Part 3

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

30. INSTALL REAR DRIVE PINION COMPANION FLANGE

(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 of SST center bolt before use.

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





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

SST : 09229-55010

SST : 09330-00021

Torque:

490 N*m (5000 kgf*cm, 361 ft.*lbf) or less

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 to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.

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





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

SST : 09229-55010

Drive pinion preload (at starting):

New bearing
1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.8 to 15.9 in.*lbf)

Reused bearing
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 less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10°.

Torque:

490 N*m (5000 kgf*cm, 361 ft.*lbf) or less

* 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 SUB-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 SST bolt until 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 : 09608-32010

SST : 09950-70010

09951-07200

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.





NOTICE:
Check that the side gear shaft snap ring is securely fitted into the groove.

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 SST bolt to alter the shape of the differential carrier by approximately 0.1mm (0.004 in.).

SST : 09571-50010

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

HINT
* Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
* The approximate 0.1 mm clearance between the differential case bearing outer race and the side gear shaft snap ring only needs to be enough so that the side gear shaft snap ring can move slightly.

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

(e) 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.

(f) Loosen the thinnest side gear shaft snap ring on the ring gear tooth side.





SST : 09571-50010

(g) Tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.





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





SST : 09571-50010

34. 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.





Total preload (at starting):





35. 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.

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

36. 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.

37. INSTALL REAR DRIVE PINION NUT

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





SST : 09930-00010

38. 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 installation depth:

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

NOTICE:
* Make sure to check the identification marks on the oil seals before installation because the parts numbers differ between the left and right sides.
* To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seal.
* After installing oil seal, tap it in until surface is flush with the rear differential carrier.

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

39. 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)

40. TEMPORARILY TIGHTEN REAR DIFFERENTIAL FILLER PLUG

(a) Using a hexagon wrench (10 mm), temporarily install the differential filler plug.

HINT
Add differential oil before installing the gasket and fully tightening the rear differential filler plug.

41. 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.

42. 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 sealing 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)

43. INSTALL REAR DIFFERENTIAL CARRIER COVER

(a) Apply FIPG to the differential carrier at the position shown in the illustration.





FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
* Apply the seal packing in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter.
* 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 differential with oil or drive immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least 12 hours after installation of parts using FIPG sealant.

44. 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)