Part 1

REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE)

Components:

REMOVAL
1. REMOVE REAR WHEEL
2. DRAIN DIFFERENTIAL OIL
a) Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.
b) Using a hexagon wrench (10 mm), remove the differential drain plug and gasket, and drain the oil.

3. REMOVE FRONT EXHAUST PIPE ASSEMBLY
4. REMOVE TAIL EXHAUST PIPE ASSEMBLY
5. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
6. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
7. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

8. REMOVE REAR STABILIZER BAR
9. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

a) Support the differential carrier with a jack.

NOTICE: Do not drop the differential carrier.

b) Using a hexagon wrench (12 mm), remove the 3 hexagon bolts.

c) Remove the 2 bolts, 2 differential mount stoppers and differential carrier rear.

DISASSEMBLY
1. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

a) Remove the breather plug from the differential carrier cover.

2. REMOVE REAR DIFFERENTIAL CARRIER COVER

a) Remove the 8 bolts from the differential carrier cover.

b) Using a brass bar and a hammer, remove the differential carrier cover from the differential carrier.

NOTICE:
^ Place the brass bar onto the corners of the carrier cover.
^ Do not damage the sealing surface of the differential carrier.

3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

a) Remove the bolt and oil deflector from the differential carrier cover.

4. SECURE REAR DIFFERENTIAL CARRIER

a) Set the differential carrier to the overhaul stand, etc., as shown in the illustration.

5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
6. INSPECT DIFFERENTIAL RING GEAR BACKLASH
7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
9. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
11. INSPECT TOTAL PRELOAD
12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

a) Using SST, remove the 2 oil seals.
SST 09308-00010

13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

a) Install SST to the differential carrier.
SST 09571-50010
b) Tighten the SST bolt (A) until the SST disc lightly touches the case bearing outer race.

c) Install a dial indicator to the rear differential carrier.
d) 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 rear most position (upper side in the illustration) of the area around where the side gear shaft 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

e) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

f) Remove the dial indicator and loosen the SST bolt.

NOTICE: Do not remove the SST.

14. 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 back surface of 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 three or four times should be enough.

b) Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.

HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

15. REMOVE REAR DIFFERENTIAL CASE BEARING

a) Tighten the SST bolt and push out the case bearing outer race on the back surface of the ring gear.
SST 09571-50010

NOTICE: Do not drop the case bearing outer race.

b) Remove the SST

16. REMOVE REAR DIFFERENTIAL CASE BEARING

a) Raise the ring gear 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.

17. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

a) Remove the rear differential case assembly.

NOTICE: Do not damage the case bearing.

18. REMOVE REAR DRIVE PINION NUT

a) Using SST and a hammer, unstake the staked part of the drive pinion nut.
SST 09930-00010

NOTICE:
^ Be sure to use the SST with the tapered surface facing the shaft.
^ Do not grind the tip of the SST with a grinder, etc.
^ Completely loosen the staked part of the nut when removing it.
^ Do not damage the threads of the drive pinion.

b) Using SST to hold the flange, remove the drive pinion nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)

19. 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.

20. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

HINT: Perform this procedure only when the dust deflector is damaged.

a) Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)

21. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

a) Using SST, remove the oil seal from the differential carrier.
SST 09308-00010

22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

a) Remove the 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 DIFFERENTIAL DRIVE PINION BEARING SPACER

a) Remove the drive pinion spacer.

25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

a) Remove the rear drive pinion front tapered roller bearing inner race from the differential carrier.

b) Using a brass bar and a hammer, remove the rear drive pinion front tapered roller bearing outer race from the differential carrier.

26. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

a) Using SST and a press, remove the rear drive pinion rear tapered roller bearing inner race from the drive pinion.
SST 09950-00020

HINT: If either the drive pinion or ring gear is damaged, replace both as a set.

b) Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing outer race from the differential carrier.
c) Remove the plate washer.

27. REMOVE DIFFERENTIAL RING GEAR

a) Put matchmarks on the ring gear and differential case.
b) Remove the 10 ring gear set bolts.

c) Using a plastic hammer, tap on the ring gear to separate it from the differential case.

NOTICE: Do not damage the ring gear.

28. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY
29. REMOVE REAR DIFFERENTIAL CASE BEARING

HINT: Perform this procedure only when replacing the case bearing or differential case.

a) Using SST, remove the case bearing inner races LH and RH from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00350, 09951-00480, 09952-06010)

NOTICE:
^ Do not deform the bearing cage if the bearing is to be reused.
^ Hook the SST claw from the dent of the differential case to the bearing inner race.
^ Apply grease to the threads and tip of the SST center bolt before use.

30. INSPECT DIFFERENTIAL PINION AND SIDE GEAR

INSPECTION
1. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

a) Set the dial indicator perpendicular to the end of the ring gear face.
b) Rotate the ring gear and measure the backlash.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

2. INSPECT DIFFERENTIAL RING GEAR BACKLASH

a) While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
If the backlash is not within the specified range, adjust the backlash or repair as necessary.

3. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

a) Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.
b) Rotate the ring gear in both directions.

c) Inspect the tooth contact pattern.

d) If the teeth are not contacting properly, use the table to select a proper plate washer for correction.

HINT:
^ If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
^ If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.

Washer Thickness (part 1):

Washer Thickness (part 2):

4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

a) Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 inch).
If not, replace the rear differential case sub assembly with a new one.

5. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the differential case and check that the backlash is 0 mm (0 inch).
If not, replace the rear differential case sub-assembly with a new one.

6. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION

a) Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 inch) away from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 inch)
If the runout is greater than the maximum, replace the drive pinion and ring gear.

7. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

a) Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed. Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion preload.
Drive pinion preload (at starting):
New bearing: 1.22 to 1.80 Nm (12.4 to 18.4 kgf-cm, 10.8 to 15.9 inch lbs.)
Reused bearing: 0.50 to 0.80 Nm (5.1 to 8.2 kgf-cm, 4.3 to 6.9 inch lbs.)
If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary

8. INSPECT TOTAL PRELOAD

a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting):
New bearing: 1.64 to 3.06 Nm (16.7 to 31.2 kgf-cm, 14.5 to 27.1 inch lbs.)
Reused bearing: 0.92 to 2.06 Nm (9.4 to 20.1 kgf-cm, 8.1 to 18.2 inch lbs.)

9. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

HINT: Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.

a) Install the differential case to the differential carrier.

NOTICE: Do not damage the case bearing.

b) Using SST and a hammer, install the case bearing outer race on the ring gear tooth side.

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.

c) Install SST to the differential carrier.
d) Tighten the SST bolt (A) until the SST disc lightly touches the case bearing outer race.

e) Using SST and a hammer, install the case bearing outer race on the ring gear back surface side.

HINT: Tap in the case bearing outer race until it touches the case bearing inner race roller.

f) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
g) Place a dial indicator on the differential case flange surface at a right angle.

h) Using a dial indicator, measure the differential case runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the rear differential case with a new one.

i) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

j) Tighten the SST bolt to push out the ring gear back surface side case bearing outer race.

NOTICE: Do not drop the case bearing outer race.

k) Remove the SST

l) Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.

m) Remove the differential case from the differential carrier.

NOTICE: Do not damage the case bearing.

REASSEMBLY
1. INSTALL DIFFERENTIAL RING GEAR

a) Clean the contact surfaces of the differential case and ring gear.
b) Clean the differential ring gear set bolt hole.
c) Heat the ring gear to approximately 100°C (212°F) in boiling water.

CAUTION: Use thick gloves to protect your hands as the ring gear is hot.

d) Carefully take the ring gear out of the boiling water.
e) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

f) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
g) Align the matchmarks on the ring gear and the differential case.
h) After the ring gear has cooled sufficiently, install 10 new ring gear set bolts to which thread lock has been applied.
Thread lock: Part No.08833-00100, THREE BOND 1360 K or equivalent.

NOTICE: New ring gear set bolts should be used every time the ring gear is installed.

i) Torque the 10 set bolts uniformly, a little at a time.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)

j) Tighten the bolts further by 60° to 90°.

NOTICE: Tighten diagonally opposite bolts in pairs.

2. INSTALL REAR DIFFERENTIAL CASE BEARING

a) Using SST and a press, install the case bearing inner races LH and RH to the differential case.

SST 09950-60010 (09951-00560, 09951-00570), 09950-70010 (09951-07100)

NOTICE:
^ Do not apply hypoid gear oil to a new bearing.
^ Do not deform the bearing cage. Set the SST to the center of the differential case.
^ If the bearing is replaced, replace it and its outer race as a set.
^ The bearing for the two different sides of the differential case have different part numbers. Install 90366-50087 to the differential case on the ring gear tooth side, and install 9036650027 to the differential case on the side that does not have the ring gear teeth. Use the part numbers to determine correct bearing placement.

3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

a) Using SST and a press, install the rear drive pinion rear tapered roller bearing inner race to the drive pinion.
SST 09316-60011 (09316-00031), 09612-10093 (09613-22011)

b) Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and plate washer.
SST 09255-10012, 09950-70010 (09951-07200)

HINT: Select a plate washer of the same thickness as the removed one.

4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

a) Using SST and a press, install the rear drive pinion front tapered roller bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)

5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

HINT: Perform this procedure only when replacing the dust deflector.

a) Using SST and a press, insert a new dust deflector into the companion flange.
SST 09316-60011 (09316-00011)

NOTICE:
^ Slowly press in the dust deflector but not press it excessively.
^ If any burrs remain after pressing in the deflector, remove them.

6. INSTALL DIFFERENTIAL DRIVE PINION

a) Using SST and a press, install the differential drive pinion.
SST 09316-60011 (09316-00011), 09608-04031

HINT: Install the spacer and oil seal after adjusting the tooth contact pattern.