Disassembly

DISASSEMBLY





1. Set differential carrier to overhaul stand etc., as shown.





2. Check drive pinion shaft runout.
Using dial indicator, measure the drive pinion shaft runout.
Maximum runout: 0.08 mm (0.0031 inch).
If the runout is not within the specification, replace the drive pinion and/or ring gear.
3. Remove differential carrier cover.
a. Remove the eight bolts from the carrier cover.
b. Using a brass bar and hammer, separate the cover and carrier.





4. Check ring gear runout.
Using a dial indicator, measure the ring gear runout.
Maximum runout:
With Turbo and Manual Transmission: 0.08 mm (0.0031 inch).
Other models: 0.05 mm (0.0020 inch).
If the runout is not within the specification, replace the drive pinion, ring gear and/or differential case.





5. Check ring gear backlash.
Using a dial indicator, measure the backlash of the ring gear and drive pinion at three points (minimum) and check that the average value is within the specification.
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).

If the backlash is not within the specification, adjust the ring gear backlash.





6. Measure drive pinion preload.
Using Special Service Tool (SST) 09229-55010 or equivalent, (or a 36 mm deep socket) and a torque wrench, measure the drive preload of backlash between the drive pinion and ring gear.
Preload (at starting):
With Turbo and manual transmission: 1.0 - 1.2 Nm (8.9 - 10.6 inch lbs.).
Other models: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).





7. Check 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:
With Turbo and Manual Transmission (M/T): 0.4 - 0.6 Nm (3.4 - 5.2 inch lbs.).
Other models: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).
If necessary, disassemble and inspect the differential.





8. Conventional differential only:
Check pinion gear backlash.
Using a dial indicator, 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 the correct thrust washer.
9. Check tooth contact pattern.





10. Remove side gear shaft.
a. With Turbo and Manual Transmission (2JZ-GTE):
Equally tighten both bolts at the same time and pull out the side gear shaft.

NOTICE: Pull out the side gear shaft until a nut can fit behind the shaft. Pulling the shaft out too far will damage the dust cover.

Fig. 23 Removing Side Gear Shaft:

b. Using Special Service Tool (SST) 09520-24010 or equivalent, two bolts and nuts, remove the side gear shaft.
c. Using a screwdriver, remove the snap ring from the side gear shaft.





11. Remove side gear shaft oil seals.
Using SST 09308-00010 or equivalent, remove the oil seal.
12. Remove differential carrier retainer (and adjusting plate washer).
a. Remove the eight bolts.
b. With Turbo and Manual Transmission (2JZ-GTE):
Using SST 09550-10012 (09558-10010), 09550-40010 (09951-04010, 09952-04020, 09953-04020, 09954-04010, 09955-04070, 09957-04010, 09958-04010), remove the carrier retainer and adjusting plate washer.





c. Others:
Using two screwdrivers, remove the carrier retainer.





d. Using a screwdriver, remove the O-ring from the carrier retainer.





13. Remove differential case.
Take the differential case out of the carrier while lifting the ring gear side, as shown in the illustration.





14. Remove side bearing outer race (and adjusting plate washer).
a. With Turbo and Manual Transmission (2JZ-GTE):
Using a brass bar and hammer, remove the outer race.

Fig. 26 Removing Side Bearing Outer Race & Plate Washer:

b. Others:
Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) or equivalents, and a press, remove the outer race and the adjusting plate washer.
15. Remove drive pinion, oil slinger (2JZ-GTE M/T), spacer and companion flange.
a. Using a chisel and hammer, loosen the staked part of the nut.





b. Using SST 09229-55010 or equivalent (and a 36 mm deep socket wrench), remove the nut.





c. Using a press, remove the drive pinion with the rear bearing and spacer.

NOTICE: Be careful not to drop the drive pinion.

d. Remove the companion flange.
e. Remove the oil slinger (2JZ-GTE M/T) and spacer from the drive pinion.





16. Remove oil seal.
Using SST 09308-00010 or equivalent, remove the oil seal.
17. Remove oil slinger (Except 2JZ-GTE M/T) and front bearing.
Remove the oil slinger, and front bearing by hand.





18. Remove rear bearing from drive pinion.
Using SST 09950-00020 or equivalent, and a press, remove the rear bearing from the drive pinion.





19. Remove front and rear bearing outer races and adjusting plate washer.
Using a brass bar and hammer, remove the front and rear bearing outer races and adjusting plate washer from the differential carrier.

HINT: Measure the adjusting plate washer thickness and make a note of it for reassembly.





20. Remove left and right hand side bearings.
Using SST 09550-10012 (09558-10010), 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04070, 09957-04010, 09958-04010) or equivalents, remove the left and right hand side bearings from the differential case.

HINT: Fix the claws of SST to the notch in the differential case.

21. Remove ring gear.





a. Place matchmarks on the ring gear and differential case.
b. Remove the ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
22. Conventional differential:
Disassemble differential case.





NOTICE: Do not disassemble the differential case except conventional differential.





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case.
- Pinion shaft.
- 2 Pinion gears.
- 2 Pinion gear thrust washers.
- 2 Side gears.
- 2 Side gears thrust washers.

REPLACEMENT
1. Replace companion flange dust deflector.





a. Using Special Service Tool (SST) 09950-00020, 09950-60010 (09951-00510) or equivalents, and a press, remove the dust deflector.

Fig. 30 Installing Companion Flange Dust Deflector:

b. With Turbo and manual transmission (2JZ-GTE):
Using SST 09316-20011, 09316-60011 (09316-00011) and a press, install a new dust deflector.
c. Others:
Using SST 09316-60011 (09316-00011) or equivalents, and a press, install a new dust deflector.
2. Replace side gear shaft dust cover.
a. Using a screwdriver, remove the dust cover.

Fig. 32 Installing New Side Gear Shaft Dust Cover:

b. Using SST 09502-24010, 09950-60020, (09951-00780), 09950-70010 (09951-07150) or equivalents, and a press, install a new dust cover.