing outer race

• As shown in the illustrations at the left, fill grease inside of the

Installation: Packing grease in outer bearing inner race

Adjustment: Wheel hub bearing starting torque

Installation: Brake hose

Installation: Wheel speed sensor harnesses

Service standards (Unit: mm)

Tightening torque (Unit: N·m {kgf·m})

Lubricant and/or sealant

Special tools (Unit: mm)

Removal: Reduction and differential