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


  1. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A01FH4GE01

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

  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01FGSA

      Remove the 8 bolts.

    2. A01FDHJ

      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


    1. A01FHV8

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

  4. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01FFF2

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

  5. SECURE REAR DIFFERENTIAL CARRIER


    1. A01FEM6

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

  6. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01FG9D

      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. A01FGUW

      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. A01FISI

      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.

      A01FDE8E01
      Text in Illustration
      *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 closer to the ring gear (*e, *f) - -

  9. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01FF2M

      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. A01FFS4E06
      Text in Illustration
      *a 30 mm (1.18 in.)

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

      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. A01FIYR

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

      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)
      1.87 to 2.17 N*m (19.07 to 22.13 kgf*cm, 16.55 to 19.21 in.*lbf)

  12. INSPECT TOTAL PRELOAD


    1. A01FIYR

      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)
      2.17 to 2.73 N*m (22.13 to 27.84 kgf*cm, 19.21 to 24.16 in.*lbf)

  13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01FILYE02
      Text in Illustration
      *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. A01FHSBE01

      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. A01FGZOE03
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09330-00021

  15. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A01FFHCE03
      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, 09955-03030, 09956-03030 )

      Note

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

  16. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

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


    1. A01FDNIE02

      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.

  17. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01FFXJE03
      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

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01FGFW

      Remove the rear differential drive pinion oil slinger.

  19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01FG2YE03
      Text in Illustration
      *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 grease to the threads and tip of SST center bolt before use.

  20. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01FIXA

      Remove the rear differential drive pinion bearing spacer.

  21. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01FIT5E09
      Text in Illustration
      *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. A01FIZ3E02

      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. A01FEO3

      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. A01FJ4SE01

      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. A01FG72E02
      Text in Illustration
      *1 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. A01FDRPE02
      Text in Illustration
      *1 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. A01FI19E05
      Text in Illustration
      *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. A01FH6X

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

    5. A01FG2E

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

      Note

      Do not damage the differential ring gear.

  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. A01FG9Z

      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.

      A01FHI4E03
      Text in Illustration
      *a Left (Differential Ring Gear Back) Side *b Right (Differential Ring Gear Teeth) Side
    4. A01FI3PE05
      Text in Illustration
      *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 N*m  { 870 kgf*cm, 63 ft.*lbf }
    6. A01FGO9

      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.

      A01FHI4E04
      Text in Illustration
      *a Left (Differential Ring Gear Back) Side *b Right (Differential Ring Gear Teeth) Side
    9. A01FG9Z

      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.

    A01FFI7E03

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

      Text in Illustration
      *a Turn
      *b Hold

      Note

      Do not overtighten the vise.

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

  27. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01FGZY

      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.