Manual Transmission

Rear Differential Carrier / 2JZ-GTE M/T:

Rear Differential Carrier / Except 2JZ-GTE M/T:

ASSEMBLY
1. Conventional differential only:
Adjust the differential pinion gear backlash, as follows:





a. Install the proper thrust washers on the side gears.

NOTE: Using the measurements listed below, select thrust washers which will ensure that the backlash is within the specification.

Thrust washer thickness:
1.6 mm (0.063 inch).
1.7 mm (0.067 inch).
1.8 mm (0.071 inch).

b. Install the side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.

NOTE: Align the holes of the differential case and pinion shaft.





c. Push the side gear shafts gently into the differential case by hand and install them.





d. Measure the pinion gear backlash while holding one side gear toward the case.

Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch).

If the backlash is not within the specification, install different thickness side gear thrust washers.

e. Remove the side gear shaft.

2. Conventional differential only:
Install the ring gear on the differential case, as follows:





a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Stake the differential case.

3. Install ring gear on the differential case, as follows:
a. Clean the contact surfaces of the differential case, the threads of the ring gear and differential case.





b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





NOTE: Align the matchmarks on the ring gear and the differential case.

e. Temporarily tighten the two bolts so that the bolt holes in the ring gear and differential case are not misaligned.





f. After the ring gear has cooled sufficiently, install new ring gear set bolts to which thread lock has been applied.

Thread lock: Part No. 08833 - 00100, THREE BOND 1360 K or equivalent.

NOTICE: New ring gear set bolts should be used in every case.

g. Torque the set bolts uniformly and a little at a time.

Torque: 64 Nm (47 ft. lbs.).





h. Tighten the bolts an additional 60° - 90°.

NOTICE: Tighten the bolts in diagonally opposite pairs.





4. Install side bearings. Using SST 09710 - 30050, 09726 - 36010, 09950 - 70010 (09951 - 07150) or equivalents, and a press, install the side bearings.
5. Install drive pinion bearing outer races and adjusting plate washer, as follows:

NOTICE: Always reassemble with a new adjusting plate washer.

NOTE: The adjusting plate washer is used for adjusting the tooth contact pattern. 42 types of washer with differential thicknesses are available. First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

Fig. 33 Installing New Adjusting Washer & Front Bearing Outer Race:

a. Using SST 9502-24010, 09950-70010 (09951-07150) or equivalents and a press, install the front bearing outer race.

Fig. 34 Installing Rear Bearing Outer Race:

b. Using SST 09950 - 60020 (09951 - 01030), 09950-70010 (09951 -07150) or equivalents and a press, install a new adjusting plate washer and the rear bearing outer race.

Fig. 35 Installing Rear Bearing To Drive Pinion:

6. Install rear bearing to drive pinion. Using SST 09316 - 20011 or equivalent, and a press, install the rear bearing to the drive pinion.
7. Temporarily install drive pinion, front bearing, (oil slinger) and companion flange, as follows:
a. Position the drive pinion in the differential carrier.





b. Using SST 09608 - 04031, 09608 - 06041 or equivalents, and a press, install the front bearing, and companion flange.

NOTE: Assemble the spacer, oil slinger and oil seal after adjusting the tooth contact pattern.

NOTICE: Be careful not to press the bearing too far onto the drive pinion's bearing surface.

8. Temporarily adjust drive pinion preload, as follows:
a. Adjust the drive pinion preload by tightening the nut.





NOTE: Using SST 09330 - 00021 or equivalents, (and a 36 mm deep socket wrench) to hold the companion flange and tighten the nut.

NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





b. Using SST 09229 - 55010 (or a 36 mm deep socket) and a torque wrench, measure the drive pinion preload.

New Bearing preload (at starting): 2.0 - 2.5 Nm (17.3 - 21.7 inch lbs.).

Reused Bearing Preload (at Starting): 1.0 - 1.2 Nm (8.9 - 10.6 inch lbs.).

Fig. 36 Installing Side Bearing Outer Race & Adjusting Washer:

9. Install side bearing outer race (and adjust plate washer).
Using SST 09950 - 60020 (09951 - 00910), 09950 - 70010 (09951 - 07150) or equivalents, and a press, install the outer race.





10. Install differential case in carrier. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
11. Install (adjusting plate washer and) differential carrier retainers, as follows:
a. Place the adjusting washer to the carrier retainer.
b. Using SST 09950 - 60020 (09951 - 00910), 09950 - 70010 (09951 - 07150) or equivalents, and a hammer, install the carrier retainer with adjusting washer.

NOTE: Do not install a new O-ring and a new oil seal. Install it after inspect tooth contact pattern.

c. Tighten the eight bolts.

Torque: 47 Nm (35 ft. lbs.).





12. Check ring gear backlash. Using a dial indicator, measure the backlash of the ring gear and drive pinion at three positions at least.

Backlash (average value): 0.08 - 0.13 mm (0.0031 - 0.0051 inch).

NOTICE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 inch).

NOTE: The measured values should be used for reference when selecting washers, so make a memo of the values.

Adjusting Washer Thickness: 2JZ-GTE M/T:

Washer Thickness For All Models Except 2JZ-GTE M/T:

If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.





13. Measure total preload. Using SST 09229 - 55010 (or a 36 mm deep socket) and a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.

Total preload (at starting), Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.).

If the measured preload is less than the specification, replace the washer of the ring gear's tooth surface side with a thicker one. If the preload is greater than the specification, replace the washer of the ring gear's tooth surface side with thinner one.

NOTE: Changing the washer thickness by 0.02 mm (0.0008 inch) will change the total preload by approximately 0.1 Nm (0.9 inch lbs.).

14. Inspect tooth contact pattern, as follows:.





a. Coat three or four teeth at three different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.

Fig. 17 Proper Contact Pattern:

If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.





NOTICE: Be sure to always use a new part when replacing adjusting washer.





NOTE: Refer to table for selection of the adjusting washer.

Adjusting Washer Thickness For 2JZ-GTE M/T:

Adjusting Washer Thickness For All Models Except 2JZ-GTE M/T:

NOTE: Adjust washers are available in 42 different thickness, in increments of 0.01 mm (0.004 inch).

15. Remove differential retainer, differential case and drive pinion.





16. Install spacer (and oil slinger) on drive pinion. Install a new spacer and the oil slinger on the drive pinion.
17. Position drive pinion in differential carrier.
18. Install front bearing (and oil slinger).
19. Install oil seal, as follows:








a. Using SST 09316 - 60011 (09316 - 00011, 09316 - 00071), 09502 - 24010 or equivalents, and a press, install a new oil seal to the differential carrier.
b. Apply Multipurpose (MP) grease to a new oil seal lip.





20. Install companion flange. Using SST 09608 - 04031, 09608 - 06041 or equivalents, and a press, install the companion flange.

NOTICE:
^ Be careful not to damage the oil seal.
^ Be careful not to press the bearing too far onto the drive pinion's bearing surface.

21. Adjust drive pinion preload, as follows:
a. Coat the drive pinion's threads and a new nut's flange with hypoid gear oil for Limited Slip Differential (LSD).





b. Using SST 09330 - 00021, (or a 36 mm deep socket wrench), tighten the nut.





c. Using SST 09229 - 55010 (or a 36 mm deep socket) and a torque wrench, measure the preload.

New bearing preload (at starting): 2.0 - 2.5 Nm (17.3 - 21.7 inch lbs.).

Reused bearing preload (at starting): 1.0 - 1.2 Nm (8.9-10.6 inch lbs.).

If the preload is greater than the specification, replace the spacer and repeat the preload procedure.





If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) at a time until the specified preload is reached.

Maximum torques: 510 Nm (376 ft. lbs.)

If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.





22. Check drive pinion shaft runout. Measure the drive pinion shaft runout.

Maximum runout: 0.08 mm (0.0031 inch).

23. Install differential case in carrier.
24. Install O-ring, as follows:
a. Coat a new O-ring with hypoid gear oil.





b. Install the O-ring to the carrier retainer.

25. Install oil seal, as follows:








a. Using SST 09223 - 15030, 09950 - 70010 (09951 - 07150) or equivalents, and a press, install a new oil seal to the carrier retainer.
b. Coat MP grease to the oil seal lip.

26. Install side bearing retainer.
27. Stake drive pinion nut.

NOTICE: Do not damage the drive pinion.

28. Install both gear shafts, as follows:
a. Install a new snap ring to the shaft.
b. Coat MP grease onto the snap ring.





c. Using a brass bar and hammer, install both side gear shafts.

NOTICE: Be careful not to damage the side gear shaft and the oil seal.

NOTE: Whether or not the side gear shaft is in contact with the pinion shaft can be known by the sound or feeling when driving it in.





29. Inspect differential carrier. Using vernier calipers, measure the distance between the mating surfaces of the two side gear shafts, as shown.

Standard distance: 293.4 +/- 0.65 mm (11.551 - 0.026 inch).

30. Recheck backlash, total preload and tooth contact pattern.
31. Remove differential carrier from overhaul stand, etc.
32. Install differential carrier cover, as follows:
a. Clean the contact surfaces of the carrier and cover of any residual Formed In Place Gasket (FIPG) material using cleaner.





b. Coat FIPG to the carrier or cover.
FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent

NOTICE: After installing the cover, wait at least one hour before filling it with oil or running the vehicle.

c. Install the carrier cover to the carrier with the eight bolts.

Torque: 78 Nm (58 ft. lbs.).





d. Install the breather plug.

Torque: 21 Nm (15 ft. lbs.).