REAR DIFFERENTIAL CARRIER OIL SEAL (for 2GR-FSE) REPLACEMENT


  1. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

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  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01FDQD

      Remove the 8 bolts.

    2. A01FEB9

      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. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A01FHJTE01

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

  4. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01FI9SE01

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

      SST
      09308-00010

  5. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. A01FI0NE05
      Text in Illustration
      *1 Disc

      Install SST to the rear differential carrier with the 2 bolts (A).

      SST
      09571-50010

    2. Tighten SST bolt (B) until SST disc lightly touches the rear differential case bearing outer race RH on the differential ring gear tooth side.

    3. A01FEL6E01

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    4. Tighten SST bolt and alter the shape of the rear differential carrier to create a 0.1 mm (0.00394 in.) clearance between the rear differential case bearing outer race RH and rear differential side gear shaft snap ring.

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

      Tech Tips

      A clearance of approximately 0.1 mm (0.00394 in.) between the rear differential case bearing outer race RH and rear differential side gear shaft snap ring is sufficient for the rear differential side gear shaft snap ring to move slightly.

    5. A01FH7AE01

      Using SST, remove the rear differential side gear shaft snap ring on the differential ring gear tooth side.

      SST
      09905-00031

      Tech Tips

      For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

    6. Remove the dial indicator and loosen SST bolt.

      Note

      Do not remove SST.

    7. A01FG43E01

      Using SST and a hammer, create a clearance between the rear differential case bearing outer race LH on the back surface of the differential ring gear and the rear differential side gear shaft snap ring.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

    8. A01FDOQE01

      Using snap ring pliers, remove the rear differential side gear shaft snap ring on the back surface of the differential ring gear.

      SST
      09905-00031

      Tech Tips

      For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

  6. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01FHZDE01

      Tighten SST bolt and push out the rear differential case bearing outer race LH on the back surface of the differential ring gear.

      SST
      09571-50010

      Note

      Do not drop the rear differential case bearing outer race LH.

      Tech Tips

      Put identification marks on the rear differential case bearing outer race and rear differential side gear shaft snap ring to show the location for installation (back side or teeth side), or keep the races and snap rings separate so that they can be distinguished.

    2. A01FI0NE02

      Remove the 2 bolts and SST.

    3. A01FFWCE01

      Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the rear differential case bearing outer race RH on the differential ring gear tooth side.

      Tech Tips

      Put identification marks on the rear differential case bearing outer race and rear differential side gear shaft snap ring to show the location for installation (back side or teeth side), or keep the races and snap rings separate so that they can be distinguished.

  7. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01FFP6

      Remove the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing.

  8. REMOVE REAR DRIVE PINION NUT


    1. A01FHHEE01

      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. A01FGISE03
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )

  9. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A01FHVHE03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note

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

  10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01FG97E02
      Text in Illustration
      *1 Rear Differential Carrier Oil Seal

      Using SST, remove the rear differential carrier oil seal from the rear differential carrier.

      SST
      09308-00010

  11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01FILI

      Remove the rear differential drive pinion oil slinger.

  12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01FI93

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

  13. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01FFZ9E01

      Using a press, remove the differential drive pinion from the rear differential carrier.

      Note

      Do not drop the differential drive pinion.

  14. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01FECEE01
      Text in Illustration
      *A A Type
      *B B Type

      Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

  15. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01FECEE01
      Text in Illustration
      *A A Type
      *B B Type

      Install a new rear differential drive pinion bearing spacer to the differential drive pinion.

      Tech Tips


      • For the A type rear differential drive pinion bearing spacer, install the side with the larger internal diameter towards the differential drive pinion.

      • For the B type rear differential drive pinion bearing spacer, both sides are the same.

  16. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01FI93

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

  17. INSTALL DIFFERENTIAL DRIVE PINION


    1. A01FG09E05

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

      SST
      09316-60011   ( 09316-00011, 09316-00041 )
      09608-04031

  18. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01FILI

      Install the rear differential drive pinion oil slinger.

  19. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01FGE7E03
      Text in Illustration
      *1 Rear Differential Carrier Oil Seal

      Using SST and a hammer, install a new rear differential carrier oil seal.

      SST
      09316-60011   ( 09316-00011 )
      09710-30012   ( 09710-04101 )
      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      Note


      • Tap the oil seal uniformly so that the oil seal is straight.

      • Do not excessively tap the oil seal.

  20. INSTALL REAR DRIVE PINION COMPANION FLANGE


    1. A01FHF4E04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange to the differential drive pinion.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note

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

    2. Coat the threads of a new rear drive pinion nut with hypoid gear oil LSD.

    3. A01FFNHE03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and tighten the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )
      Torque:
      490 N*m  { 5000 kgf*cm, 361 ft.*lbf, or less }

      Note


      • Do not tighten the nut excessively, otherwise the threads will be stripped.

      • Apply hypoid gear oil LSD to the threads of the drive pinion nut and differential drive pinion.

      Tech Tips

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

  21. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01FFNW

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note

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

  22. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01FH51E03

      Using SST and a hammer, install the rear differential case bearing outer race RH to the differential ring gear tooth side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Text in Illustration
      *1 Groove

      Tap in the rear differential case bearing outer race until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    2. A01FI0NE05
      Text in Illustration
      *1 Disc

      Install SST to the rear differential carrier with the 2 bolts (A).

      SST
      09571-50010

    3. Tighten SST bolt (B) until SST disc lightly touches the rear differential case bearing outer race RH.

    4. A01FDGZE01

      Using SST and a hammer, install the rear differential case bearing outer race LH to the differential ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the rear differential case bearing outer race until it touches the rear differential case bearing inner race roller.

  23. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. A01FDOQ

      Using SST, install the rear differential side gear shaft snap ring to the rear differential carrier on the differential ring gear back surface side.

      SST
      09905-00031

      Tech Tips

      Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.

    2. A01FEL6E01

      Set a dial indicator on the rear differential carrier.

    3. Tighten SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    4. A01FH7A

      Using SST, install the rear differential side gear shaft snap ring to the differential ring gear tooth side.

      SST
      09905-00031

      Tech Tips

      Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.

    5. A01FG5G

      Remove the dial indicator and tap the rear differential carrier on the differential ring gear tooth side using a plastic-faced hammer to stabilize the rear differential case bearing.

    6. A01FI0NE02

      Remove the 2 bolts and SST.

  24. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01FISYE01

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

      SST
      09229-55010

      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.

      Differential drive pinion preload (at starting)
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.44 to 2.01 N*m (14.68 to 20.50 kgf*cm, 12.74 to 17.79 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.50 to 0.80 N*m (5.10 to 8.16 kgf*cm, 4.43 to 7.08 in.*lbf)

      • If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut 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 rear drive pinion nut is more than the specified maximum value, loosen the rear drive pinion nut and check that the threads of the drive pinion nut and differential drive pinion are not stripped.

      • If the threads are not stripped, replace the rear differential drive pinion bearing spacer. Apply hypoid gear oil LSD to the threads of the differential drive pinion and repeat the procedure.

  25. INSPECT TOTAL PRELOAD


    1. A01FISYE01

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

      SST
      09229-55010
      Total preload (at starting)
      for 2WD
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.78 to 3.16 N*m (18.15 to 32.22 kgf*cm, 15.75 to 27.97 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.65 to 2.71 N*m (16.83 to 27.63 kgf*cm, 14.60 to 23.99 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.97 to 3.52 N*m (20.09 to 35.89 kgf*cm, 17.44 to 31.15 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.90 to 1.86 N*m (9.18 to 18.97 kgf*cm, 7.97 to 16.46 in.*lbf)
      for AWD
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.76 to 3.09 N*m (17.03 to 31.51 kgf*cm, 14.78 to 27.35 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.63 to 2.67 N*m (16.62 to 27.23 kgf*cm, 14.43 to 23.63 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.95 to 3.45 N*m (19.88 to 35.18 kgf*cm, 17.26 to 30.53 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.88 to 1.82 N*m (8.98 to 18.56 kgf*cm, 7.79 to 16.11 in.*lbf)

  26. STAKE REAR DRIVE PINION NUT


    1. A01FFQ0E01

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

      SST
      09930-00010

  27. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01FIEAE05

      Using SST and a hammer, install 2 new rear differential side gear shaft oil seals.

      SST
      09223-15030
      09950-70010   ( 09951-07200 )
      Oil seal installation depth (A)
      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      Note


      • Make sure to check the identification marks on the rear differential side gear shaft oil seals before installation because the part numbers differ between the left and right sides.

      • To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seals.

      • When installing the rear differential side gear shaft oil seals, tap them in until the outer surface of each seal is flush with the rear differential carrier.

    2. Apply MP grease to the rear differential side gear shaft oil seal lips.

  28. INSTALL REAR DIFFERENTIAL CARRIER COVER


    1. A01FHL1E08
      Text in Illustration
      *1 Seal Packing
      *a 2 to 3 mm (0.0788 to 0.118 in.)

      Apply seal packing to the rear differential carrier as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent

      Note


      • Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and end of application.

      • Install the rear differential carrier cover within 3 minutes of application.

    2. A01FDQD

      Install the rear differential carrier cover with the 8 bolts.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

      Note

      Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.

  29. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY

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