Part 1

REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE)

Components:

REMOVAL
1. REMOVE REAR WHEEL
2. DRAIN DIFFERENTIAL OIL
a) Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.
b) Using a hexagon wrench (10 mm), remove the differential drain plug and gasket, and drain the oil.

3. REMOVE FRONT EXHAUST PIPE ASSEMBLY
4. REMOVE TAIL EXHAUST PIPE ASSEMBLY
5. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
6. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
7. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

8. REMOVE REAR STABILIZER BAR
9. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

a) Support the differential carrier with a jack.

NOTICE: Do not drop the differential carrier.

b) Using a hexagon wrench (12 mm), remove the 3 hexagon bolts.

c) Remove the 2 bolts, 2 rear upper differential mount stoppers, 2 rear lower differential mount stoppers and differential carrier rear.

DISASSEMBLY
1. REMOVE REAR DIFFERENTIAL BREATHER PLUG

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

2. REMOVE REAR DIFFERENTIAL CARRIER COVER

a) Remove the 8 bolts from the differential carrier cover.

b) Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.

NOTICE: Do not damage the sealing surface of the differential carrier.

3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR BOLT

a) Remove the bolt and oil deflector from the differential carrier cover.

4. SECURE REAR DIFFERENTIAL CARRIER

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

5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
6. INSPECT DIFFERENTIAL RING GEAR BACKLASH
7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2WD)
9. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE
10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
11. INSPECT TOTAL PRELOAD
12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

a) Using SST, remove the 2 oil seals.
SST 09308-00010

13. REMOVE REAR DRIVE PINION NUT

a) Using SST and a hammer, unstake the staked part of the drive pinion nut.
SST 09930-00010

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

b) Using SST to hold the flange, remove the drive pinion nut.
SST 09330-00021

14. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 2WD)

a) Using SST, remove 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.

15. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 4WD)

a) Using SST, remove 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.

16. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

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

a) Using SST and a press, remove the dust deflector.
SST 09950-00020, 09950-60010 (09951-00380), 09950-70010 (09951-07100)

NOTICE: Do not drop the companion flange.

17. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

a) Using SST, remove the oil seal from the differential carrier.
SST 09308-00010

18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

a) Remove the drive pinion oil slinger.

19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

a) Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.
SST 09556-22010

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

20. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

a) Remove the drive pinion bearing spacer.

21. REMOVE DIFFERENTIAL CASE ASSEMBLY

a) Put matchmarks on either set of the bearing cap and differential carrier.
b) Remove the 4 bolts and 2 bearing caps.

NOTICE: Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.

c) Using SST and a hammer, remove the 2 side gear shaft plate washers.
SST 09504-22011

NOTICE: Put identification marks on the side gear shaft plate washer to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

HINT: Measure the thickness of the plate washers and note it.

d) Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.

NOTICE:
^ Do not damage the differential case bearing or ring gear.
^ Put identification marks on the 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.

22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a) Remove the drive pinion from the differential carrier.

b) Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.
SST 09950-00020

NOTICE: Do not drop the drive pinion.

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

c) Remove the drive pinion plate washer from the drive pinion.

HINT: Measure the thickness of the plate washer and note it.

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

NOTICE: Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.

23. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

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

NOTICE: Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.

24. REMOVE DIFFERENTIAL RING GEAR

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Put matchmarks on the ring gear and differential case.
c) Using a chisel and a hammer, unstake the 5 lock plates.

d) Remove the 10 ring gear set bolts and 5 lock plates.

e) Using a plastic hammer, tap on the ring gear to separate it from the differential case.

HINT: Use cloth to prevent damage to the ring gear teeth.

25. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY
26. REMOVE REAR DIFFERENTIAL CASE BEARING (for 2WD)

HINT: Perform this procedure only when replacing the case bearing or differential case.

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Using SST, remove the case bearing inner races LH and RH from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480, 09951-00350, 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 differential case to the bearing inner race.
^ Apply grease to the threads and tip of the SST center bolt before use.

27. REMOVE REAR DIFFERENTIAL CASE BEARING (for 4WD)

HINT: Perform this procedure only when replacing the case bearing or differential case.

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Using SST, remove the case bearing inner races LH and RH from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480, 09951-00330, 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 differential case to the bearing inner race.
^ Apply grease to the threads and tip of the SST center bolt before use.

28. REMOVE DIFFERENTIAL PINION AND SIDE GEAR (for 4WD)

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Using a pin punch (3 mm) and a hammer, remove the straight pin.

c) Remove the following parts from the differential case.

HINT:
^ Differential pinion shaft: [A]
^ Differential pinion: [B]
^ Differential pinion thrust washer: [C]
^ Differential side gear: [D]
^ Differential side gear thrust washer: [E]

d) Remove the differential pinion shaft from the differential case.

e) Remove the 2 differential pinion gears and 2 differential pinion thrust washers from the differential case.

f) Remove the 2 differential side gear and 2 differential side gear thrust washers from the differential case.