Part 3

REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE) Continued

11. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

a) Using SST and a press, install the outer race of the rear drive pinion front tapered roller bearing to the differential carrier.
SST 09950-60020 (09951-00720), 09950-70010 (09951-07100)

12. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

a) Using SST and a press, install a new dust deflector.
SST 09636-20010

NOTICE:
^ Slowly press in the dust deflector.
^ If any burrs remain after pressing in the deflector, remove them.

13. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (for 2WD)

a) Install the drive pinion and the inner race of the rear drive pinion front tapered roller bearing to the differential carrier.

NOTICE:
^ Do not drop the drive pinion.
^ Install the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.

b) Install the drive pinion oil slinger to the drive pinion.

c) Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)

NOTICE:
^ Hold the drive pinion until the SST is installed.
^ Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
^ Apply grease to the threads and tip of the SST center bolt before use.

d) Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021
Torque: 338 Nm (3,450 kgf-cm, 249 ft. lbs.) or less

NOTICE:
^ Tighten the nut to approximately 100 Nm (1,020 kgf-cm, 74 ft. lbs.), and tighten it further while checking the preload.
^ Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
^ As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.

e) Turn the bearing clockwise and counterclockwise several times to stabilize it.

f) Using a torque wrench, measure the drive pinion preload.

Drive Pinion Preload (at starting):

NOTICE:
^ Record the preload for total preload measurement.
^ Do not apply hypoid gear oil to a new bearing.

If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

14. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (for 4WD)

b) Install the drive pinion oil slinger to the drive pinion.

c) Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

NOTICE:
^ Hold the drive pinion until the SST is installed.
^ Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
^ Apply grease to the threads and tip of the SST center bolt before use.

d) Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021
Torque: 223 Nm (2,280 kgf-cm, 164 ft. lbs.) or less

NOTICE:
^ Tighten the nut to approximately 100 Nm (1,020 kgf-cm, 74 ft. lbs.), and tighten it further while checking the preload.
^ Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
^ As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.

e) Turn the bearing clockwise and counterclockwise several times to stabilize it.

f) Using a torque wrench, measure the drive pinion preload.

Drive Pinion Preload (at starting):

a) Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

NOTICE: Be sure to install the bearing outer races in each correct position.

b) Install the differential case to the differential carrier.

c) Install the right and left (on the back and tooth sides) side gear shaft washers so that the case bearing is not loose.

HINT:
^ If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft plate washer and install it.
^ If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft plate washer with the same thickness as the removed one.

16. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH
17. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

a) After adjusting the backlash of the differential ring gear, remove the teeth side side gear shaft plate washer.
b) Using a micrometer, measure the thickness of the removed side gear shaft plate washer.
c) Select a new side gear shaft plate washer which is 0.06 to 0.09 mm (0.0024 to 0.0035 inch) thicker than the removed one.

HINT: Select a 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 side gear shaft plate washer.
SST 09504-22011

e) Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

NOTICE: Make sure 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. lbs.)

g) Set the dial indicator to the end of the differential ring gear face.
h) While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Backlash:
2WD: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
4WD: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)
If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft plate washers equally HINT
^ Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
^ Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.

18. INSPECT TOTAL PRELOAD

a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Preload (at Starting):

HINT:
^ If the measured preload is less than the specified value, replace the side gear shaft plate washer of the ring gear tooth surface side with a thicker one.
^ If the preload is greater than the specified value, replace the side gear shaft plate washer of the ring gear tooth surface side with a thinner one.

b) Set the dial indicator perpendicular to the end of the ring gear face.
c) While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash:

HINT:
^ If the backlash is not within the specified range, change the thickness of the right and left side gear shaft plate washers by equal amounts to adjust it.
^ Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
^ Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.

19. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
20. REMOVE REAR DRIVE PINION NUT

a) Using SST to hold the flange, remove the drive pinion nut.

21. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 2WD)
22. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 4WD)
23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

a) Install a new drive pinion bearing spacer to the drive pinion.

NOTICE: Be sure to face the larger inner diameter side rearward as shown in the illustration.

26. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

a) Install the rear drive pinion front tapered roller bearing to the drive pinion.

27. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

a) Install the drive pinion oil slinger to the drive pinion.

28. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 2WD)

a) Using SST and a companion flange, install the rear drive pinion front tapered roller bearing.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)

NOTICE: Apply grease to the threads and tip of the SST center bolt before use.

29. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 4WD)

a) Using SST and a companion flange, install the rear drive pinion front tapered roller bearing.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

NOTICE: Apply grease to the threads and tip of the SST center bolt before use.

30. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 2WD)
31. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 4WD)
32. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

a) Using SST and a hammer, install a new oil seal.
SST 09554-22010
Oil seal installation depth: 1.55 to 2.45 mm (0.061 to 0.096 inch)
b) Apply MP grease to the oil seal lip.

33. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 2WD)

a) Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)

NOTICE: Apply grease to the threads and tip of the SST center bolt before use.

b) Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021
Torque: 338 Nm (3,450 kgf-cm, 249 ft. lbs.) or less

NOTICE:
^ Tighten the nut to approximately 100 Nm (1,020 kgf-cm, 74 ft. lbs.), and tighten it further while checking the preload.
^ Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.

34. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 4WD)

a) Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

NOTICE: Apply grease to the threads and tip of the SST center bolt before use.

b) Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021
Torque: 223 Nm (2,280 kgf-cm, 164 ft. lbs.) or less

NOTICE:
^ Tighten the nut to approximately 100 Nm (1,020 kgf-cm, 74 ft. lbs.), and tighten it further while checking the preload.
^ Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.

35. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

a) Using a torque wrench, measure the preload of the drive pinion.

Drive Pinion Preload (at starting):

^ If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.
Torque:
2WD: 338 Nm (3,450 kgf-cm, 249 ft. lbs.) or less
4WD: 223 Nm (2,280 kgf-cm, 164 ft. lbs.) or less
^ If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
^ If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

36. INSPECT TOTAL PRELOAD
37. INSPECT DIFFERENTIAL RING GEAR BACKLASH
38. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE
39. INSTALL REAR DRIVE PINION NUT

a) Using a SST and a hammer, stake the drive pinion nut.
SST 09930-00010

40. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 2WD)

a) Using SST and a hammer, install 2 new oil seals.
SST 09213-70011, 09950-60010 (09951-00410, 09951-00620, 09952-06010), 09950-70010 (09951-07100)
Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 inch)
b) Apply MP grease to the oil seal lip.

41. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD)

a) Using SST and a hammer, install 2 new oil seals.
SST 09710-04101, 09950-60010 (09951-00580, 09951-00620, 09952-06010), 09950-70010 (09951-07100)
Oil seal installation depth: 0 to 1.0 mm (0 to 0.039 inch)
b) Apply MP grease to the oil seal lip.

42. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a) Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

43. REMOVE REAR DIFFERENTIAL CARRIER

a) Remove the differential carrier from the overhaul stand, etc.

44. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

a) Install the oil deflector and bolt to the carrier cover.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

45. INSTALL REAR DIFFERENTIAL CARRIER COVER
a) Clean any residual FIPG material on the contact surfaces using gasoline or alcohol.

b) Apply FIPG to the carrier cover.
FIPG: 08826-00090, THREE BOND 1281 or equivalent

HINT:
^ Apply FIPG in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 inch) in diameter on the entire sealing surface.
^ Overlap FIPG at least 10 mm (0.39 inch) or more at the beginning and the end of application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least 12 hours after installation of parts using FIPG sealant.

c) Install the carrier cover with the 8 bolts.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)

46. INSTALL REAR DIFFERENTIAL BREATHER PLUG

a) Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)

INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY
a) Support the differential carrier rear assembly with a jack.

NOTICE: Do not drop the differential carrier.

b) Using a hexagon wrench (12 mm), temporarily install the differential carrier to the suspension member with 3 new bolts.

c) Install the 2 rear upper differential mount stoppers, 2 rear lower differential mount stoppers. Temporarily install the differential carrier rear to the suspension member with 2 new bolts.

d) Using a hexagon wrench (12 mm) and torque wrench, tighten the 3 bolts to the specified torque.
Torque: 142 Nm (1,450 kgf-cm, 105 ft. lbs.)

e) Using a torque wrench, tighten the 2 bolts to the specified torque.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)

NOTICE: Do not tilt the inner sleeve or distort the rubber parts when fully tightening the differential mount stopper.

2. INSTALL REAR STABILIZER BAR
3. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
4. INSTALL REAR DRIVE SHAFT ASSEMBLY RH HINT:
Installation procedure of the RH side is the same as that of the LH side.

5. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
6. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

7. INSTALL TAIL EXHAUST PIPE ASSEMBLY
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY
9. ADD DIFFERENTIAL OIL
10. INSPECT DIFFERENTIAL OIL
11. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
12. CHECK FOR EXHAUST GAS LEAKS
13. CHECK ABS SPEED SENSOR SIGNAL