Disassembly

DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE): DISASSEMBLY

1. REMOVE REAR DIFFERENTIAL CARRIER COVER 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 a hammer, remove the differential carrier cover from the differential carrier.

NOTICE:
* Set the brass bar on the ribbed part of the differential carrier cover.
* Do not damage the installation surface of the differential carrier.

3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(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 as shown in the illustration.

HINT
Install the differential carrier to the back surface side of the ring gear as shown in the illustration.

5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

(a) Place a dial indicator so that it is perpendicular to the back surface of the ring gear.

(b) Rotate the ring gear and measure the ring gear runout.

Maximum runout:

0.05 mm (0.0020 in.)

If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

6. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Place a dial indicator on the tip of the ring gear tooth at a right angle.

(b) Fix the companion flange in place, and measure the ring gear backlash.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
Measure the ring gear at 3 or more different places.

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

(b) Rotate the companion flange several times in the forward and backward rotation directions.

NOTICE:
Check the tooth contact pattern at 4 positions around the circumference of the ring gear.

HINT
The patterns indicated by the Prussian blue are the tooth contact locations.

8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Place a dial indicator on the tip of the side gear tooth at a right angle.

(b) Hold the pinion gear in the differential case and check that the backlash is 0 mm (0 in.).

If not, replace the rear differential case sub-assembly with a new one.

9. 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.)

If the runout is greater than the maximum, replace the drive pinion and ring gear.

10. INSPECT 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):

If the preload is not within the specified range, adjust the total preload or repair as necessary.

11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST, remove the 2 oil seals.

SST : 09308-00010

12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

(a) Install SST to the differential carrier with 2 bolts.

SST : 09571-50010

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

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

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

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
* For reassembly purposes, measure the thickness of the side gear shaft snap ring, and record the result.
* 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 side gear shaft snap ring to move slightly.

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

HINT
* For reassembly purposes, measure the thickness of the side gear shaft snap ring, and record the result.
* Place distinguishing marks on the left and right side side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

(f) Remove the dial indicator from the differential carrier.

(g) Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race.

SST : 09571-50010

HINT
Do not remove SST.

13. 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 back surface of 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 SST with a hammer 3 or 4 times should be enough.

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

HINT
* For reassembly purposes, measure the thickness of the side gear shaft snap ring, and record the result.
* Place distinguishing marks on the left and right side side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

14. REMOVE REAR DIFFERENTIAL CASE BEARING

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

SST : 09571-50010

NOTICE:
Do not drop the case bearing outer race.

HINT
* For reassembly purposes, mark the installation positions of the differential case bearing outer race and side gear shaft snap ring.
* Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

(b) Remove the 2 bolts and SST from the differential carrier.

SST : 09571-50010

15. REMOVE REAR DIFFERENTIAL CASE BEARING

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

NOTICE:
Do not drop the case bearing outer race.

HINT
* For reassembly purposes, mark the installation positions of the differential case bearing outer race and side gear shaft snap ring.
* Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Pull out the differential case from the back surface side of the ring gear, and remove it from the differential carrier.

NOTICE:
Do not damage the case bearing.

17. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

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

SST : 09229-55010

Drive pinion preload (at starting):

0.50 to 0.80 N*m (5.1 to 8.2 kgf*cm, 4.4 to 7.1 in.*lbf)

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

18. 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 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 : 09229-55010

SST : 09330-00021

SST : 09950-30012

09955-03040

19. REMOVE REAR DRIVE PINION COMPANION FLANGE

(a) Using SST, remove the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03040

09956-03060

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

20. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

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

(a) Using SST and a press, press out the dust deflector.

SST : 09950-00020

SST : 09950-60010

09951-00440

SST : 09950-70010

09951-07100

NOTICE:
* Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the dust deflector.
* Do not drop the companion flange.

21. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST, remove the oil seal from the differential carrier.

SST : 09308-00010

22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the drive pinion oil slinger.

23. REMOVE DIFFERENTIAL DRIVE PINION

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

NOTICE:
Do not drop the drive pinion.

24. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Remove the drive pinion spacer.

25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

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

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

26. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

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

SST : 09950-00020

NOTICE:
* Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the rear tapered roller bearing inner race.
* Do not drop the drive pinion.

(b) Using a brass bar and a hammer, tap out the rear drive pinion rear tapered roller bearing outer race and plate washer from the differential carrier.

NOTICE:
* Make sure to perform this procedure with the brass bar placed on the plate washer.
* Do not damage the differential carrier assembly.

HINT
For reassembly purposes, measure the thickness of the plate washer, and record the result.

27. 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) Remove the 10 ring gear set bolts.

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

NOTICE:
Do not damage the ring gear.

HINT
Place a cloth on the tooth side of the ring gear to prevent damage.

28. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

HINT
Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.

(a) Install the differential case to the differential carrier.

NOTICE:
Do not damage the case bearing.

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

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.

(c) Install SST to the differential carrier.

SST : 09571-50010

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

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

SST : 09608-32010

SST : 09950-70010

09951-07200

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

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

(g) Place a dial indicator on the differential case flange surface at a right angle.

(h) Using a dial indicator, measure the differential case runout.

Maximum runout:

0.05 mm (0.0020 in.)

If the runout is greater than the maximum, replace the rear differential case sub-assembly with a new one.

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

(j) Tighten SST bolt to push out the ring gear back surface side case bearing outer race.

SST : 09571-50010

NOTICE:
Do not drop the case bearing outer race.

(k) Remove the 2 bolts and SST from the differential carrier.

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

(m) Remove the differential case from the differential carrier.

NOTICE:
Do not damage the case bearing.

29. REMOVE REAR DIFFERENTIAL CASE BEARING

HINT
Do not remove the rear differential case bearing unless replacing the differential case or differential case bearing.

(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

SST : 09950-60010

09951-00350

09951-00480

09952-06010

NOTICE:
* Do not deform the bearing cage if the bearing is to be reused.
* Hook SST claw from the recess of the differential case to the bearing inner race.
* Apply grease to the threads and tip of SST center bolt before use.

30. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

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

NOTICE:
Do not overtighten the vise.

(b) Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the differential case and check that the backlash is 0 mm (0 in.).

If not, replace the rear differential case sub-assembly with a new one.