REAR DIFFERENTIAL CARRIER ASSEMBLY(for 4GR-FSE) DISASSEMBLY

PROCEDURE


  1. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A01MXS0

      Remove the rear differential breather plug from the rear differential carrier cover.

  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01MXLP

      Remove the 8 bolts.

    2. A01MUI0

      Using a brass bar and hammer, remove the rear differential carrier cover from the rear differential carrier.

      Note


      • Place the brass bar onto the corners of the rear differential carrier cover.

      • Do not damage the sealing surface of the rear differential carrier.

  3. REMOVE REAR DIFFERENTIAL CARRIER STRAIGHT PIN

    Tech Tips

    It is not necessary to remove a rear differential carrier straight pin unless it is being replaced.


    1. A01MZ0A

      Remove the 2 rear differential carrier straight pins from the rear differential carrier.

  4. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01MWH9

      Remove the bolt and rear differential breather plug oil deflector from the rear differential carrier cover.

  5. SECURE REAR DIFFERENTIAL CARRIER


    1. A01MYNQ

      Install the rear differential carrier to the overhaul stand as shown in the illustration.

  6. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01MVQY

      Set a dial indicator perpendicular to the end of the differential ring gear face.

    2. Rotate the differential ring gear and measure the runout.

      Maximum runout
      0.07 mm (0.00275 in.)

      If the runout is more than the specified maximum value, remove the differential ring gear and check the runout of the rear differential case sub-assembly.

  7. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01MVWI

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Standard Backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft plate washer.

  8. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01MU3G

      Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.

    2. Rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      B003WLSC08
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion away from the ring gear (*e, *f) - -

      Note

      Check the tooth contact pattern at 4 or more positions around circumference of the differential ring gear.

  9. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01MVA2

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

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

  10. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE


    1. A01MVM4C01
      *a Vertical Runout
      *b Lateral Runout
      *c 30 mm (1.18 in.)

      Using a dial indicator, measure the runout of the rear drive pinion companion flange vertically runout and Lateral runout.

      Maximum Runout
      Item Specified Condition
      Vertical runout 0.09 mm (0.00354 in.)
      Lateral runout 0.09 mm (0.00354 in.)

      Note

      Measure the runout of the rear drive pinion companion flange horizontally at a position 30 mm (1.18 in.) away from the center of the differential drive pinion shaft.

      If the runout is more than the maximum value, replace the rear drive pinion companion flange.

  11. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01MURK

      Using a torque wrench, measure the starting torque of the differential drive pinion.

      Differential drive pinion preload (at starting)
      1.87 to 2.17 N*m (19.1 to 22.1 kgf*cm, 16.6 to 19.2 in.*lbf)

      Tech Tips


      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

  12. INSPECT TOTAL PRELOAD


    1. A01MURK

      Using a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      Total preload (at starting)
      Identification Mark Specified Condition
      3.7 2.19 to 2.76 N*m (22.3 to 28.1 kgf*cm, 19.4 to 24.4 in.*lbf)
      3.9 2.17 to 2.73 N*m (22.1 to 27.8 kgf*cm, 19.2 to 24.2 in.*lbf)

      Note

      Make sure to check the identification mark because total preload is different between the 2 types of ring gears.

      A01MY91C01
      *a Identification Mark Position

  13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01MXBQC04
      *1 Rear Differential Side Gear Shaft Oil Seal

      Using SST, remove the 2 rear differential side gear shaft oil seals.

      SST
      09308-00010

  14. REMOVE REAR DRIVE PINION NUT


    1. A01MUFKN04

      Using SST and a hammer, unstake the staked part of the rear drive pinion nut.

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the differential drive pinion.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the rear drive pinion nut when removing it.

      • Do not damage the threads of the differential drive pinion.

    2. A01MVDRC02
      *a Turn
      *b Hold

      Using SST to hold the rear drive pinion companion flange, remove the rear drive pinion nut.

      SST
      09330-00021

      CAUTION:

      Hold the overhaul attachment during the operation.

  15. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A01MZ5SC01
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030 )

      Note

      Apply molybdenum grease to the threads of SST center bolt (09953-03010) before use.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 40 mm.

  16. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the rear differential dust deflector is damaged.


    1. A01MY1NE03

      Using SST and a press, remove the rear differential dust deflector.

      SST
      09950-00020
      09950-60010   ( 09951-00380 )
      09950-70010   ( 09951-07100 )

      Note

      Do not drop the rear drive pinion companion flange.

      Tech Tips

      Be sure to perform this operation while tightening the SST nuts to protect the contact surface of SST and the rear differential dust deflector.

  17. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01MWRZ

      Remove the rear differential drive pinion oil slinger.

  19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01MZ65C01
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion front tapered roller bearing inner race from the differential drive pinion.

      SST
      09556-22010

      Note

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

  20. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01MUNK

      Remove the rear differential drive pinion bearing spacer.

  21. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01MW40C02
      *a Matchmark

      Put matchmarks on either bearing cap and the rear differential carrier.

    2. Remove the 4 bolts and 2 bearing caps.

      Note

      Do not exchange bearing caps, as each cap is only suitable for its original location and the installation direction relative to the rear differential carrier for which it was manufactured.

    3. A01MY3ZN04

      Using SST and a hammer, remove the 2 rear differential side gear shaft plate washers.

      SST
      09504-22011

      Note

      Put identification marks on the rear differential side gear shaft plate washers to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

      Tech Tips

      Measure the thickness of each rear differential side gear shaft plate washer and note it.

    4. A01MZ6G

      Remove the rear differential case sub-assembly and the rear differential case bearing outer races LH and RH from the rear differential carrier.

      Note


      • Do not damage the rear differential case bearing or differential ring gear.

      • Put identification marks on the rear differential case bearing outer races to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

  22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Remove the differential drive pinion from the rear differential carrier.

    2. A01MWS0N04

      Using SST and a press, remove the rear drive pinion rear tapered roller bearing inner race from the differential drive pinion.

      SST
      09950-00020

      Note

      Do not drop the differential drive pinion.

      Tech Tips

      If either the differential drive pinion or differential ring gear is damaged, replace both as a set.

    3. Remove the rear differential drive pinion plate washer from the differential drive pinion.

      Tech Tips

      Measure the thickness of the rear differential drive pinion plate washer and note it.

    4. A01MX8XC03
      *1 Rear Drive Pinion Rear Tapered Roller Bearing Outer Race

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

      Note

      Place the brass bar onto the rear drive pinion rear tapered roller bearing outer race. Do not damage the rear differential carrier.

  23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01MXXPC03
      *1 Rear Drive Pinion Front Tapered Roller Bearing Outer Race

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

      Note

      Place the brass bar onto the rear drive pinion front tapered roller bearing outer race. Do not damage the rear differential carrier.

  24. REMOVE DIFFERENTIAL RING GEAR


    1. A01MU8FC03
      *a Matchmark

      Hold the rear differential case sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Put matchmarks on the differential ring gear and rear differential case sub-assembly.

    3. Using a chisel and hammer, unstake the 5 rear differential ring gear set bolt lock plates.

    4. A01MVCF

      Remove the 10 bolts and 5 rear differential ring gear set bolt lock plates.

    5. Using a plastic-faced hammer, tap on the differential ring gear to separate it from the rear differential case sub-assembly.

      Tech Tips

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

  25. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Tech Tips

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


    1. A01MYAF

      Install the rear differential case bearing outer races LH and RH to the rear differential case bearing inner races LH and RH respectively.

      Note


      • Be sure to install the rear differential case bearing outer races in the correct position.

      • Do not damage the rear differential case bearing or differential ring gear.

    2. Install the rear differential case sub-assembly to the rear differential carrier.

    3. Install the right and left (back side and teeth side) rear differential side gear shaft plate washers so that there is no looseness in the rear differential case bearings.

      A01MVG7C03
      *a Left (Differential Ring Gear Back) Side *b Right (Differential Ring Gear Teeth) Side
    4. A01MUD1C03
      *a Matchmark

      Align the matchmarks on the bearing cap and rear differential carrier and install the 2 bearing caps.

      Note

      Make sure that the right and left bearing caps are not interchanged.

    5. Tighten both bearing caps with the 4 bolts.

      Torque:
      85.3 N*m  { 870 kgf*cm, 63 ft.*lbf }
    6. A01MXUI

      Using a dial indicator, measure the rear differential case sub-assembly runout.

      Maximum runout
      0.07 mm (0.00275 in.)

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

    7. Remove the 4 bolts and 2 bearing caps.

      Note

      Do not exchange bearing caps, as each cap is only suitable for its original location and the installation direction relative to the carrier for which it was manufactured.

    8. Remove the right and left rear differential side gear shaft plate washers.

      A01MVG7C04
      *a Left (Differential Ring Gear Back) Side *b Right (Differential Ring Gear Teeth) Side
    9. A01MYAF

      Remove the right and left rear differential case bearing outer races and rear differential case sub-assembly.

      Note

      Do not damage the rear differential case bearing or differential ring gear.

  26. REMOVE REAR DIFFERENTIAL CASE BEARING

    Tech Tips

    Perform this procedure only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. Hold the rear differential case sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01MUM4C02
      *a Turn
      *b Hold

      Using SST, remove the rear differential case bearing inner races LH and RH from the rear differential case sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00350, 09951-00480, 09952-06010 )

      Note


      • Do not deform the bearing cage if the bearing is to be reused.

      • Hook the claws of SST to the rear differential case bearing inner race.

      • Apply molybdenum grease to the threads and tip of SST center bolt (09953-04030) before use.

  27. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01MUYD

      Secure the rear differential case sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

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

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