Part 2
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): REASSEMBLY - Continued
23. INSTALL REAR DRIVE PINION COMPANION FLANGE
(a) 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:
Apply grease to the threads of SST center bolt before use.
(b) Coat the threads of the rear drive pinion nut with hypoid gear oil LSD.
(c) 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.
24. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) 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):
* If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut by 5 to 10° to adjust it into the specified range.
Torque:
337 N*m (3444 kgf*cm, 249 ft.*lbf) or less
* If the preload is less than the specified minimum value even when the tightening torque of the rear drive pinion nut is greater than the specified maximum value, loosen the rear drive pinion nut and check that the threads of the rear drive pinion nut and differential drive pinion are not stripped.
* If the threads are not stripped, replace the rear differential drive pinion bearing spacer. Apply hypoid gear oil LSD to the threads of the differential drive pinion and repeat the procedure.
25. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total Preload (at Starting):
If the total preload is not within the specified range, adjust the total preload or repair as necessary.
26. INSPECT 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.)
27. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE
(a) Using a dial indicator, measure the runout of the rear drive pinion companion flange vertically and horizontally.
Maximum runout:
0.09 mm (0.00354 in.)
NOTICE:
Measure the runout of the rear drive pinion companion flange horizontally at a position 30 mm (1.18 in.) away from the center of the shaft.
28. STAKE REAR DRIVE PINION NUT
(a) Using SST and a hammer, stake the rear drive pinion nut.
SST : 09930-00010
29. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, install 2 new rear differential side gear shaft oil seals.
SST : 09213-70011
SST : 09950-60010
09951-00410
09951-00620
09952-06010
SST : 09950-70010
09951-07100
Oil seal installation depth (A):
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
NOTICE:
* To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seals.
* When installing the rear differential side gear shaft oil seals, tap them in until the outer surface of each seal is flush with the rear differential carrier.
(b) Apply MP grease to the rear differential side gear shaft oil seal lips.
30. INSTALL REAR DIFFERENTIAL DRAIN PLUG
(a) Using a hexagon wrench, install the rear differential drain plug with a new gasket.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
31. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
(a) Clean the seal packing attached on the rear differential carrier and rear differential carrier cover using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.
NOTICE:
Do not scratch the sealing surface.
(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
32. REMOVE REAR DIFFERENTIAL CARRIER
(a) Remove the rear differential carrier from the overhaul stand, etc.
33. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN
(a) Using a plastic hammer, install the 2 rear differential carrier straight pins to the rear differential carrier.
Protrusion (A):
8 to 9 mm (0.315 to 0.354 in.)
34. INSTALL REAR DIFFERENTIAL CARRIER COVER
(a) Apply seal packing to the rear differential carrier as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent
NOTICE:
* Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
* Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.
* Install the rear differential carrier cover within 3 minutes of application.
(b) Install the rear differential carrier cover with the 8 bolts and 2 rear differential carrier straight pins.
Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
NOTICE:
Do not fill the differential with oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.
35. INSTALL REAR DIFFERENTIAL BREATHER PLUG
(a) Install the rear differential breather plug to the rear differential carrier cover.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)