Part 2
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE): REASSEMBLY - Continued
23. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
HINT
The rear differential drive pinion bearing spacer can be installed in either direction.
24. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the rear drive pinion front tapered roller bearing inner race to the rear differential carrier.
25. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, install the differential drive pinion to the rear differential carrier.
SST : 09316-60011
09316-00011
09316-00041
SST : 09608-04031
26. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the rear differential drive pinion oil slinger.
27. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Replacement
28. INSTALL REAR DRIVE PINION COMPANION FLANGE
(a) Using SST, install the rear drive pinion companion flange to the differential drive pinion.
Text in Illustration
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTICE:
Apply grease to the threads of the SST center bolt before use.
(b) Coat the threads of a new 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
Torque : 490 Nm (5000 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 drive pinion nut and differential drive pinion.
HINT
Tighten the drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.
29. 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 or differential ring gear.
30. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a hammer, install the rear differential case 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 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 until it touches the rear differential case bearing inner race roller.
31. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
(a) Using snap ring pliers, install the rear differential side gear shaft snap ring in the rear differential carrier on the differential ring gear back surface side.
HINT
Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.
(b) Set a dial indicator on the rear differential carrier.
(c) Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).
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.).
(d) Using snap ring pliers, install the rear differential side gear shaft snap ring on the differential ring gear tooth side.
HINT
Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.
(e) Remove the dial indicator and tap the rear differential carrier on the differential ring gear tooth side using a plastic hammer to stabilize the rear differential case bearing.
(f) Remove the 2 bolts and SST.
32. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST and 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.
SST : 09229-55010
Differential drive pinion preload (at starting):
New bearing
1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.8 to 15.9 in.*lbf)
Reused bearing
0.50 to 0.80 N*m (5.1 to 8.2 kgf*cm, 4.3 to 6.9 in.*lbf)
* If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut 5 to 10°.
Torque:
490 N*m (5000 kgf*cm, 361 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 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.
33. INSPECT 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
1.64 to 3.06 N*m (16.7 to 31.2 kgf*cm, 14.5 to 27.1 in.*lbf)
Reused bearing
0.92 to 2.06 N*m (9.4 to 21.0 kgf*cm, 8.1 to 18.2 in.*lbf)
34. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
If the backlash is not within the specified range, adjust the backlash or repair as necessary.
35. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
(a) Using a dial indicator, measure the runout of the differential drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.
Maximum runout:
0.08 mm (0.00315 in.)
If the runout is greater than the maximum, replace the differential drive pinion and differential ring gear.
36. STAKE REAR DRIVE PINION NUT
(a) Using SST and a hammer, stake the rear drive pinion nut.
SST : 09930-00010
37. 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 : 09223-15030
SST : 09950-70010
09951-07200
Oil seal installation depth (A):
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
NOTICE:
* Make sure to check the identification marks on the rear differential side gear shaft 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 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.
38. INSTALL REAR DIFFERENTIAL DRAIN PLUG
(a) Using a hexagon wrench, install the differential drain plug with a new gasket.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
39. REMOVE REAR DIFFERENTIAL CARRIER
(a) Remove the 4 bolts and rear differential carrier from the overhaul stand.
NOTICE:
Clean the fitting surface between the rear differential carrier and rear differential carrier cover.
40. 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 : 7.0 Nm (70 kgf-cm, 62 in-lbf)
41. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN
(a) Using a plastic hammer, install the 2 rear differential carrier straight pins to the rear differential carrier cover.
Protrusion (A):
10 to 12 mm (0.394 to 0.472 in.)
42. INSTALL REAR DIFFERENTIAL CARRIER COVER
(a) Apply seal packing to the rear differential carrier as shown in the illustration.
Text in 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 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.
43. 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)