Part 2

20. REMOVE REAR DRIVE PINION COMPANION FLANGE REAR

(a) Using SST, remove the companion flange.





SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03040

09956-03060

21. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the differential drive pinion oil slinger.

22. REMOVE DIFFERENTIAL DRIVE PINION

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





NOTICE:
Do not drop the drive pinion.

23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Remove the rear drive pinion front tapered roller bearing from the differential carrier.





24. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

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





25. INSTALL DIFFERENTIAL DRIVE PINION

(a) Using SST and a press, install the differential drive pinion to the differential carrier.





SST : 09316-60011

09316-00011

SST : 09608-04031

26. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

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

27. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

HINT
Perform this procedure only when replacing the dust deflector.

(a) Using SST and a press, insert a new dust deflector into the companion flange.





SST : 09316-60011

09316-00011

NOTICE:
* Slowly press in the dust deflector but not excessively.
* If any burrs remain after pressing in the deflector, remove them.
28. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST and a hammer, install a new oil seal.





SST : 09316-60011

09316-00011

SST : 09710-30012

09710-04101

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

(b) Apply MP grease to the oil seal lip.

29. INSTALL REAR DRIVE PINION COMPANION FLANGE REAR

(a) Using SST, install the companion flange to the drive pinion.





SST : 09950-30012

09951-03010

09953-03010

09954-03010

09956-03060

09955-03040

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

(b) Coat the threads of a new drive pinion nut with hypoid gear oil LSD.

(c) Use SST to hold the flange and torque the drive pinion nut.





SST : 09950-30012

09955-03040

SST : 09229-55010

SST : 09330-00021

Torque : 98 to 490 Nm (1000 to 5000 kgf-cm, 72 to 361 ft-lbf)

NOTICE:
* Do not tighten excessively, otherwise the threads will be stripped.
* Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
HINT
Tighten the nut using approximately 98 N*m (1000 kgf*cm) of force, then tighten it further while observing the preload.

30. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST and a torque wrench, measure the preload.





SST : 09229-55010

Drive pinion preload (at starting):

New bearing
1.2 to 1.8 N*m (12.2 to 18.4 kgf*cm, 10.6 to 15.9 in.*lbf)

Reused bearing
0.5 to 0.8 N*m (5 to 8 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 drive pinion nut by 5 to 10°.

* 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.

31. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY

(a) Insert the differential case from the ring gear tooth side.





NOTICE:
Do not damage the case bearing inner race or ring gear.

32. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a hammer, install the ring gear tooth side case bearing outer race.





SST : 09608-32010

SST : 09950-70010

09951-07200

HINT
Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

(b) Install SST to the differential carrier.





SST : 09571-50010

(c) Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.

(d) Using SST and a hammer, install the ring gear back surface side case bearing outer race.





SST : 09950-70010

09951-07200

SST : 09608-32010

HINT
Tap in the case bearing outer race until it touches the case bearing inner race roller.

33. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

(a) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.





HINT
Use the side gear shaft snap ring installed when performing tooth contact adjustment.

(b) Set a dial indicator on the differential carrier.





(c) Tighten the SST bolt to alter the differential carrier's shape.

Shaped limit:

0.20 mm (0.0079 in.)

NOTICE:
Do not alter the shape excessively.

(d) Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.





HINT
Use the side gear shaft snap ring installed when performing tooth contact adjustment.

(e) Remove the dial indicator, tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.





34. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION

(a) Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) away from the end of the shaft.





Maximum runout:

0.08 mm (0.0031 in.)

35. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST and a hammer, install 2 new oil seals.





SST : 09223-15030

SST : 09950-70010

09951-07200

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

(b) Apply MP grease to the oil seal lips.

36. INSPECT TOTAL PRELOAD

(a) Using SST and a torque wrench, measure the total preload.





SST : 09229-55010

Total preload (at starting) for 2GR-FSE:

Drive pinion preload plus 0.46 to 1.37 N*m (4.69 to 13.97 kgf*cm, 4.07 to 12.13 in.*lbf)

Total preload (at starting) for 1UR-FSE:

Drive pinion preload plus 0.59 to 1.76 N*m (6.02 to 17.95 kgf*cm, 5.22 to 15.58 in.*lbf)

37. INSTALL REAR DRIVE PINION NUT

(a) Using a chisel and a hammer, stake the drive pinion nut.





38. REMOVE REAR DIFFERENTIAL CARRIER

(a) Remove the differential carrier from the overhaul attachment.





NOTICE:
Clean the fitting surface between the differential carrier and carrier cover.

39. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.





NOTICE:
Do not scratch the fitting surface.

(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover.

Torque : 7.0 Nm (70 kgf-cm, 62 in-lbf)

40. INSTALL REAR DIFFERENTIAL CARRIER COVER

(a) Apply seal packing 1281 to the differential carrier at the position shown in the illustration.





NOTICE:
* Apply the seal packing in drops, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter entirely.
* Overlap the seal packing at least 10 mm at the beginning and the end of application.
* Install the differential carrier cover within 3 minutes of application.
(b) Install the differential carrier cover with the 8 bolts.





Torque : 47 Nm (475 kgf-cm, 35 ft-lbf)

NOTICE:
Do not fill the 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.

41. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

(a) Install the breather plug to the carrier cover.





Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)

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-lbf)