GSIC - Global Service Information Center

# DIFFERENTIAL VACUUM ACTUATOR > REPLACEMENT

## for Preparation Click here

1. REMOVE FRONT SIDE MEMBER TO FRONT SUSPENSION CROSSMEMBER BRACE

2. REMOVE NO. 1 ENGINE UNDER COVER

3. REMOVE NO. 2 ENGINE UNDER COVER

4. DRAIN DIFFERENTIAL OIL

5. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY

1. Remove the bolt and disconnect the differential breather tube bracket.

1. Support the differential with a jack.

1. Remove the differential mounting nut No. 1.

1. Remove the 2 mounting bolts and 2 nuts.

1. Disconnect the actuator hose and connector.

1. Lower the jack.

1. Remove the 4 bolts and vacuum actuator.

6. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY

1. Remove any old FIPG material.

   NOTICE:
     Be careful not to drop oil on the contact surfaces of the actuator and clutch case.

1. Using gasoline or alcohol, clean any residual FIPG material on the contact surfaces.

1. Apply FIPG to the differential tube, as shown in the illustration.

   FIPG:
     Part No. 08826-00090, THREE BOND 1281 or equivalent

   HINT:
     Install the actuator within 10 minutes after applying FIPG.

1. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

1. Apply adhesive to 2 or 3 threads at the tip of the bolt.

   Adhesive:
     Part No. 0883-00070, THREE BOND 1281 or equivalent

1. Install the differential vacuum actuator to the differential tube with the 4 bolts.

   Torque:
     21 N*m{ 210 kgf*cm , 15 ft.*lbf }

1. Connect the actuator hose and connector.

1. Support the differential with a jack.

1. Install the 2 front mounting bolts and 2 nuts.

   Torque:
     137 N*m{ 1,400 kgf*cm , 101 ft.*lbf }

1. Install the differential mounting nuts No. 1.

   Torque:
     87 N*m{ 887 kgf*cm , 64 ft.*lbf }

1. Install the differential breather tube bracket with the bolt.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

7. REFILL DIFFERENTIAL OIL

1. Refill differential oil (Click here).

8. CHECK FOR DIFFERENTIAL OIL LEAKAGE

1. Stop the vehicle on a level surface.

1. Remove the differential filler plug and gasket.

1. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the differential filler plug hole.

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

   HINT:
     If necessary, fill the differential carrier assembly with hypoid gear oil.

   Recommended viscosity:

     Temperature | Viscosity
     Above -18°C (0°F) | SAE 90
     Below -18°C (0°F) | SAE 80W or 80W - 90

   Oil grade:
     Hypoid gear oil API GL-5
     Capacity:
     Front differential:
     w/o A.D.D.:
     1.40 to 1.50 liters (1.48 to 1.59 US qts., 1.23 to 1.31 lmp. qts.)
     w/ A.D.D.:
     1.60 to 1.70 liters (1.69 to 1.80 US qts., 1.40 to 1.50 lmp. qts.)
     Rear differential:
     2WD:
     3.15 to 3.25 liters (3.30 to 3.43 US qts., 2.77 to 2.86 lmp. qts.)
     4WD:
     3.30 to 3.40 liters (3.49 to 3.59 US qts., 2.90 to 2.99 lmp. qts.)

1. Check for oil leakage when the oil level is low.

1. Install the differential filler plug with a new gasket.

   Torque:
     Front differential:
     39 N*m{ 400 kgf*cm , 29 ft.*lbf }
     Rear differential:
     49 N*m{ 500 kgf*cm , 36 ft.*lbf }

9. INSTALL NO. 2 ENGINE UNDER COVER

10. INSTALL NO. 1 ENGINE UNDER COVER

11. INSTALL FRONT SIDE MEMBER TO FRONT SUSPENSION CROSSMEMBER BRACE