Part 1

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

REASSEMBLY

1. INSTALL DIFFERENTIAL PINION AND SIDE GEAR (for 4WD)

(a) Install the following parts to the differential case.
- Differential pinion: [A]
- Differential pinion thrust washer: [B]
- Differential pinion shaft: [C]
- Differential side gear: [D]
- Differential side gear thrust washer: [E]
- Make sure that there is no dirt or foreign matter on the thrust washer, side gear, etc. before installing them.
- If replacing either the side gears or pinion gears, replace them as a set.
- Apply hypoid gear oil API GL-5 to all sliding and rotating parts.

(b) Install the 2 side gears and 2 side gear thrust washers to the differential case.

(d) Insert the differential pinion shaft into the differential case.
HINT: Align the holes of the differential case and differential pinion shaft.

2. INSPECT AND ADJUST DIFFERENTIAL SIDE GEAR BACKLASH (for 4WD) Rear Differential Carrier Assembly

3. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN (for 4WD)

(a) Using a pin punch (3 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.

(b) Using a chisel and a hammer, stake the outside of the differential case pin hole.
4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2WD) Rear Differential Carrier Assembly

5. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and ring gear.
(b) Clean the differential ring gear set bolt hole.
(c) Heat the ring gear to approx. 100°C (212°F) in boiling water.
CAUTION: Use thick gloves to protect hands as the ring gear is hot.

(d) Carefully take the ring gear out of the boiling water.
(e) Hold the differential case in a vise between aluminum plates.
NOTE: Do not overtighten the vise.

(f) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

(g) Align the matchmarks on the ring gear and differential case.
(h) Temporarily install 5 new lock plates and 10 bolts.
(i) After the ring gear cools down, tighten the 10 bolts uniformly.
Torque: 97 Nm (985 kgf-cm, 72 ft-lbf)

(j) Using a chisel and a hammer, stake the 5 lock plates.
(1) Stake one claw so that it is flush against the flat surface of the bolt.
(2) Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.
6. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the case bearing inner races LH and RH to the differential case.

SST: 09950-60010
09951-00430
09951-00580
09951-00590
09952-06010
SST: 09950-70010
09951-07100
SST: 09710-04081
NOTICE:
- Do not apply hypoid gear oil to a new bearing.
- Do not deform the bearing cage.
- Place the SST carefully on the inner races of the bearings or on the center of the differential case (as applicable).
- If the bearing is replaced, replace it and the outer race as a set.

7. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Rear Differential Carrier Assembly

8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Install the drive pinion plate washer to the drive pinion.
- Temporarily install the inner race of the rear drive pinion rear tapered roller bearing to prevent the drive pinion washer from being dropped.
- The drive pinion washer can be installed in either direction.

(b) Using SST and a press, install the inner race of the rear drive pinion rear tapered roller bearing to the drive pinion.
SST: 09506-30012
9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (for 2WD)

(a) Using SST and a press, install the outer race of the rear drive pinion rear tapered roller bearing to the differential carrier.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07200
10. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (for 4WD)

(a) Using SST and a press, install the outer race of the rear drive pinion rear tapered roller bearing to the differential carrier.
SST: 09950-60020
09951-00790
SST: 09950-70010
09951-07200
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
SST: 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.
- 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
- 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 N*m (3,450 kgf*cm, 249 ft.*lbf) or less
- Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), 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):

- 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
- 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 N*m (2,280 kgf*cm, 164 ft.*lbf) or less
- Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), 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.
NOTE: 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 Rear Differential Carrier Assembly

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 in.) 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.
NOTE: 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-lbf)

(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 in.)
4WD
0.10 to 0.15 mm (0.0039 to 0.0059 in.)
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):

Reused differential case bearing:

- 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 Rear Differential Carrier Assembly

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) Disassembly

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

23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Disassembly

24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Disassembly

25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new drive pinion bearing spacer to the drive pinion.
NOTE: Be sure to face the larger inner diameter side rearward as shown in the illustration.