REAR AXLE SHAFT > INSTALLATION

for Preparation Click here



1. INSTALL REAR AXLE SHAFT OIL SEAL


    F042743E01
  1. Using SST and a hammer, tap in a new oil seal.

    SST
    09950-60020   (09951-00770)
    09950-70010   (09951-07150)
  1. Apply MP grease to the lip of the oil seal.

    NOTICE:
    Do not allow foreign matter, etc. to contact the axle shaft housing hole.


2. INSTALL REAR AXLE SHAFT
  1. Apply MP grease to a new O-ring.

  1. Install the O-ring to the axle shaft.



    C159453
  1. Install the rear axle shaft and parking brake plate with the 4 nuts.

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }


3. CONNECT REAR SPEED SENSOR LH


    C154449E03
  1. Install the speed sensor (labeled A) with the nut (labeled B).

    Torque:
    11 N*m{ 107 kgf*cm , 8 ft.*lbf }
  1. Connect the speed sensor connector (labeled C).

    NOTICE:
    Securely connect the connector.


4. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY


    C154244
  1. Connect the No. 3 parking brake cable with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }


5. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH
  1. Apply high temperature grease to the parking brake shoe lever.



    C155125
    C117760E02
  1. Install the parking brake shoe lever to the No. 3 parking brake cable.

    NOTICE:
    Carefully distinguish the parking brake shoe lever RH and LH.


6. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH
  1. Apply high temperature grease to the areas of the backing plate that contact the shoe.



    C154249E01
  1. Using SST, install the No. 2 parking brake shoe with the shoe hold down spring pin, compression spring and shoe hold down spring cup.

    SST
    09718-00011  


7. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH
  1. Apply high temperature grease to the areas of the backing plate that contact the shoe.



    C193371E01
  1. Apply the high temperature grease to the areas of the shoe adjusting screw set shown in the illustration.

  1. Set the parking brake shoe and shoe adjuster screw set in place.

  1. Connect the tension spring.



    C155124E01
  1. Using SST, install the No. 1 parking brake shoe with the shoe hold down spring pin, compression spring and shoe hold down spring cup.

    SST
    09718-00011  


8. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH


    C179358E01
  1. Using SST, install the shoe return spring.

    SST
    09703-30011  


9. CHECK PARKING BRAKE INSTALLATION


  1. Check that each part is installed properly.


    C156989E01



10. INSTALL REAR DISC LH


    C211015E01
  1. Align the matchmarks and install the rear disc.



11. ADJUST PARKING BRAKE SHOE CLEARANCE
  1. Temporarily install the hub nuts.

  1. Remove the hole plug.



    C158874E01
  1. Insert a screwdriver into the adjustment hole of the disc. Rotate the adjustment wheel in the "X" direction until the shoes are locked. Then rotate the adjustment wheel in the "Y" direction 8 notches.

  1. Check that the disc can be rotated smoothly. If not, rotate the adjustment wheel in the "Y" direction and check again.

  1. Install the hole plug.

  1. Remove the hub nuts.



12. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH


    C158344
  1. Connect the rear disc brake cylinder and install 2 new bolts.

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

    NOTICE:
    1. Do not twist the flexible hose.
    2. Make sure that the bolts are free from damage and foreign matter.
    3. Do not overtighten the bolts.


13. CONNECT REAR BRAKE FLEXIBLE HOSE
  1. Set the flexible hose to the connecting point with the brake tube, and then install a new clip.



    C154492E03
  1. Using union nut wrench, connect the flexible hose to the brake tube while holding the flexible hose with a wrench.

    Torque:
    without union nut wrench:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }
    with union nut wrench:
    14 N*m{ 145 kgf*cm , 10 ft.*lbf }

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.8 in.).

    NOTICE:
    1. Do not bend or damage the brake tube.
    2. Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point.


14. FILL RESERVOIR WITH BRAKE FLUID
  1. Fill the brake fluid (Click here).



15. BLEED BRAKE LINE
  1. Bleed brake line

    1. Remove the brake master cylinder reservoir filler cap assembly.

    2. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.

      Brake fluid:
      SAE J1703 or FMVSS No. 116 DOT3
    3. Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.

    4. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

    5. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

    6. Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out.

    7. Tighten the bleeder plug completely.

      Torque:
      11 N*m{ 110 kgf*cm , 8 ft.*lbf }
    8. Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH.

    9. Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.

    10. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

    11. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

    12. Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out.

    13. Tighten the bleeder plug completely.

      Torque:
      11 N*m{ 110 kgf*cm , 8 ft.*lbf }
    14. Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH.

  1. Check and bleed brake system.

    1. If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures.

      1. Low pedal or spongy pedal.
      2. Brake pedal is depressed firmly but braking is insufficient.
  1. Check and adjust brake fluid level in reservoir (Click here).



16. CHECK BRAKE FLUID LEVEL IN RESERVOIR


C155477
  1. Check the fluid level and add fluid if necessary.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3

    HINT:
    The brake fluid level must always be adjust to the MAX line.


17. CHECK FOR BRAKE FLUID LEAKS


18. INSTALL REAR WHEEL LH

Torque:
for Aluminum Wheel:
131 N*m{ 1336 kgf*cm , 97 ft.*lbf }
for Steel Wheel:
209 N*m{ 2131 kgf*cm , 154 ft.*lbf }


19. INSPECT DIFFERENTIAL OIL


    D025304E27
  1. Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the differential filler plug hole.

    NOTICE:
    1. Too much or too little oil will lead to differential problems.
    2. After changing the oil, drive the vehicle and then check the oil level again.

    Oil type:
    Item
    Oil type and viscosity
    Front differential
    Toyota Genuine Differential gear oil LT 75W-85 GL-5 or equivalent.
    Rear differential

    Front differential capacity:
    Specified Condition
    2.00 to 2.10 liters (2.12 to 2.21 US qts., 1.76 to 1.84 Imp. qts.)

    Rear differential capacity:

    Engine type
    Wheelbase type
    Cab type
    Drive type
    Specified Condition
    3UR-FE. 3UR-FBE
    3220 mm (10 ft. 6.8 in.)
    Regular
    2WD
    3.45 to 3.55 liters (3.65 to 3.75 US qts., 3.04 to 3.12 Imp. qts.)
    4WD
    3700 mm (12 ft. 1.7 in.)
    Regular
    2WD
    3.55 to 3.65 liters (3.76 to 3.85 US qts., 3.13 to 3.21 Imp. qts.)
    4WD
    Double
    2WD
    4WD
    CrewMax
    2WD
    3.70 to 3.80 liters (3.91 to 4.01 US qts., 3.26 to 3.34 Imp. qts.)
    4WD
    3.55 to 3.65 liters (3.76 to 3.85 US qts., 3.13 to 3.21 Imp. qts.)
    4180 mm (13 ft. 8.6 in.)
    Double
    2WD
    3.70 to 3.80 liters (3.91 to 4.01 US qts., 3.26 to 3.34 Imp. qts.)
    4WD
    1GR-FE and 1UR-FE
    3220 mm (10 ft. 6.8 in.)
    Regular
    2WD
    4.00 to 4.10 liters (4.23 to 4.33 US qts., 3.52 to 3.60 Imp. qts.)
    4WD
    3700 mm (12 ft. 1.7 in.)
    ALL
    2WD
    4.55 to 4.65 liters (4.81 to 4.91 US qts., 4.01 to 4.09 Imp. qts.)
    4WD
    4180 mm (13 ft. 8.6 in.)
    2WD
    4WD
  1. for Rear Differential:

    1. Install a new gasket and the filler plug.

      Torque:
      49 N*m{ 500 kgf*cm , 36 ft.*lbf }
  1. for Front Differential:

    1. Using a 10 mm hexagon wrench, install a new gasket and the filler plug.

      Torque:
      39 N*m{ 398 kgf*cm , 29 ft.*lbf }


20. INSPECT FOR DIFFERENTIAL OIL LEAK


21. CHECK PARKING BRAKE PEDAL TRAVEL
  1. Firmly depress the parking brake pedal.

  1. Release the parking brake.

  1. Slowly depress the parking brake pedal with a force of approximately 300 N (31 kgf, 67.4 lbf) and count the number of clicks.

    Standard:
    6 to 9 clicks


22. ADJUST PARKING BRAKE PEDAL TRAVEL
  1. Depress the parking brake pedal.



    C159467E01
  1. Apply load equivalent to 4 kN (408 kgf, 899.2 lbf) on equalizer twice to pull No. 2 and No. 3 parking brake cable to remove initial elongation.

  1. Release the parking brake pedal to the original position.



    C154230
  1. Loosen the pedal side No. 1 parking brake cable lock nut.

  1. Turn the pedal side No. 1 parking brake cable adjustment nut until the parking brake pedal travel is correct.

    Standard parking brake pedal travel:
    Pedal Load
    Specified Condition
    300 N (31 kgf, 67.4 lbf)
    6 to 9 clicks
  1. Using a wrench or equivalent to hold the adjustment nut, tighten the lock nut.

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

    NOTICE:
    Pay attention that the adjustment nut does not rotate with the lock nut during tightening.


  1. Additionally, excessive pedal travel can be adjusted on the No. 1 parking brake cable underbody side as follows.

    1. Release the parking brake pedal to the original position.



    2. C159467E02
    3. Loosen the underbody side No. 1 parking brake cable lock nut.

    4. Turn the underbody side No. 1 parking brake cable adjustment nut until the parking brake pedal travel is correct.

      Standard parking brake pedal travel:
      Pedal Load
      Specified Condition
      300 N (31 kgf, 67.4 lbf)
      6 to 9 clicks
    5. Tighten the No. 1 parking brake cable underbody lock nut.

      Torque:
      13 N*m{ 128 kgf*cm , 9 ft.*lbf }

      NOTICE:
      Pay attention that the adjustment nut does not rotate with the lock nut during tightening.
  1. Depress and release the parking brake pedal 3 or 4 times. Then check the number of clicks when depressing the pedal.

    Standard:
    6 to 9 clicks
    If the result is not as specified, adjust the parking brake pedal travel again.
  1. Check whether the parking brake drags or not.
    If the parking brake drags, adjust the shoe clearance.

  1. When operating the parking brake pedal, check that the parking brake pedal indicator light comes on at the first notch.
    If not, adjust the parking brake switch installation position.



23. CHECK SRS WARNING LIGHT
  1. Check the SRS warning light (Click here).



24. CHECK SPEED SENSOR SIGNAL
  1. Check the speed sensor signal (Click here).