Differential Carrier Assembly

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

1. 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.

2. 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.

3. 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

4. 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.

5. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Hold the differential case sub-assembly 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.

(c) 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.

6. 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.

7. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed. Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion 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 not within the specified range, adjust the drive pinion preload or repair as necessary.

8. 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.

9. 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 with 2 bolts.

SST : 09571-50010

(d) Tighten bolt (A) until 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 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.

SST : 09571-50010

(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.