Part 2

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

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 0.1mm (0.004 in.).

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more that 0.2 mm (0.008 in.).

(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 N*m (12.4 to 18.4 kgf*cm, 10.7 to 16.0 in.*lbf)

Reused bearing
0.50 to 0.80 N*m (5.0 to 8.2 kgf*cm, 4.4 to 7.1 in.*lbf)

* If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10°.

Torque:

490 N*m (5,000 kgf*cm, 361 ft.*lbf) 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 Testing and Inspection

35. INSPECT DIFFERENTIAL RING GEAR BACKLASH Testing and Inspection

36. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Testing and Inspection

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

SST : 09950-70010

09951-07200

Oil seal installation depth:

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

NOTICE:
* Make sure to check the identification marks on the oil seals before installation because the parts numbers differ between the left and right sides.
* To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seal.
* After installing oil seal, tap it in until surface is flush with the rear differential carrier.
(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-lbf)

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 in-lbf)

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 in.) 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-lbf)

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-lbf)