REAR DIFFERENTIAL CARRIER ASSEMBLY (for 3GR-FE) > DISASSEMBLY

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1. REMOVE NO.1 REAR DIFFERENTIAL MOUNT CUSHION

HINT:
Perform this operation only when the No.1 rear differential mount cushion is damaged.



    C101189E01

  1. Using SST, remove the No.1 rear differential mount cushion.

    SST
    09570-24010  
    09316-12010  

    NOTICE:
    1. Do not bring SST into contact with the sub-frame.
    2. Do not slant the bolts of SST.
    3. Set the SST in the correct direction.
    4. Screw the 2 bolts of SST equally into the 2 holes of the rear differential mount.



2. REMOVE NO.2 REAR DIFFERENTIAL MOUNT CUSHION

HINT:
Perform this operation only when the No.2 rear differential mount cushion is damaged.



    C101190E01

  1. Using SST, remove the No.2 rear differential mount cushion.

    SST
    09570-24010  
    09316-12010  

    NOTICE:
    1. Do not bring SST into contact with the sub-frame.
    2. Do not slant the bolt of SST.
    3. Set the SST in the correct direction.



3. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    G033076

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



4. REMOVE REAR DIFFERENTIAL CARRIER COVER


    G033000

  1. Remove the 8 bolts from the differential carrier cover.



    G033001

  1. Using a brass bar and a hammer, remove the differential carrier cover from the differential carrier.



5. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    C112933

  1. Remove the bolt and oil deflector from the differential carrier cover.



6. FIX REAR DIFFERENTIAL CARRIER


    G021127E01

  1. Set the differential carrier to an overhaul stand, etc., as shown in the illustration.



7. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    G021128

  1. Set the dial indicator perpendicular to the end of the ring gear face.

  1. Rotate the ring gear and measure the runout.

    Maximum runout:
    0.07 mm (0.0028 in.)

    If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.



8. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    G021129

  1. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

    Backlash:
    0.13 to 0.18 mm (0.0051 to 0.0071 in.)

    If the backlash is not within the specified range, adjust the side bearing preload or repair as necessary.



9. INSPECT REAR DIFFERENTIAL SIDE GEAR BACKLASH


    C104918

  1. Using a dial indicator, check the backlash of the side gear while holding 1 pinion gear toward the differential case.

    Backlash:
    0.05 to 0.20 mm (0.0020 to 0.0079 in.)

    If the backlash is not within the specified range, install 2 side gear thrust washers of different thickness.



10. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE


    F001237E01

  1. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

    Maximum runout:
    0.09 mm (0.0035 in.)

    If the runout is greater than the maximum value, replace the companion flange sub-assembly rear.



11. INSPECT TOTAL PRELOAD


    SA02352

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

    Total preload (at starting):
    0.88 to 1.37 N*m (9.0 to 14.0 kgf*cm, 7.8 to 12.1 in.*lbf)

    If necessary, disassemble and inspect the differential.



12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    C108735E01

  1. Using SST, remove the 2 oil seals.

    SST
    09308-00010  



13. REMOVE REAR DRIVE PINION NUT


    C108736E01

  1. Using SST and a hammer, unstake the staked part of the drive pinion nut.

    SST
    09930-00010  

    NOTICE:
    1. Be sure to use SST with the tapered surface facing the shaft.
    2. Do not grind the tip of the SST with a grinder etc.
    3. Completely loosen the staked part of the nut when removing it.
    4. Do not damage the threads of the drive pinion.



    SA02349E01

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

    SST
    09330-00021  



14. REMOVE REAR DRIVE PINION COMPANION FLANGE


    R011391E01

  1. Using SST, remove the companion flange.

    SST
    09950-30012   (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

    NOTICE:
    Apply grease to the threads and tip of the SST center bolt before use.



15. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

HINT:
Perform this procedure only when the dust deflector is damaged.



    C112931E01

  1. Using SST and a press, remove the dust deflector.

    SST
    09950-00020  
    09950-60010   (09951-00510)
    09950-70010   (09951-07150)



16. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    C108737E01

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

    SST
    09308-10010  

    NOTICE:
    Apply grease to the threads and tip of the SST center bolt before use.



17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    C110826

  1. Remove the drive pinion oil slinger.



18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    C108738E01

  1. Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.

    SST
    09556-22010  

    NOTICE:
    Apply grease to the threads and tip of the SST center bolt before use.



19. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    C093601

  1. Remove the drive pinion bearing spacer.



20. REMOVE REAR DIFFERENTIAL CASE


    C108739E01

  1. Put matchmarks on either set of the bearing cap and differential carrier.

  1. Remove the 4 bolts and 2 bearing caps.

    NOTICE:
    Do not swap a bearing cap and carrier as they are manufactured as a set.



    F046026E01

  1. Using SST and a hammer, remove the 2 side gear shaft plate washers.

    SST
    09504-22011  

    HINT:
    Measure the thickness of the plate washers and note it down.



    C068107

  1. Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.

    NOTICE:
    1. Do not damage the differential case bearing or ring gear.
    2. Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.



21. REMOVE DIFFERENTIAL DRIVE PINION

  1. Remove the drive pinion from the differential carrier.



22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    R010668E01

  1. Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.

    SST
    09950-00020  

    HINT:
    If either the drive pinion or ring gear is damaged, replace both as a set.

  1. Remove the drive pinion plate washer from the drive pinion.



23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    C051361

  1. Using a brass bar and a hammer, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.



24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    C051362

  1. Using a brass bar and a hammer, remove the outer race of the rear drive pinion rear tapered roller bearing from the differential carrier.



25. REMOVE DIFFERENTIAL RING GEAR


    C104914E01

  1. Hold the differential case in a vise between aluminum plates.

    NOTICE:
    Do not overtighten the vise.

  1. Put matchmarks on the ring gear and differential case.

  1. Using a screwdriver and a hammer, unstake the 5 lock plates.



    C103292E01

  1. Remove the 10 ring gear set bolts and 5 lock plates.

  1. Using a plastic hammer, tap on the ring gear to separate it from the differential case.



26. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY

HINT:
Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.

  1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

    NOTICE:
    Be sure to install the bearing outer races in each correct position.

  1. Install the differential case to the differential carrier.

  1. Install the right and left (back side and teeth side) side gear shaft plate washers so that there is no looseness on the case bearings.

  1. Install the right and left bearing caps with the 4 bolts.

    Torque:
    85 N*m{ 870 kgf*cm , 63 ft.*lbf }



    C068112

  1. Using a dial indicator, measure the differential case runout.

    Maximum case runout:
    0.07 mm (0.0028 in.)

    If the runout is greater than the maximum value, replace the differential case assembly with a new one.

  1. Remove the right and left bearing caps, 2 side gear shaft plate washers and differential case.



27. REMOVE REAR DIFFERENTIAL CASE BEARING

HINT:
Perform this procedure only when replacing the case bearing or differential case.



    F040345E01

  1. Hold the differential case in a vise between aluminum plates.

    NOTICE:
    Do not overtighten the vise.

  1. Using SST, remove the case bearing inner race LH and RH from the differential case.

    SST
    09950-40011   (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

    NOTICE:
    1. Do not deform the bearing cage if the bearing is to be reused.
    2. Hook the SST claw from the dent of the differential case to the bearing inner race.
    3. Apply grease to the threads and tip of the SST center bolt before use.



28. REMOVE REAR DIFFERENTIAL PINION SHAFT PIN


    C063262

  1. Using a pin punch (3 mm) and a hammer, remove the straight pin.



    ZK01879E02

  1. Remove the differential pinion shaft. [A]

  1. Remove the 2 differential pinion gears. [B]

  1. Remove the 2 differential pinion thrust washers. [C]

  1. Remove the 2 side gears. [D]

  1. Remove the 2 side gear thrust No.1 washers. [E]



29. INSPECT DIFFERENTIAL PINION AND SIDE GEAR

  1. Check that there is no damage to the differential pinion gear and side gear. If the differential pinion gear and/or side gear is damaged, replace them with new ones.



30. INSPECT REAR DIFFERENTIAL CASE

  1. Check that there is no damage to the differential case. If the differential case is damaged, replace it.