Part 1

DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE): 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-lbf)

(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

SST : 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 90366-50027 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

SST : 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

SST : 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

SST : 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

SST : 09608-04031

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

7. 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

SST : 09330-00021

HINT
Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), 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 N*m (11.4 to 17.3 kgf*cm, 9.9 to 15.0 in.*lbf)

Reused bearing
0.40 to 0.70 N*m (4.1 to 7.2 kgf*cm, 3.5 to 6.2 in.*lbf)

NOTICE:
Record the preload for total preload measurement.

(f) 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

SST : 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

SST : 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 in.).

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 in.).

HINT
* Set the dial indicator to the rearmost 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 in.)

NOTICE:
The difference between the maximum and minimum values must be within 0.05 mm (0.002 in.).

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

SST : 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 in.), the backlash also changes by 0.02 mm (0.0008 in.).

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 in.).

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 in.)

(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 in.).

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 in.).

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 in.)

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 N*m (1.57 to 30.2 kgf*cm, 13.6 to 26.2 in.*lbf)

Reused bearing
0.82 to 1.96 N*m (8.4 to 20.0 kgf*cm, 7.3 to 17.3 in.*lbf)

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 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 0.9 in.*lbf).

(b) Set a dial indicator to the end of the differential ring gear face.





(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 in.)

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 in.), the backlash will also change by approximately 0.02 mm (0.0008 in.).
(d) Recheck the total preload.

14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Testing and Inspection

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 in.) 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 in.).

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 in.) 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

SST : 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

SST : 09330-00021

SST : 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

SST : 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

SST : 09710-30012

09710-04101

Oil seal installation depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

(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

SST : 09330-00021

SST : 09950-30012

09955-03040

Torque:

490 N*m (5,000 kgf*cm, 361 ft.*lbf) 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 N*m (1,020 kgf*cm, 74 ft.*lbf), 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

SST : 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

SST : 09950-70010

09951-07200

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