Axle Beam: Service and Repair

REAR AXLE BEAM ASSY
REPLACEMENT
1. REMOVE REAR WHEEL
2. REMOVE FLOOR PANEL SIDE PLATE LH





a) Remove the 3 bolts and the floor panel side plate.
3. REMOVE FLOOR PANEL SIDE PLATE RH

HINT: Use the same procedures for the RH side and LH side.

4. SEPARATE HEIGHT CONTROL SENSOR SUB-ASSY REAR LH (W/ DISCHARGE HEAD LAMP)





a) Remove the nut and separate the height control sensor sub-assy.
5. REMOVE SENSOR CONNECTING BRACKET REAR (W/ DISCHARGE HEAD LAMP)





a) Remove the 2 nuts and the sensor connecting bracket.
6. REMOVE REAR BRAKE DRUM SUB-ASSY
7. SEPARATE SKID CONTROL SENSOR WIRE





a) Remove the 2 bolts and clip, and separate the skid control sensor wire and parking brake cable from the rear axle beam.

NOTICE:
^ Ensure no foreign matter is on the end of the skid control sensor wire.
^ Ensure that the skid control sensor wire is separated from the rear axle beam.

HINT: Use the same procedures for the RH side and LH side.

8. REMOVE REAR AXLE BEAM DAMPER
9. REMOVE STABILIZER BAR REAR
10. SEPARATE REAR BRAKE TUBE NO.4





a) Separate the rear brake tube from the flexible hose using SST.
SST 09023-00100

NOTICE: Do not damage the rear brake tube or flexible hose.

b) Remove the clip.
11. SEPARATE REAR BRAKE TUBE NO.3
SST 09023-00100

HINT: Use the same procedures for the RH side and LH side.

12. REMOVE REAR AXLE HUB & BEARING ASSY LH





a) Remove the 4 bolts. Remove the axle hub & bearing assy and parking brake plate assy from the rear axle beam.

NOTICE:
^ Do not twist the parking brake cable.
^ Use rope, etc. to suspend the parking brake plate assy.

13. REMOVE REAR AXLE HUB & BEARING ASSY RH

HINT: Use the same procedures for the RH side and LH side.

14. SEPARATE REAR SHOCK ABSORBER WITH COIL SPRING





a) Remove the 2 nuts from the left- and right-hand sides. Remove the rear shock absorber with coil spring (lower side) from the rear axle beam.
15. REMOVE REAR AXLE BEAM ASSY





a) Support the rear axle beam with a jack. Insert a wooden block between the jack and the center of the rear axle beam to prevent damage.





b) Remove the 2 bolts and 2 nuts from the left- and righthand sides.

NOTICE: Keep the nut from rotating when removing the bolt.

c) Remove the rear axle beam by slowly lowering the jack.

NOTICE: Ensure that the skid control sensor wire is completely separated from the rear axle beam.

16. REMOVE REAR AXLE CARRIER BUSH LH





a) Place a matchmark on the rear axle beam after aligning it with the bush recess.
b) Make 2 bends in the rim of the bush using a chisel and hammer.
c) Remove the bush from the rear axle beam using SST.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04051, 09957-04010, 09958-04011), 09950-60010 (09951-00630)

NOTICE:
^ Do not erase the matchmark on the rear axle beam when removing the bush.
^ Apply chassis black if the rear axle beam is scratched.

17. REMOVE REAR AXLE CARRIER BUSH RH
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04051, 09957-04010, 09958-04011), 09950-60010 (09951-00630)

HINT: Use the same procedures for the RH side and LH side.

18. INSTALL REAR AXLE CARRIER BUSH LH
a) Temporarily install a new bush recess by aligning it with the matchmark on the rear axle beam (when replacing bush only).

NOTICE: Install the bush in the same direction as before it was removed.





b) Temporarily install a new bush as shown in the illustration (when replacing the rear axle beam).





c) Install the bush to the rear axle beam using SST.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04051, 09957-04010, 09958-04011), 09950-60010 (09951-00620), 09710-04101

NOTICE:
^ Hang the claw of SST to the bush deeply and firmly.
^ Do not damage the rubber sections indicated by the arrow in the illustration when installing the bush.

19. INSTALL REAR AXLE CARRIER BUSH RH
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04051, 09957-04010, 09958-04011), 09950-60010 (09951-00620), 09710-04101

HINT: Use the same procedures for the RH side and LH side.

20. TEMPORARILY TIGHTEN REAR AXLE BEAM ASSY





a) Support the rear axle beam with a jack. Insert a wooden block between the jack and the center of the rear axle beam to prevent damage.
b) Slowly raise the jack to install the rear axle beam on the vehicle. Insert the 2 bolts from inside the vehicle and temporarily tighten them with the 2 nuts (one nut and bolt each for both the left- and right-hand sides).
21. TEMPORARILY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING





a) Install the left- and right-hand side rear shock absorber with coil spring (lower side) to the rear axle beam. Temporarily tighten the nuts.
22. INSTALL REAR AXLE HUB & BEARING ASSY LH





a) Install the parking brake plate assy and the axle hub & bearing assy to the rear axle beam using the 4 bolts.
Torque: 61 Nm (622 kgf-cm, 45 ft. lbs.)
23. INSTALL REAR AXLE HUB & BEARING ASSY RH

HINT: Use the same procedures for the RH side and LH side.

24. INSTALL REAR BRAKE TUBE NO.4





a) Temporarily tighten the rear brake tube and flexible hose.

NOTICE:
^ Do not damage the rear brake tube or flexible hose.
^ Replace the rear brake tube and flexible hose with new parts if they are damaged.

b) Install the rear brake tube to the rear axle beam and secure it with the clip.





c) Fully tighten the rear brake tube using SST.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
25. INSTALL REAR BRAKE TUBE NO.3
SST 09023-00100

HINT: Use the same procedures for the RH side and LH side.

26. INSTALL STABILIZER BAR REAR
27. INSTALL REAR AXLE BEAM DAMPER
28. INSTALL SKID CONTROL SENSOR WIRE





a) Install the skid control sensor wire and parking brake cable to the rear axle beam using the 2 bolts and clip.
Torque:
Bolt A: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
Bolt B: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

NOTICE: Do not twist the skid control sensor wire while installing.

HINT: Use the same procedures for the RH side and LH side.

29. INSTALL REAR BRAKE DRUM SUB-ASSY
30. STABILIZE SUSPENSION
a) Install the rear wheel.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b) After jacking down the vehicle, bounce the vehicle up and down to stabilize the rear suspension.
31. FULLY TIGHTEN REAR AXLE BEAM ASSY





a) Hold the nut and rotate the bolt to fully tighten the rear axle beam on the LH side.
Torque: 85 Nm (867 kgf-cm, 63 ft. lbs.)

NOTICE: Ensure the vehicle is lowered to the ground.

HINT: Use the same procedures for the RH side and LH side.

32. FULLY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING





a) Install the rear shock absorber with coil spring (lower side) and tighten the nut.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)

NOTICE: Ensure the vehicle is lowered to the ground.

HINT: Use the same procedures for the RH side and LH side.

33. INSTALL SENSOR CONNECTING BRACKET REAR (W/ DISCHARGE HEAD LAMP)





a) Install the sensor connecting bracket using the 2 nuts.
34. INSTALL HEIGHT CONTROL SENSOR SUB-ASSY REAR LH (W/ DISCHARGE HEAD LAMP)





a) Install the height control sensor sub-assy using the nut.
35. INSTALL FLOOR PANEL SIDE PLATE LH





a) Install the floor panel side plate using the 3 bolts.
36. INSTALL FLOOR PANEL SIDE PLATE RH

HINT: Use the same procedures for the RH side and LH side.

37. BLEED BRAKE LINE
38. INSPECT BRAKE FLUID
39. INSPECT REAR WHEEL ALIGNMENT
40. PERFORM INITIALIZATION (W/ DISCHARGE HEAD LAMP)
41. ADJUST HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP)
42. CHECK ABS SPEED SENSOR SIGNAL