Part 2

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

12. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

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

(b) Tighten SST bolt to alter the shape of the differential carrier 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 is 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 (A) until SST disc is separated from the case bearing outer race.

SST : 09571-50010

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

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

13. 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):

NOTICE:
* If the measured preload is less than the specified value, replace the side gear shaft snap ring 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 snap ring of the ring gear tooth surface side with a thinner one.

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

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

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
* Measure at 3 or more areas around the circumference of the ring gear.
* 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.

14. 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.

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

HINT
* If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
* If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.

Washer thickness

15. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

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

(b) 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
* 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.
* 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.

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

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

NOTICE:
Do not remove SST.

16. 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 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 ring gear back surface side.

17. REMOVE REAR DIFFERENTIAL CASE BEARING

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

SST : 09571-50010

NOTICE:
Do not drop the case bearing outer race.

HINT
* To use as a reference for installation, clearly write the installation positions of the rear differential case bearing (outer race) and the side gear shaft snap ring.
* 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.

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

18. 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 the side gear shaft snap ring before removing the case bearing outer race. Write down the result.
* 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.

19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Remove the rear differential case assembly.

NOTICE:
Do not damage the case bearing.

20. 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

21. 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.

22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the differential 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 DRIVE PINION FRONT TAPERED ROLLER BEARING

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

25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

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

HINT
The bearing spacer can be installed in either direction.

26. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

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

27. INSTALL DIFFERENTIAL DRIVE PINION

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

SST : 09316-60011

09316-00011

09316-00041

SST : 09608-04031

28. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

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

29. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

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

SST : 09316-60011

09316-00011

SST : 09710-30012

09710-04101

NOTICE:
* Tap the oil seal uniformly so that the oil seal is straight.
* Do not excessively tap the oil seal.

(b) Using a vernier caliper, measure the depth of the oil seal.

Oil seal installation depth:

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

NOTICE:
* Measure at 3 or more areas around the circumference of the oil seal.
* Make sure difference between the maximum and minimum measured values is less than 0.65 mm, as a greater difference may lead to oil leaks.

(c) Apply MP grease to the lip of the oil seal.