Part 2
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): REASSEMBLY (Continued)
10. ADJUST REAR DIFFERENTIAL CASE BEARING PRELOAD
(a) After adjusting the backlash of the differential ring gear, remove the teeth side rear differential side gear shaft plate washer.
(b) Using a micrometer, measure the thickness of the removed rear differential side gear shaft plate washer.
(c) Select a new rear differential side gear shaft plate washer which is 0.06 to 0.09 mm (0.00236 to 0.00354 in.) thicker than the removed one.
HINT
Select a rear differential side gear shaft plate washer which can be pressed in 2/3 of the way with a finger.
(d) Using SST and a plastic hammer, drive in the rear differential side gear shaft plate washer.
SST : 09504-22011
(e) Align the matchmarks on the bearing cap and rear differential carrier, and install the 2 bearing caps.
Text in Illustration
NOTICE:
Make sure that the right and left bearing caps are not interchanged.
(f) Tighten both bearing caps with the 4 bolts.
Torque : 85 Nm (870 kgf-cm, 63 ft-lbf)
(g) Set a dial indicator to the end of the differential ring gear face.
(h) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
(i) If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left rear differential side gear shaft plate washers equally.
HINT
* Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft plate washer.
11. INSPECT TOTAL PRELOAD
(a) 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):
HINT
* If the measured preload is less than the specified value, replace the rear differential side gear shaft plate washer of the differential ring gear tooth surface side with a new thicker one.
* If the preload is greater than the specified value, replace the rear differential side gear shaft plate washer of the differential ring gear tooth surface side with a new thinner one.
(b) Set a dial indicator perpendicular to the end of the differential ring gear face.
(c) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
HINT
* If the backlash is not within the specified range, change the thickness of the right and left rear differential side gear shaft plate washers by equal amounts to adjust it.
* Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.
* Inspect tooth contact to use the result as a reference for selecting a rear differential side gear shaft plate washer.
12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at the 3 different positions on the differential ring gear with Prussian blue.
(b) Rotate the differential ring gear in both directions.
(c) Inspect the tooth contact pattern.
(d) If the teeth are not contacting properly, use the following table to select a proper rear differential drive pinion plate washer for correction.
Text in Illustration
NOTICE:
* 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 rear differential drive pinion plate washer has been changed, adjust the backlash and measure the total preload.
Rear Differential Drive Pinion Plate Washer Thickness
13. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the rear drive pinion companion flange, remove the rear drive pinion nut.
Text in Illustration
SST : 09330-00021
14. REMOVE REAR DRIVE PINION COMPANION FLANGE Disassembly
15. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Disassembly
16. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Disassembly
17. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
NOTICE:
Be sure to face the larger inner diameter side as shown in the illustration.
18. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the rear drive pinion front tapered roller bearing to the differential drive pinion.
19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the rear differential drive pinion oil slinger to the differential drive pinion.
20. INSTALL REAR DRIVE PINION COMPANION FLANGE
(a) Using SST and a rear drive pinion companion flange, install the rear drive pinion companion flange and rear drive pinion front tapered roller bearing.
Text in Illustration
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030
NOTICE:
Apply grease to the threads of SST center bolt before use.
21. REMOVE REAR DRIVE PINION COMPANION FLANGE Disassembly
22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Replacement
23. INSTALL REAR DRIVE PINION COMPANION FLANGE
(a) Using SST, install the rear drive pinion companion flange.
Text in Illustration
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030
NOTICE:
Apply grease to the threads of SST center bolt before use.
(b) Coat the threads of the rear drive pinion nut with hypoid gear oil LSD.
(c) Using SST and a torque wrench, hold the rear drive pinion companion flange and tighten the rear drive pinion nut.
Text in Illustration
SST : 09330-00021
Torque : 337 Nm (3444 kgf-cm, 249 ft-lb for less)
NOTICE:
* Tighten the rear drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the differential drive pinion preload.
* Apply hypoid gear oil LSD to the rear drive pinion nut and the threads of the differential drive pinion.
24. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the starting torque of the differential drive pinion. 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):
* If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut by 5 to 10° to adjust it into the specified range.
Torque:
337 N*m (3444 kgf*cm, 249 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 greater than the specified maximum value, loosen the rear drive pinion nut and check that the threads of the rear 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
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total Preload (at Starting):
(b) If the total preload is not within the specified range, adjust the total preload or repair as necessary.
26. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.
Backlash:
0.13 to 0.18 mm (0.00512 to 0.00708 in.)
27. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE
(a) Using a dial indicator, measure the runout of the rear drive pinion companion flange vertically and horizontally.
Maximum runout:
0.09 mm (0.00354 in.)
NOTICE:
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 shaft.
28. STAKE REAR DRIVE PINION NUT
(a) Using SST and a hammer, stake the rear drive pinion nut.
SST : 09930-00010
29. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, install 2 new rear differential side gear shaft oil seals.
SST : 09213-70011
SST : 09950-60010
09951-00410
09951-00620
09952-06010
SST : 09950-70010
09951-07100
Oil seal installation depth (A):
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
NOTICE:
* 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.
(b) Apply MP grease to the rear differential side gear shaft oil seal lips.
30. INSTALL REAR DIFFERENTIAL DRAIN PLUG
(a) Using a hexagon wrench, install the rear differential drain plug with a new gasket.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
31. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
(a) Clean the seal packing attached on the rear differential carrier and rear differential carrier cover using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.
NOTICE:
Do not scratch the sealing surface.
(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
32. REMOVE REAR DIFFERENTIAL CARRIER
(a) Remove the rear differential carrier from the overhaul stand, etc.
33. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN
(a) Using a plastic hammer, install the 2 rear differential carrier straight pins to the rear differential carrier.
Protrusion (A):
8 to 9 mm (0.315 to 0.354 in.)
34. INSTALL REAR DIFFERENTIAL CARRIER COVER
(a) 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
NOTICE:
* 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 the end of application.
* Install the rear differential carrier cover within 3 minutes of application.
(b) Install the rear differential carrier cover with the 8 bolts and 2 rear differential carrier straight pins.
Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
NOTICE:
Do not fill the differential with oil or drive 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.
35. INSTALL REAR DIFFERENTIAL BREATHER PLUG
(a) Install the rear differential breather plug to the rear differential carrier cover.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)