Disassembly

AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE): DISASSEMBLY

1. REMOVE REAR DIFFERENTIAL BREATHER PLUG

(a) Remove the rear differential breather plug from the rear differential carrier cover.





2. REMOVE REAR DIFFERENTIAL CARRIER COVER

(a) Remove the 8 bolts.





(b) Using a brass bar and a hammer, remove the rear differential carrier cover from the rear differential carrier.





NOTICE:
* Place the brass bar onto the corners of the rear differential carrier cover.
* Do not damage the sealing surface of the rear differential carrier.

3. REMOVE REAR DIFFERENTIAL CARRIER STRAIGHT PIN

(a) Remove the 2 rear differential carrier straight pins from the rear differential carrier cover.





4. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Remove the bolt and rear differential breather plug oil deflector from the rear differential carrier cover.





5. SECURE REAR DIFFERENTIAL CARRIER

(a) Set the rear differential carrier to an overhaul stand, etc. as shown in the illustration.





6. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

(a) Set a dial indicator perpendicular to the end of the differential ring gear face.





(b) Rotate the differential ring gear and measure the runout.

Maximum runout:

0.05 mm (0.00196 in.)

If the runout exceeds the specified maximum value, remove the differential ring gear and check the runout of the rear differential case sub-assembly.

7. 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.

8. 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.





9. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the rear differential case sub-assembly and check that the backlash is 0 mm (0 in.).





If not, replace the rear differential case sub-assembly with a new one.

10. 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.

11. INSPECT 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):

0.50 to 0.80 N*m (5.1 to 8.2 kgf*cm, 4.3 to 6.9 in.*lbf)

12. 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):

0.92 to 2.06 N*m (9.4 to 21.0 kgf*cm, 8.1 to 18.2 in.*lbf)

13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST, remove the 2 rear differential side gear shaft oil seals.





SST : 09308-00010

14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

(a) Install SST to the rear differential carrier with the 2 bolts (A).





Text in Illustration





SST : 09571-50010

(b) Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing outer race RH on the differential ring gear tooth side.

HINT
Set a 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) Install a dial indicator to the rear differential carrier.





(d) Tighten the SST bolt and alter the shape of the rear differential carrier to create a 0.1 mm (0.00394 in.) clearance between the rear differential case bearing outer race RH and rear differential side gear shaft snap ring.

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
Approximately 0.1 mm (0.00394 in.) clearance between the rear differential case bearing outer race RH and the rear differential side gear shaft snap ring is sufficient for the rear differential side gear shaft snap ring to move slightly.

(e) Using snap ring pliers, remove the rear differential side gear shaft snap ring on the differential ring gear tooth side.





HINT
For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

(f) Remove the dial indicator and loosen the SST bolt.

NOTICE:
Do not remove SST.

(g) Using SST and a hammer, create a clearance between the rear differential case bearing outer race LH on the back surface of the differential ring gear and rear differential side gear shaft snap ring.





SST : 09608-32010

SST : 09950-70010

09951-07200

HINT
The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

(h) Using snap ring pliers, remove the rear differential side gear shaft snap ring on the back surface of the differential ring gear.





HINT
For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

15. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Tighten the SST bolt and push out the rear differential case bearing outer race LH on the back surface of the differential ring gear.





SST : 09571-50010

NOTICE:
Do not drop the rear differential case bearing outer race LH.

HINT
* To use as a reference for installation, clearly write the installation positions (back side or teeth side) of the rear differential case bearing outer race and the rear differential side gear shaft snap ring.
* Put identification marks on the rear differential case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

(b) Remove the 2 bolts and SST.





(c) Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the rear differential case bearing outer race RH on the differential ring gear tooth side.





HINT
* To use as a reference for installation, clearly write the installation positions (back side or teeth side) of the rear differential case bearing outer race and the rear differential side gear shaft snap ring.
* Put identification marks on the rear differential case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Remove the rear differential case sub-assembly as shown in the illustration.





NOTICE:
Do not damage the rear differential case bearing.

17. REMOVE REAR DRIVE PINION NUT

(a) Using SST and a hammer, unstake the staked part of the rear drive pinion nut.





SST : 09930-00010

NOTICE:
* Be sure to use SST with the tapered surface facing the differential drive pinion.
* Do not grind the tip of SST with a grinder, etc.
* Completely loosen the staked part of the rear drive pinion nut when removing it.
* Do not damage the threads of the differential drive pinion.

(b) 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

18. REMOVE REAR DRIVE PINION COMPANION FLANGE

(a) Using SST, remove the rear drive pinion companion flange.





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.

19. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

HINT
Perform this procedure only when the rear differential dust deflector is damaged.

(a) Using SST and a press, remove the rear differential dust deflector.





SST : 09950-00020

SST : 09950-60010

09951-00440

SST : 09950-70010

09951-07100

NOTICE:
Do not drop the rear drive pinion companion flange.

20. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Replacement

21. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the rear differential drive pinion oil slinger.





22. REMOVE DIFFERENTIAL DRIVE PINION

(a) Using a press, remove the differential drive pinion from the rear differential carrier.





NOTICE:
Do not drop the differential drive pinion.

23. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Remove the rear differential drive pinion bearing spacer from the differential drive pinion.





24. 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.





(b) Using a brass bar and a hammer, remove the rear drive pinion front tapered roller bearing outer race from the rear differential carrier.





25. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, remove the rear drive pinion rear tapered roller bearing inner race from the differential drive pinion.





SST : 09950-00020

HINT
If either the differential drive pinion or differential ring gear is damaged, replace both as a set.

(b) Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing outer race from the rear differential carrier.





(c) Remove the rear differential drive pinion plate washer.

26. REMOVE DIFFERENTIAL RING GEAR

(a) Put matchmarks on the differential ring gear and rear differential case sub-assembly.





Text in Illustration





(b) Remove the 10 ring gear set bolts.

(c) Using a plastic hammer, tap on the differential ring gear to separate it from the rear differential case sub-assembly.





NOTICE:
Do not damage the differential ring gear.

27. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

HINT
Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.

(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.

(b) 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 RH until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

(c) Install SST to the rear differential carrier with the 2 bolts (A).





Text in Illustration





SST : 09571-50010

(d) Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing outer race RH.

(e) 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.

(f) 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.





(g) Place a dial indicator on the rear differential case sub-assembly flange surface at a right angle.





(h) Using a dial indicator, measure the rear differential case sub-assembly runout.

Maximum runout:

0.05 mm (0.00196 in.)

If the runout is greater than the maximum, replace the rear differential case sub-assembly with a new one.

(i) Using snap ring pliers, remove the rear differential side gear shaft snap ring on the differential ring gear back surface side.





(j) Tighten the SST bolt to push out the rear differential case bearing outer race LH on the back surface of the differential ring gear.





NOTICE:
Do not drop the differential side bearing outer race LH.

(k) Remove the 2 bolts and SST.





(l) Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the differential side bearing outer race RH on the differential ring gear tooth side.





(m) Remove the rear differential case sub-assembly from the rear differential carrier as shown in the illustration.





NOTICE:
Do not damage the rear differential case bearing.

28. REMOVE REAR DIFFERENTIAL CASE BEARING

HINT
Perform this procedure only when replacing the rear differential case bearing or rear differential case sub-assembly.

(a) Using SST, remove the rear differential case bearing inner races LH and RH from the rear differential case sub-assembly.





Text in Illustration





SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00350

09951-00480

09952-06010

NOTICE:
* Do not deform the bearing cage if the bearing is to be reused.
* Hook the SST claw from the dent of the rear differential case sub-assembly to the rear differential case bearing inner race.
* Apply grease to the threads and tip of the SST center bolt before use.

29. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Secure the rear differential case sub-assembly in a vise between aluminum plates.





NOTICE:
Do not overtighten the vise.

(b) Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the rear differential case sub-assembly and check that the backlash is 0 mm (0 in.).

If not, replace the rear differential case sub-assembly with a new one.