Part 1
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-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 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.
Text in Illustration
(g) Align the matchmarks on the differential ring gear and the rear differential case sub-assembly.
(h) After the differential ring gear has cooled sufficiently, install 10 new ring gear set bolts to which thread lock has been applied.
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent.
NOTICE:
* New ring gear set bolts should be used every time the differential ring gear is installed.
* Do not allow oil to adhere to the ring gear set bolt during installation.
(i) Tighten the 10 ring gear set bolts uniformly, a little at a time.
Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)
NOTICE:
Tighten diagonally opposite ring gear set bolts in pairs.
(j) Tighten the 10 ring gear set bolts further 60° to 90°.
NOTICE:
Tighten diagonally opposite ring gear set bolts in pairs.
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 : 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 SST to the center of the rear differential case sub-assembly.
* If the bearing is replaced, replace it and its outer race as a set.
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 differential drive pinion.
SST : 09316-60011
09316-00031
SST : 09612-24014
09613-22011
(b) Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and a new rear differential drive pinion plate washer.
Text in Illustration
SST : 09255-10012
SST : 09950-70010
09951-07200
HINT
Select a rear differential drive pinion 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
(b) Install the rear drive pinion front tapered roller bearing inner race to the rear differential carrier.
5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
HINT
Perform this procedure only when replacing the rear differential dust deflector.
(a) Using SST and a press, insert a new rear differential dust deflector to the rear drive pinion companion flange.
SST : 09316-60011
09316-00011
NOTICE:
* Slowly press in the rear differential dust deflector but not press it excessively.
* If any burrs remain after pressing in the rear differential dust deflector, remove them.
6. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, install the differential drive pinion.
SST : 09316-60011
09316-00011
09316-00041
SST : 09608-04031
HINT
Install the rear differential drive pinion bearing spacer and rear differential carrier oil seal after adjusting the tooth contact pattern.
7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the rear differential drive pinion oil slinger.
8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST, install the rear drive pinion companion flange.
Text in Illustration
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTICE:
* 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 of the 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 : 09229-55010
SST : 09330-00021
SST : 09950-30012
09955-03040
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 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.
(d) Turn the bearing clockwise and counterclockwise several times to stabilize it.
(e) Using SST and a torque wrench, measure the preload.
SST : 09229-55010
Differential 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.
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 rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.
NOTICE:
Do not damage the rear differential case bearing and differential ring gear.
10. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a hammer, install the differential side bearing outer race RH on the differential ring gear tooth side.
Text in Illustration
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
Tap in the rear differential case bearing outer race RH until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.
(b) Install SST to the rear differential carrier with the 2 bolts (A).
Text in Illustration
SST : 09571-50010
(c) Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing outer race RH.
(d) Using SST and a hammer, install the rear differential case bearing outer race LH on the differential ring gear back surface side.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
Tap in the rear differential case bearing outer race LH until it touches the rear differential case bearing inner race roller.
11. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
(a) Using snap ring pliers, install the thinnest rear differential side gear shaft snap ring on the back surface of the differential ring gear.
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 snap ring 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 snap ring with the same thickness as the removed one.
(b) Install a dial indicator to the rear differential carrier.
HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the rear differential side gear shaft oil seal is tapped in.
(c) Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).
SST : 09571-50010
NOTICE:
Observe the dial indicator to ensure that the shape of the rear differential carrier does not change more than 0.2 mm (0.00787 in.).
HINT
Tighten the SST bolt to apply the preload to the rear differential case bearing.
(d) Turn the differential ring gear clockwise and counterclockwise several times.
(e) Using a dial indicator, measure the backlash of the differential ring gear at 3 positions.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
NOTICE:
The difference between the maximum and minimum values must be within 0.05 mm (0.00197 in.).
HINT
* Record the measured backlash to use as a reference for selecting a rear differential 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 differential ring gear tooth side with a rear differential side gear shaft snap ring of different thickness as described in the following procedure.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft snap ring.
(f) Loosen the SST bolt and separate the SST disc from the rear differential case bearing outer race RH.
NOTICE:
Do not remove SST.
(g) Using SST and a hammer, create a clearance between the rear differential side gear shaft snap ring on the differential ring gear back surface side and rear differential case bearing outer race LH.
SST : 09608-32010
SST : 09950-70010
09951-07200
(h) Using snap ring pliers, remove the rear differential side gear shaft snap ring on the differential ring gear back surface side.
(i) Using snap ring pliers, install a rear differential side gear shaft snap ring with a different thickness.
HINT
When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash also changes by 0.02 mm (0.000787 in.).
Rear Differential Side Gear Shaft Snap Ring Thickness
(j) Using a plastic hammer, lightly tap the differential ring gear tooth side of the rear differential carrier.
(k) Install a dial indicator to the rear differential carrier.
HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the rear differential side gear shaft oil seal is tapped in.
(l) Tighten the SST bolt to alter the shape of the rear differential carrier approximately 0.1 mm (0.00394 in.).
SST : 09571-50010
NOTICE:
Observe the dial indicator to ensure that the shape of the rear differential carrier does not change more than 0.2 mm (0.00787 in.).
(m) Using a dial indicator, measure the backlash of the differential ring gear at 3 positions.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
(n) If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the back surface of the differential ring gear with one of a different thickness.
HINT
* Record the measured backlash to use as a reference for selecting a rear differential side gear shaft snap ring.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft snap ring.
12. ADJUST REAR DIFFERENTIAL CASE BEARING PRELOAD
(a) Install a dial indicator to the rear differential carrier.
HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the rear differential side gear shaft oil seal is tapped in.
(b) Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).
SST : 09571-50010
NOTICE:
Observe the dial indicator to ensure that the shape of the rear differential carrier does not change more than 0.2 mm (0.00787 in.).
(c) Using snap ring pliers, install the thinnest rear differential side gear shaft snap ring on the differential ring gear tooth side.
(d) Remove the dial indicator and loosen the bolt until the SST disc is separated from the rear differential case bearing outer race RH on the differential ring gear tooth side.
Text in Illustration
(e) Using a plastic hammer, lightly tap the differential ring gear tooth side of the rear differential carrier to stabilize the rear differential case bearing.
(f) Using a dial indicator, measure the backlash of the differential 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 rear differential side gear shaft snap ring on the differential ring gear tooth side with a thicker one.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
HINT
If the value is not within the specified range, replace it with one of a different thickness in the following procedure.
(g) Remove the 2 bolts and SST.
13. ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.
SST : 09229-55010
Total preload (at starting):
New bearing
1.54 to 2.96 N*m (15.7 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 differential ring gear tooth surface side with a thicker one.
* If the measured preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the differential 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 (0.000787 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 1 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, rotate the differential ring gear and measure the backlash.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 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 rear differential side gear shaft snap rings equally.
* When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash will also change by approximately 0.02 mm (0.000787 in.).
(d) Recheck the total preload.
14. 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
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 rear differential drive pinion plate washer has been changed, adjust the backlash and measure the total preload.
Rear Differential Drive Pinion Plate Washer Thickness
15. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING Disassembly
16. REMOVE REAR DIFFERENTIAL CASE BEARING Disassembly
17. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY Disassembly
18. 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 : 09229-55010
SST : 09330-00021
SST : 09950-30012
09955-03040
19. REMOVE REAR DRIVE PINION COMPANION FLANGE Disassembly
20. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Disassembly
21. REMOVE DIFFERENTIAL DRIVE PINION Disassembly
22. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Remove the rear drive pinion front tapered roller bearing inner race from the rear differential carrier.