Part 1
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): REASSEMBLY
1. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the rear differential case sub-assembly and differential ring gear.
(b) Clean the rear differential ring gear set bolt hole.
(c) Heat the differential ring gear to approximately 100°C (212°F) in boiling water.
Text in Illustration
CAUTION:
Use thick gloves to protect your hands as the differential ring gear is hot.
(d) Carefully take the differential ring gear out of the boiling water.
(e) Secure the rear differential case sub-assembly between aluminum plates in a vise.
NOTICE:
Do not overtighten the vise.
(f) After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the rear differential case sub-assembly.
(g) Align the matchmarks on the differential ring gear and the rear differential case sub-assembly.
Text in Illustration
(h) Temporarily install 5 new rear differential ring gear set bolt lock plates and the 10 rear differential ring gear set bolts.
(i) After the differential ring gear cools down, tighten the 10 ring gear set bolts uniformly.
Torque : 97 Nm (984 kgf-cm, 71 ft-lbf)
(j) Using a chisel and a hammer, stake the 5 rear differential ring gear set bolt lock plates.
(1) Stake one claw so that it is flush against the flat surface of the bolt.
(2) Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.
2. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the rear differential case bearing inner races LH and RH to the rear differential case sub-assembly.
Text in Illustration
SST : 09710-30012
09710-04081
SST : 09950-60010
09951-00430
09951-00580
09951-00590
09952-06010
SST : 09950-70010
09951-07100
NOTICE:
* Do not apply hypoid gear oil to a new bearing.
* Do not deform the bearing cage. Set SST to the center of the rear differential case subassembly.
* If the bearing is replaced, replace it and its outer race as a set.
3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Install the rear differential case bearing outer races LH and RH to the rear differential case bearing inner races LH and RH respectively.
NOTICE:
Be sure to install the rear differential case bearing outer races in each correct position.
(b) Install the rear differential case sub-assembly to the rear differential carrier.
(c) Install the right and left (back side and teeth side) side rear differential side gear shaft plate washers so that there is no looseness on the case bearings.
Text in Illustration
HINT
* If the rear differential case bearing is new, select a thinner rear differential side gear shaft plate washer and install it.
* If the rear differential case bearing is reused, install a rear differential side gear shaft plate washer with the same thickness as the removed one.
(d) Align the matchmarks on the bearing cap and rear differential carrier, and install the 2 bearing caps.
Text in Illustration
NOTICE:
Make sure that the right and left bearing caps are not interchanged.
(e) Tighten both bearing caps with the 4 bolts.
Torque : 85 Nm (870 kgf-cm, 63 ft-lbf)
(f) Using a dial indicator, measure the runout of the differential ring gear.
Maximum runout:
0.07 mm (0.00275 in.)
(g) Remove the 4 bolts and 2 bearing caps.
Text in Illustration
NOTICE:
Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.
(h) Remove the right and left (back side and teeth side) side rear differential side gear shaft plate washers.
Text in Illustration
(i) Remove the right and left bearing caps and rear differential case sub-assembly.
NOTICE:
Do not damage the rear differential case bearing or differential ring gear.
4. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the rear differential drive pinion plate washer to the differential drive pinion.
Text in Illustration
HINT
* Temporarily install the inner race of the rear drive pinion rear tapered roller bearing to prevent the rear differential drive pinion plate washer from being dropped.
* The rear differential drive pinion plate washer can be installed in either direction.
(b) Using SST and a press, install the inner race of the rear drive pinion rear tapered roller bearing to the differential drive pinion.
SST : 09506-30012
(c) Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race to the rear differential carrier.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07200
5. 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 to the rear differential carrier.
SST : 09950-60020
09951-00720
SST : 09950-70010
09951-07100
6. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
HINT
Perform this procedure only when replacing the rear differential dust deflector.
(a) Using SST and a press, install a new rear differential dust deflector to the rear drive pinion companion flange.
SST : 09636-20010
NOTICE:
* Slowly press in the rear differential dust deflector.
* If any burrs remain after pressing in the rear differential dust deflector, remove them.
7. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the differential drive pinion and the rear drive pinion front tapered roller bearing inner race to the rear differential carrier.
NOTICE:
* Do not drop the differential drive pinion.
* Install the rear differential drive pinion bearing spacer and rear differential carrier oil seal after adjusting the tooth contact pattern.
(b) Install the rear differential drive pinion oil slinger to the differential drive pinion.
(c) Using SST, install the rear drive pinion companion flange.
Text in Illustration
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030
NOTICE:
* Hold the differential drive pinion until the SST is installed.
* Install the rear drive pinion companion flange so that there is a slight looseness on the differential drive pinion because the rear differential drive pinion bearing spacer is not yet installed.
* Apply grease to the threads and tip of the SST center bolt before use.
(d) Coat the threads of a new rear drive pinion nut with hypoid gear oil LSD.
(e) Using SST and a torque wrench, hold the rear drive pinion companion flange and tighten the rear drive pinion nut.
Text in Illustration
SST : 09330-00021
Torque : 337 Nm (3444 kgf-cm, 249 ft-lbf) or less
NOTICE:
* Tighten the rear drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the differential drive pinion preload.
* Apply hypoid gear oil LSD to the rear drive pinion nut and the threads of the differential drive pinion.
* As there is no rear differential drive pinion bearing spacer, tighten the rear drive pinion nut a little at a time and do not overtighten it.
(f) Turn the bearing clockwise and counterclockwise several times to stabilize it.
(g) Using a torque wrench, measure the starting torque of the differential drive pinion. The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed. Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.
Differential Drive Pinion Preload (at Starting):
NOTICE:
* Record the differential drive pinion preload for total preload measurement.
* Do not apply hypoid gear oil to a new rear drive pinion tapered roller bearing.
If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.
8. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Install the rear differential case bearing outer races LH and RH to the rear differential case bearing inner races LH and RH respectively.
NOTICE:
Be sure to install the rear differential case bearing outer races in each correct position.
(b) Install the rear differential case sub-assembly to the rear differential carrier.
(c) Install the right and left (on the back and tooth sides) side rear differential side gear shaft plate washers so that the rear differential case bearing is not loose.
Text in Illustration
HINT
* If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are new, select a thinner rear differential side gear shaft plate washer and install it.
* If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are reused, install a rear differential side gear shaft plate washer with the same thickness as the removed one.
9. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH
(a) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
HINT
* Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft plate washer.
(b) Select a new rear differential side gear shaft plate washer that will set differential ring gear backlash within the specified range, and install it to the differential ring gear back side.
Rear Differential Side Gear Shaft Plate Washer Thickness
(c) Make the rear differential case bearing and rear differential side gear shaft plate washer snug by tapping on the rear differential carrier with a plastic hammer.
(d) Set a dial indicator perpendicular to the end of the differential ring gear face.
(e) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
(f) If the backlash is not within the specified range, select a new rear differential side gear shaft plate washer that will set the differential ring gear backlash within the specified range and install it into the differential ring gear back side.
(g) Select a thicker rear differential side gear shaft plate washer so that the clearance (A) becomes zero or close to zero.
Text in Illustration
(h) Make the rear differential case bearing and rear differential side gear shaft plate washer snug by tapping on the rear differential carrier with a plastic hammer.
(i) Set a dial indicator perpendicular to the end of the differential ring gear face.
(j) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
If the backlash is not within the specified range, adjust the thickness of the right and left rear differential side gear shaft plate washers by an equal amount so that the backlash comes within the specified range.
10. ADJUST REAR DIFFERENTIAL CASE BEARING PRELOAD
(a) After adjusting the backlash of the differential ring gear, remove the teeth side rear differential side gear shaft plate washer.
(b) Using a micrometer, measure the thickness of the removed rear differential side gear shaft plate washer.
(c) Select a new rear differential side gear shaft plate washer which is 0.06 to 0.09 mm (0.00236 to 0.00354 in.) thicker than the removed one.
HINT
Select a rear differential side gear shaft plate washer which can be pressed in 2/3 of the way with a finger.
(d) Using SST and a plastic hammer, drive in the rear differential side gear shaft plate washer.
SST : 09504-22011
(e) Align the matchmarks on the bearing cap and rear differential carrier, and install the 2 bearing caps.
Text in Illustration
NOTICE:
Make sure that the right and left bearing caps are not interchanged.
(f) Tighten both bearing caps with the 4 bolts.
Torque : 85 Nm (870 kgf-cm, 63 ft-lbf)
(g) Set a dial indicator to the end of the differential ring gear face.
(h) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left rear differential side gear shaft plate washers equally.
HINT
* Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft plate washer.
11. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.
Total Preload (at Starting):
HINT
* If the measured preload is less than the specified value, replace the rear differential side gear shaft plate washer of the differential ring gear tooth surface side with a new thicker one.
* If the preload is greater than the specified value, replace the rear differential side gear shaft plate washer of the differential ring gear tooth surface side with a new thinner one.
(b) Set a dial indicator perpendicular to the end of the differential ring gear face.
(c) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
HINT
* If the backlash is not within the specified range, change the thickness of the right and left rear differential side gear shaft plate washers by equal amounts to adjust it.
* Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft plate washer.
12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at the 3 different positions on the differential ring gear with Prussian blue.
(b) Rotate the differential ring gear in both directions.
(c) Inspect the tooth contact pattern.
(d) If the teeth are not contacting properly, use the following table to select a proper rear differential drive pinion plate washer for correction.
Text in Illustration
NOTICE:
* 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 rear differential drive pinion plate washer has been changed, adjust the backlash and measure the total preload.
Rear Differential Drive Pinion Plate Washer Thickness
13. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the rear drive pinion companion flange, remove the rear drive pinion nut.
Text in Illustration
SST : 09330-00021
14. REMOVE REAR DRIVE PINION COMPANION FLANGE Disassembly
15. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Disassembly
16. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Disassembly
17. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
NOTICE:
Be sure to face the larger inner diameter side as shown in the illustration.
18. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the rear drive pinion front tapered roller bearing to the differential drive pinion.
19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the rear differential drive pinion oil slinger to the differential drive pinion.
20. INSTALL REAR DRIVE PINION COMPANION FLANGE
(a) Using SST and a rear drive pinion companion flange, install the rear drive pinion companion flange and rear drive pinion front tapered roller bearing.
Text in Illustration
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030
NOTICE:
Apply grease to the threads of SST center bolt before use.
21. REMOVE REAR DRIVE PINION COMPANION FLANGE Disassembly
22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Replacement