Part 1

DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

1. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of differential case and ring gear.

(b) Clean the differential ring gear set bolt hole.

(c) Heat the ring gear approx. 100°C (212°F) in boiling water.

CAUTION:
Use thick gloves to protect your 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.

NOTICE:
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 the differential case.

(h) After the ring gear has been cooled sufficiently, install the new 10 ring gear set bolts to which thread lock has been applied.

Thread lock:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

NOTICE:
New ring gear set bolts should be used in every case.

(i) Torque the 10 set bolts uniformly, a little at a time.

Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)

(j) Tighten the bolts further by 60° to 90°.

NOTICE:
Tighten the bolts, diagonally opposite of each other, in pairs.

2. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the case bearing inner race LH and RH to the differential case.

SST : 09950-60010

09951-00550

09951-00560

SST : 09950-70010

09951-07200

NOTICE:
* Do not apply hypoid gear oil to a new bearing.
* Do not deform the bearing cage. Set the SST to the center of the differential case.
* If the bearing is replaced, replace it with the bearing outer race as a set.

3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, install the rear drive pinion rear tapered roller bearing inner race to the drive pinion.

SST : 09502-24010

(b) Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and plate washer.

SST : 09950-70010

09951-07200

SST : 09255-10012

HINT
Select a plate washer of the same thickness as the one removed.

4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, install the rear drive pinion front tapered roller bearing outer race.

SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07200

5. INSTALL DIFFERENTIAL DRIVE PINION

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

SST : 09316-60011

09316-00011

SST : 09608-04031

HINT
Assemble the spacer and oil seal after adjusting the tooth contact pattern.

6. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Install the drive pinion oil slinger.

7. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST, install the companion flange.

SST : 09950-30012

09951-03010

09954-03010

09956-03060

09955-03040

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

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

(c) Using SST to hold the flange, torque the drive pinion nut.

SST : 09229-55010

SST : 09330-00021

HINT
Tighten the nut to approximately 98 N*m (1000 kgf*cm, 72 ft.*lbf), and tighten it further while checking the preload.

NOTICE:
* 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.

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

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

Drive pinion preload (at starting) for 2RG-FSE:

New bearing
0.91 to 1.67 N*m (9.3 to 17.0 kgf*cm, 8.1 to 14.8 in.*lbf)

Reused bearing
0.19 to 0.67 N*m (1.9 to 6.8 kgf*cm, 4.3 to 5.9 in.*lbf)

Drive pinion preload (at starting) for 1UR-FSE:

New bearing
1.22 to 1.80 N*m (12.43 to 18.35 kgf*cm, 10.80 to 15.93 in.*lbf)

Reused bearing
0.50 to 0.80 N*m (5.10 to 8.15 kgf*cm, 4.43 to 7.08 in.*lbf)

NOTICE:
Record the preload for total preload measurement.

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

8. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY

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

NOTICE:
Do not damage the case bearing and ring gear.

9. 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 surfaces 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.

10. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

HINT
This procedure is required only when the final gear set (drive pinion & ring gear) is replaced.

(a) Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.

(b) Install a dial indicator to the differential carrier.

(c) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

SST : 09571-50010

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
* Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
* Tighten the SST bolt to apply the preload to the case bearing.

(d) Turn the ring gear clockwise and counterclockwise several times.

(e) Using a dial indicator, measure the backlash of the ring gear at 3 positions.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
The difference between the maximum and minimum values must be within 0.05 mm (0.002 in.)

HINT
Write the values for reference to select a side gear shaft snap ring. If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

(f) Loosen the SST bolt and separate the SST disc from the case bearing outer race on the ring gear tooth side.

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

SST : 09608-32010

SST : 09950-70010

09951-07200

(h) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.

(i) Using snap ring pliers, install a side gear shaft snap ring with a different thickness.

HINT
* There are 39 different thicknesses of the side gear shaft snap ring available in 0.02 mm (0.0008 in.) increments.
* When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash also changes by 0.02 mm (0.0008 in.).

Snap ring thickness

(j) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.

(k) Install a dial indicator to the differential carrier.

(l) Tighten the SST bolt to alter the differential carrier's shape approximately 0.1 mm (0.004 in.).

SST : 09571-50010

HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.

(m) Using a dial indicator, measure the ring gear backlash.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

(n) If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness.

11. ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Install a dial indicator to the differential carrier.

(b) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

SST : 09571-50010

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.

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

(d) Remove the dial indicator and loosen the bolt until the SST disc is separated from the case bearing outer race.

(e) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.

(f) Check the backlash around the ring gear. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT
If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

(g) Loosen the SST bolt and separate the SST disc from the case bearing outer race on the ring gear tooth side.

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

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

(j) Using snap ring pliers, install a side gear shaft snap ring with a different thickness.

(k) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.

(l) Check the backlash around the ring gear. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT
If a value is not within the specified range, replace it with one of a different thickness in the same procedure.

12. ADJUST TOTAL PRELOAD

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

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)

NOTICE:
* If the measured preload is less than the specification, replace the rear differential side gear shaft snap ring of the ring gear's tooth surface side with a thicker one.
* If the preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thinner one.

HINT
When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 0.9 in.*lbf).

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

(c) While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
* 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 snap rings equally.
* When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will also change by approximately 0.02 mm (0.0008 in.).

(d) Recheck the total preload.

13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.

(b) Rotate the ring gear in both directions.

(c) Inspect the tooth contact pattern.

(d) If the teeth are not contacting properly, use the following table to select a proper plate washer for correction.

NOTICE:
Make sure to always replace the plate washer with a new one.

HINT
There are 42 thicknesses of the rear differential drive pinion plate washers available in 0.01 mm (0.04 in.) increments.

Washer thickness

14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

(a) Install the SST to the rear differential carrier.

SST : 09571-50010

(b) Install a dial indicator to the rear differential carrier.

(c) Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the case bearing outer race and side gear shaft snap ring.

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
* Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.
* Approximately 0.1 mm (0.004 in.) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly.

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

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

NOTICE:
Do not remove the SST.

15. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

(a) Using SST and a hammer, create a clearance between the case bearing outer race on the ring gear and side gear shaft snap ring.

SST : 09608-32010

SST : 09950-70010

09951-07200

HINT
The clearance is not visible, but tapping the SST with a hammer three or four times should be enough.

(b) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.

16. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Tighten the SST bolt and push out the case bearing outer race on the ring gear back surfaces side.

SST : 09571-50010

NOTICE:
Do not drop the case bearing outer race.

(b) Remove the SST.

17. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.

HINT
For reassembly, check the installation position of the case bearing outer race and of the side gear shaft snap ring before removing the case bearing outer race. Write down the result.

18. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY

(a) Remove rear differential case assembly.

NOTICE:
Do not damage the case bearing.

19. REMOVE REAR DRIVE PINION NUT

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

SST : 09229-55010

SST : 09330-00021

SST : 09950-30012

09955-03040