Disassembly

DIFFERENTIAL: REAR 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.
- Place the brass bar onto the corners of the carrier cover.
- Do not damage the sealing 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 the overhaul stand, etc., as shown in the illustration.
5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Component Tests and General Diagnostics

6. INSPECT DIFFERENTIAL RING GEAR BACKLASH Component Tests and General Diagnostics

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Component Tests and General Diagnostics

8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Component Tests and General Diagnostics

9. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Component Tests and General Diagnostics

10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Component Tests and General Diagnostics

11. INSPECT TOTAL PRELOAD Component Tests and General Diagnostics

12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL






(a) Using SST, remove the 2 oil seals.
SST: 09308-00010
13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING






(a) Install SST to the differential carrier.
SST: 09571-50010
(b) Tighten the SST bolt (A) until the SST disc lightly touches the case bearing outer race.






(c) Install a dial indicator to the rear differential carrier.
(d) Tighten the 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.
NOTE: 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.
- 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.





(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. Write down the result.

(f) Remove the dial indicator and loosen the SST bolt.
NOTE: Do not remove the SST.

14. 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 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 back surface of the ring gear.
HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

15. REMOVE REAR DIFFERENTIAL CASE BEARING






(a) Tighten the SST bolt and push out the case bearing outer race on the back surface of the ring gear.
SST: 09571-50010
NOTE: Do not drop the case bearing outer race.





(b) Remove the SST.
16. 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.
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.

17. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY






(a) Remove the rear differential case assembly.
NOTE: Do not damage the case bearing.

18. REMOVE REAR DRIVE PINION NUT






(a) Using SST and a hammer, unstake the staked part of the drive pinion nut.
SST: 09930-00010
- Be sure to use the SST with the tapered surface facing the shaft.
- Do not grind the tip of the 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
NOTE: Apply grease to the threads and tip of the 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, remove the dust deflector.
SST: 09950-60010
09951-00440
SST: 09950-00020
SST: 09950-70010
09951-07100
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.
NOTE: 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, remove the rear drive pinion rear tapered roller bearing inner race from the drive pinion.
SST: 09950-00020
HINT: If either the drive pinion or ring gear is damaged, replace both as a set.





(b) Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing outer race from the differential carrier.
(c) Remove the plate washer.
27. REMOVE DIFFERENTIAL RING GEAR






(a) Put matchmarks on the ring gear and differential case.
(b) Remove the 10 ring gear set bolts.






(c) Using a plastic hammer, tap on the ring gear to separate it from the differential case.
NOTE: Do not damage the ring gear.

28. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY Component Tests and General Diagnostics

29. REMOVE REAR DIFFERENTIAL CASE BEARING
HINT: Perform this procedure only when replacing the case bearing or differential case.





(a) 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
- Do not deform the bearing cage if the bearing is to be reused.
- Hook the SST claw from the dent of the differential case to the bearing inner race.
- Apply grease to the threads and tip of the SST center bolt before use.

30. INSPECT DIFFERENTIAL PINION AND SIDE GEAR Component Tests and General Diagnostics