Part 2
REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE) Continued7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a) Install the drive pinion oil slinger.
8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a) Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09954-03010, 09956-03060, 09955-03040)
NOTICE:
^ Install the companion flange so that there is a slight looseness on the drive pinion because the bearing spacer is not yet installed.
^ Apply grease to the threads and tip of the SST center bolt before use.
b) Coat the threads of the drive pinion nut with hypoid gear oil LSD.
c) Using SST to hold the flange, torque the drive pinion nut.
SST 09229-55010, 09330-00021
HINT: Tighten the nut to approximately 100 Nm (1,020 kgf-cm, 74 ft. lbs.), and tighten it further while checking the preload.
NOTICE:
^ Apply hypoid gear Oil LSD to the nut and the threads of the drive pinion.
^ As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.
d) Turn the bearing clockwise and counterclockwise several times to stabilize it.
e) Using SST and a torque wrench, measure the preload.
Drive pinion preload (at starting):
New bearing: 1.12 to 1.70 Nm (11.4 to 17.3 kgf-cm, 9.9 to 15.0 inch lbs.)
Reused bearing: 0.40 to 0.70 Nm (4.1 to 7.2 kgf-cm, 3.5 to 6.2 inch lbs.)
NOTICE: Record the preload for total preload measurement.
If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary.
9. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a) Insert the differential case from the ring gear tooth side to install the differential case.
NOTICE: Do not damage the case bearing and ring gear.
10. INSTALL REAR DIFFERENTIAL CASE BEARING
a) Using SST and a hammer, install the ring gear tooth side case bearing outer race.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.
b) Install SST to the differential carrier.
SST 09571-50010
c) Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.
d) Using SST and a hammer, install the ring gear back surface side case bearing outer race.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the case bearing outer race until it touches the case bearing inner race roller.
11. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a) Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.
HINT:
^ If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft snap ring and install it.
^ If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft snap ring with the same thickness as the removed one.
b) Install a dial indicator to the differential carrier.
c) Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.004 inch).
SST 09571-50010
NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 inch).
HINT:
^ Set the dial indicator to the rear most position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
^ Tighten the SST bolt to apply the preload to the case bearing.
d) Turn the ring gear clockwise and counterclockwise several times.
e) Using a dial indicator, measure the backlash of the ring gear at 3 positions.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
NOTICE: The difference between the maximum and minimum values must be within 0.05 mm (0.002 inch).
HINT:
^ Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
^ If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the ring gear tooth side with a snap ring of different thickness as described in the following procedure.
^ Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
f) Loosen the SST bolt and separate the SST disc from the case bearing outer race on the ring gear tooth side.
g) Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear back surface side and case bearing outer race.
SST 09608-32010, 09950-70010 (09951-07200)
h) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
i) Using snap ring pliers, install a side gear shaft snap ring with a different thickness.
HINT: When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash also changes by 0.02 mm (0.0008 inch).
Snap Ring Thickness:
j) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.
k) Install a dial indicator to the differential carrier.
l) Tighten the SST bolt to alter the shape of the differential carrier approximately 0.1 mm (0.004 inch).
SST 09571-50010
HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
m) Using a dial indicator, measure the backlash of the ring gear at 3 positions.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
n) If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness.
HINT:
^ Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
^ Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
12. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a) Install a dial indicator to the differential carrier.
b) Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.004 inch).
SST 09571-50010
NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 inch).
HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
c) Using snap ring pliers, install the thinnest side gear shaft snap ring on the ring gear tooth side.
d) Remove the dial indicator and loosen the bolt (A) until the SST disc is separated from the case bearing outer race.
e) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.
f) Using a dial indicator, measure the backlash of the ring gear at 3 positions. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
HINT: If a value is not within the specified range, replace it with one of a different thickness in the following procedure.
g) Loosen the SST bolt and separate the SST disc from the case bearing outer race on the ring gear tooth side.
13. ADJUST TOTAL PRELOAD
a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Total preload (at starting):
New bearing: 1.54 to 2.96 Nm (1.57 to 30.2 kgf-cm, 13.6 to 26.2 inch lbs.)
Reused bearing: 0.82 to 1.96 Nm (8.4 to 20.0 kgf-cm, 7.3 to 17.3 inch lbs.)
NOTICE:
^ If the measured preload is less than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thicker one.
^ If the preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thinner one.
HINT: When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the total preload will change by approximately 0.1 Nm (1 kgf-cm, 0.9 inch lbs.).
b) Set a dial indicator to the end of the differential ring gearface.
c) While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
NOTICE:
^ If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft snap rings equally.
^ When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash will also change by approximately 0.02 mm (0.0008 inch).
d) Recheck the total preload.
14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
15. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a) Install the SST to the rear differential carrier.
SST 09571-50010
b) Install a dial indicator to the rear differential carrier.
c) Tighten the SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.004 inch) clearance between the case bearing outer race and side gear shaft snap ring.
NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 inch).
HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
^ Approximately 0.1 mm (0.004 inch) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly
d) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.
e) Remove the dial indicator and loosen the SST bolt.
NOTICE: Do not remove the SST.
16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a) Using SST and a hammer, create a clearance between the case bearing outer race on the ring gear and side gear shaft snap ring.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: The clearance is not visible, but tapping the SST with a hammer 3 or 4 times should be enough.
b) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
17. REMOVE REAR DIFFERENTIAL CASE BEARING
a) Tighten the SST bolt and push out the case bearing outer race on the ring gear back surface side.
SST 09571-50010
NOTICE: Do not drop the case bearing outer race.
HINT:
^ To use as a reference for installation, clearly write the installation positions of the rear differential case bearing (outer race) and the rear differential side gear shaft snap ring.
^ Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
b) Remove the SST
18. REMOVE REAR DIFFERENTIAL CASE BEARING
a) Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.
HINT:
^ For reassembly, check the installation position of the case bearing outer race and the side gear shaft snap ring before removing the case bearing outer race. Write down the result.
^ Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a) Remove the rear differential case assembly.
NOTICE: Do not damage the case bearing.
20. REMOVE REAR DRIVE PINION NUT
a) Using SST to hold the flange, remove the drive pinion nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
21. REMOVE REAR DRIVE PINION COMPANION FLANGE
a) Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
NOTICE: Apply grease to the threads and tip of the SST center bolt before use.
22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a) Remove the differential drive pinion oil slinger.
23. REMOVE DIFFERENTIAL DRIVE PINION
a) Using a press, remove the drive pinion from the differential carrier.
NOTICE: Do not drop the drive pinion.
24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a) Remove the rear drive pinion front tapered roller bearing from the differential carrier.
25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a) Install a new drive pinion bearing spacer to the drive pinion.
HINT: The bearing spacer can be installed in either direction.
26. INSTALL DIFFERENTIAL DRIVE PINION
a) Using SST and a press, install the differential drive pinion to the differential carrier.
SST 09316-60011 (09316-00011, 09316-00041), 09608-04031
27. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a) Install the differential drive pinion oil slinger to the differential drive pinion.
28. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a) Using SST and a hammer, install a new oil seal.
SST 09316-60011 (09316-00011), 09710-30012 (09710-04101)
Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 inch)
b) Apply MP grease to the oil seal lip.
29. INSTALL REAR DRIVE PINION COMPANION FLANGE
a) Using SST, install the companion flange to the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)
NOTICE: Apply grease to the threads and tip of the SST center bolt before use.
b) Coat the threads of a new drive pinion nut with hypoid gear oil LSD.
c) Use SST to hold the flange and torque the drive pinion nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
Torque: 490 Nm (5,000 kgf-cm, 361 ft. lbs.) or less
NOTICE:
^ Do not tighten excessively, otherwise the threads will be stripped.
^ Apply hypoid gear Oil LSD to the threads of the nut and drive pinion.
HINT: Tighten the nut to approximately 100 Nm (1,020 kgf-cm, 74 ft. lbs.), then tighten it further while observing the preload.
30. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a) Insert the differential case from the ring gear tooth side.
NOTICE: Do not damage the case bearing inner race or ring gear.
31. INSTALL REAR DIFFERENTIAL CASE BEARING
a) Using SST and a hammer, install the ring gear tooth side case bearing outer race.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.
b) Install SST to the differential carrier.
SST 09571-50010
c) Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.
d) Using SST and a hammer, install the ring gear back surface side case bearing outer race.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the case bearing outer race until it touches the case bearing inner race roller.
32. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
HINT: Use the side gear shaft snap ring installed when performing tooth contact adjustment.
b) Set a dial indicator on the differential carrier.
c) Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.004 inch).
NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 inch).
d) Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.
HINT: Use the side gear shaft snap ring installed when performing tooth contact adjustment.
e) Remove the dial indicator and tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.
f) Remove the SST
33. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a) Using SST and a torque wrench, measure the preload.
SST 09229-55010
Drive pinion preload (at starting):
New bearing: 1.22 to 1.80 Nm (12.4 to 18.4 kgf-cm, 10.7 to 16.0 inch lbs.)
Reused bearing: 0.50 to 0.80 Nm (5.0 to 8.2 kgf-cm, 4.4 to 7.1 inch lbs.)
^ If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 100.
Torque: 490 Nm (5,000 kgf-cm, 361 ft. lbs.) or less
^ If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
^ If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.
34. INSPECT TOTAL PRELOAD
35. INSPECT DIFFERENTIAL RING GEAR BACKLASH
36. INSPECT RUN OUT OF DIFFERENTIAL DRIVE PINION
37. INSTALL REAR DRIVE PINION NUT
a) Using SST and a hammer, stake the drive pinion nut.
SST 09930-00010
38. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a) Using SST and a hammer, install 2 new oil seals.
SST 09223-15030, 09950-70010 (09951-07200)
Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 inch)
b) Apply MP grease to the oil seal lips.
39. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a) Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
40. REMOVE REAR DIFFERENTIAL CARRIER
a) Remove the differential carrier from the overhaul attachment.
NOTICE: Clean the fitting surface between the differential carrier and carrier cover.
41. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
a) Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.
NOTICE: Do not scratch the sealing surface.
b) Install the rear differential breather plug oil deflector to the rear differential carrier cover.
Torque: 7.0 Nm (70 kgf-cm, 62 inch lbs.)
42. INSTALL REAR DIFFERENTIAL CARRIER COVER
a) Apply FIPG to the differential carrier at the position shown in the illustration.
FIPG: 08826-00090, THREE BOND 1281 or equivalent
NOTICE:
^ Apply the seal packing in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 inch) in diameter.
^ Overlap the seal packing at least 10 mm at the beginning and the end of application.
^ Install the differential carrier cover within 3 minutes of application.
b) Install the differential carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 35 ft. lbs.)
NOTICE: Do not fill the differential with oil or drive immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least 12 hours after installation of parts using FIPG sealant.
43. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG
a) Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY
a) Support the differential carrier rear assembly with a jack.
NOTICE: Do not drop the differential carrier.
b) Using a hexagon wrench (12 mm), temporarily install the differential carrier to the suspension member with 3 new bolts.
c) Install the mount stopper upper and mount stopper. Temporarily install the differential carrier rear to the suspension member with 2 new bolts.
d) Using a hexagon wrench (12 mm) and torque wrench, tighten the 3 bolts to the specified torque.
Torque: 142 Nm (1,450 kgf-cm, 105 ft. lbs.)
e) Using a torque wrench, tighten the 2 bolts to the specified torque.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)
NOTICE: Do not tilt the inner sleeve or distort rubber parts when fully tightening the differential mount stopper.
2. INSTALL REAR STABILIZER BAR
3. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
4. INSTALL REAR DRIVE SHAFT ASSEMBLY RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
5. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
6. INSTALL TAIL EXHAUST PIPE ASSEMBLY
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY
8. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
9. ADD DIFFERENTIAL OIL
10. INSPECT DIFFERENTIAL OIL
11. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
12. CHECK FOR EXHAUST GAS LEAKS
13. CHECK ABS SPEED SENSOR SIGNAL