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

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1. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN


    FA01121

  1. Install the 2 thrust No.1 washers to the 2 side gears.

    NOTICE:
    1. Make sure that there is no dirt or foreign matter on the thrust washer, side gear etc. before installing them.
    2. If replacing either the side gear or pinion, replace them as a set.
    3. Apply hypoid gear oil API GL-5 to all sliding and rotating parts.

  1. Install the 2 side gears, 2 differential pinion gears, 2 differential pinion thrust washers and differential pinion shaft to the differential case.

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



    C104919

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

    NOTICE:
    Do not overtighten the vise.

  1. Measure the side gear backlash 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 the 2 side gear thrust No.1 washers of different thicknesses.

    HINT:
    Refer to the following table to select the 2 side gear thrust No.1 washer.

    Thrust washer thickness:
    Thickness mm (in.)
    		Thickness mm (in.)
    1.48 to 1.52 (0.0583 to 0.0598)
    		1.73 to 1.77 (0.0681 to 0.0697)
    1.53 to 1.57 (0.0602 to 0.0618)
    		1.78 to 1.82 (0.0701 to 0.0717)
    1.58 to 1.62 (0.0622 to 0.0638)
    		1.83 to 1.87 (0.0720 to 0.0736)
    1.63 to 1.67 (0.0642 to 0.0657)
    		1.88 to 1.92 (0.0740 to 0.0756)
    1.68 to 1.72 (0.0661 to 0.0677)
    		-



    FA01124

  1. Using a pin punch (3 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.



    C063131

  1. Using a chisel and a hammer, stake the outside of the differential case pin hole.



2. INSTALL DIFFERENTIAL RING GEAR


    SA01143E01

  1. Clean the contact surfaces of differential case and ring gear.

  1. Clean the differential ring gear set bolt hole.

  1. Heat the ring gear to approx. 100°C (212°F) in boiling water.

    CAUTION:
    Use thick gloves to protect hands as the ring gear is hot.

  1. Carefully take the ring gear out of the boiling water.

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

    NOTICE:
    Do not overtighten the vise.

  1. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.



    C103291E01

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

  1. Temporarily install 5 new lock plates and 10 bolts.

  1. After the ring gear cools down, tighten the 10 bolts uniformly.

    Torque:
    97 N*m{ 985 kgf*cm , 72 ft.*lbf }



    C104915

  1. Using a chisel and a hammer, stake the 5 lock plates.

    1. Stake one claw so that it is flush against the flat surface of the bolt.

    2. Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.



3. INSTALL REAR DIFFERENTIAL CASE BEARING


    C102938E01

  1. Using SST and a press, install the case bearing inner race LH and RH to the differential case.

    SST
    09950-60010   (09951-00550, 09951-00560)
    09950-70010   (09951-07100)

    NOTICE:
    1. Do not apply hypoid gear oil to a new bearing.
    2. Do not deform the bearing cage.
    3. Set the SST to the center of the differential case.
    4. If the bearing is replaced, replace it and the outer race as a set.



4. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    C108739E01

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

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

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



    C068116

  1. Using a dial indicator, measure the runout of the ring gear.

    Maximum runout:
    0.07 mm (0.0028 in.)

    If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.

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



5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    C108741E01

  1. Using SST and a press, install the outer race of the rear drive pinion rear tapered roller bearing to the differential carrier.

    SST
    09950-60020   (09951-00790)
    09950-70010   (09951-07200)



6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    C108742E01

  1. Using SST and a press, install the outer race of the rear drive pinion front tapered roller bearing to the differential carrier.

    SST
    09950-60020   (09951-00720)
    09950-70010   (09951-07100)



7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    C108743E01

  1. Install the drive pinion plate washer to the drive pinion.

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

    SST
    09506-30012  



8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    C110825

  1. Install the drive pinion and the inner race of the rear drive pinion front tapered roller bearing to the differential carrier.

    HINT:
    Assemble the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.



    C110826

  1. Install the drive pinion oil slinger to the drive pinion.



    R011163E01

  1. Using SST, install the companion flange.

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

    NOTICE:
    1. Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
    2. Apply grease to the threads and tip of the SST center bolt before use.

  1. Coat the threads of the drive pinion nut with hypoid gear oil LSD.



    SA02351E01

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

    SST
    09330-00021  

    HINT:
    Tighten the nut approximately 98 N*m (1,000 kgf*cm, 72 ft.*lbf), and tighten it further while checking the preload.

    NOTICE:
    1. Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
    2. As there is no bearing spacer, tighten the nut a little at a time and do not overtighten.

  1. Turn the bearing clockwise and counterclockwise several times to stabilize it.



    SA02352

  1. Using a torque wrench, measure the preload.

    Drive pinion preload (at starting):
    New bearing:
    0.88 to 1.47 N*m (9.0 to 15.0 kgf*cm, 7.8 to 13.0 in.*lbf)
    Reused bearing:
    0.39 to 0.69 N*m (4.0 to 7.0 kgf*cm, 3.5 to 6.1 in.*lbf)

    NOTICE:
    Record the preload for total preload measurement.

    If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.



9. INSTALL REAR DIFFERENTIAL CASE

  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.



10. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    ZK02032

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

  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.)



11. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    C051373

  1. Select a side gear shaft plate washer that will set ring gear backlash within the specified range, and install it to the ring gear back side.

    HINT:
    1. If the case bearing is new, select a thinner side gear shaft plate washer and install it.
    2. If the case bearing is reused, install a side gear shaft plate washer with the same thickness as the removed one.


    Washer thickness:

    Thickness mm (in.)
    		Thickness mm (in.)
    		Thickness mm (in.)
    2.57 to 2.59 (0.1012 to 0.1020)
    		2.89 to 2.91 (0.1138 to 0.1146)
    		3.21 to 3.23 (0.1264 to 0.1271)
    2.59 to 2.61 (0.1020 to 0.1028)
    		2.91 to 2.93 (0.1146 to 0.1154)
    		3.23 to 3.25 (0.1271 to 0.1280)
    2.61 to 2.63 (0.1028 to 0.1035)
    		2.93 to 2.95 (0.1154 to 0.1161)
    		3.25 to 3.27 (0.1280 to 0.1287)
    2.63 to 2.65 (0.1035 to 0.1043)
    		2.95 to 2.97 (0.1161 to 0.1169)
    		3.27 to 3.29 (0.1287 to 0.1295)
    2.65 to 2.67 (0.1043 to 0.1051)
    		2.97 to 2.99 (0.1169 to 0.1177)
    		3.29 to 3.31 (0.1295 to 0.1303)
    2.67 to 2.69 (0.1051 to 0.1059)
    		2.99 to 3.01 (0.1177 to 0.1185)
    		3.31 to 3.33 (0.1303 to 0.1311)
    2.69 to 2.71 (0.1059 to 0.1067)
    		3.01 to 3.03 (0.1185 to 0.1193)
    		3.33 to 3.35 (0.1311 to 0.1319)
    2.71 to 2.73 (0.1067 to 0.1075)
    		3.03 to 3.05 (0.1193 to 0.1201)
    		3.35 to 3.37 (0.1319 to 0.1327)
    2.73 to 2.75 (0.1075 to 0.1083)
    		3.05 to 3.07 (0.1201 to 0.1209)
    		3.37 to 3.39 (0.1327 to 0.1335)
    2.75 to 2.77 (0.1083 to 0.1091)
    		3.07 to 3.09 (0.1209 to 0.1217)
    		3.39 to 3.41 (0.1335 to 0.1343)
    2.77 to 2.79 (0.1091 to 0.1098)
    		3.09 to 3.11 (0.1217 to 0.1224)
    		3.41 to 3.43 (0.1343 to 0.1350)
    2.79 to 2.81 (0.1098 to 0.1106)
    		3.11 to 3.13 (0.1224 to 0.1232)
    		3.43 to 3.45 (0.1350 to 0.1358)
    2.81 to 2.83 (0.1106 to 0.1114)
    		3.13 to 3.15 (0.1232 to 0.1240)
    		3.45 to 3.47 (0.1358 to 0.1366)
    2.83 to 2.85 (0.1114 to 0.1122)
    		3.15 to 3.17 (0.1240 to 0.1248)
    		3.47 to 3.49 (0.1366 to 0.1374)
    2.85 to 2.87 (0.1122 to 0.1130)
    		3.17 to 3.19 (0.1248 to 0.1256)
    		-
    2.87 to 2.89 (0.1130 to 0.1138)
    		3.19 to 3.21 (0.1256 to 0.1264)
    		-

  1. Make snug the differential case bearing and side gear shaft plate washer by tapping on the ring gear with a plastic hammer.



    ZK02032

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

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

    HINT:
    Backlash: 0.13 mm (0.0051 in.)



    C051373

  1. If the backlash is not within the specified range, select a side gear shaft plate washer that will set the ring gear backlash within the specified range and install it into the ring gear back side.



    C104416E01

  1. Select a thicker side gear shaft plate washer so that the clearance between the case bearing outer race end on the ring gear teeth side and the carrier becomes 0 or around 0.

  1. Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.



    ZK02032

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

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

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

    If backlash is not within the specified range, adjust the thickness of the right and left side gear shaft plate washers by an equal amount so that the backlash comes within the specified range.



12. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    C012218

  1. After adjusting the backlash of the differential ring gear, remove the teeth side gear shaft plate washer.

  1. Using a micrometer, measure the thickness of the removed side gear shaft plate washer.

  1. Select a new side gear shaft plate washer which is 0.06 to 0.09 mm (0.0024 to 0.0035 in.) thicker than the removed one.

    HINT:
    Select a side gear shaft plate washer which can be pressed in 2/3 of the way with a finger.



    F040494E01

  1. Using SST and a plastic hammer, drive in the side gear shaft plate washer.

    SST
    09504-22011  



    C108739E01

  1. Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

    NOTICE:
    Make sure the right and left bearing caps are not interchanged.

  1. Tighten both bearing caps with the 4 bolts.

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



    C068124

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

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

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

    If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft plate washers equally.



13. INSPECT TOTAL PRELOAD


    C011899

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

    Total preload (at starting):
    Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf)

    If the preload is not within the specified range, adjust it by the side gear shaft plate washer on the ring gear teeth side.



14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    F001259

  1. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

  1. Rotate the ring gear in both directions.



  1. Inspect the tooth contact pattern.


    SA01653E01



    SA01586E01

  1. If the teeth are not contacting properly, use the following table to select a proper washer for correction.

    NOTICE:
    1. If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
    2. If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.


    Washer thickness:

    Thickness mm (in.)
    		Thickness mm (in.)
    		Thickness mm (in.)
    1.69 to 1.71 (0.0665 to 0.0673)
    		1.93 to 1.95 (0.0760 to 0.0768)
    		2.17 to 2.19 (0.0854 to 0.0862)
    1.72 to 1.74 (0.0677 to 0.0685)
    		1.96 to 1.98 (0.0772 to 0.0780)
    		2.20 to 2.22 (0.0866 to 0.0874)
    1.75 to 1.77 (0.0688 to 0.0697)
    		1.99 to 2.01 (0.0783 to 0.0791)
    		2.23 to 2.25 (0.0878 to 0.0886)
    1.78 to 1.80 (0.0701 to 0.0709)
    		2.02 to 2.04 (0.0795 to 0.0803)
    		2.26 to2.28 (0.0890 to 0.0898)
    1.81 to 1.83 (0.0713 to 0.0720)
    		2.05 to 2.07 (0.0807 to 0.0815)
    		2.29 to 2.31 (0.0902 to 0.0909)
    1.84 to 1.86 (0.0724 to 0.0732)
    		2.08 to 2.10 (0.0819 to 0.0827)
    		2.32 to 2.34 (0.0913 to 0.0921)
    1.87 to 1.89 (0.0736 to 0.0744)
    		2.11 to 2.13 (0.0831 to 0.0839)
    		-
    1.90 to 1.92 (0.0748 to 0.0756)
    		2.14 to 2.16 (0.0843 to 0.0850)
    		-



15. REMOVE REAR DRIVE PINION NUT


16. REMOVE REAR DRIVE PINION COMPANION FLANGE


17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    C093601

  1. Install a new drive pinion bearing spacer to the drive pinion.

    NOTICE:
    Be sure to face the larger inner diameter side rearward as shown in the illustration.



20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    C110825

  1. Install the rear drive pinion front tapered roller bearing to the drive pinion.



21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    C110826

  1. Install the drive pinion oil slinger to the drive pinion.



22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    C108754E01

  1. Using SST and a hammer, install a new oil seal.

    SST
    09554-22010  

    Oil seal drive in depth:
    1.55 to 2.45 mm (0.061 to 0.096 in.)

  1. Apply MP grease to the oil seal lip.



23. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    C112934E01

  1. Using SST and a press, install a new dust deflector.

    SST
    09636-20010  

    NOTICE:
    1. Slowly press in the dust deflector.
    2. If any burrs remain after pressing in the deflector, remove them.



24. INSTALL REAR DRIVE PINION COMPANION FLANGE


    R011163E02

  1. Using SST, install the companion flange to the drive pinion.

    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.

  1. Coat the threads of a new drive pinion nut with hypoid gear oil LSD.



    SA02351E01

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

    SST
    09330-00021  

    Torque:
    338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less



25. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

  1. Using a torque wrench, measure the preload of the drive pinion.

    Preload (at starting):
    New bearing:
    0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf)
    Reused bearing:
    0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf)

    1. If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.
    2. If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
    3. If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.



26. 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):
    Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf)

    If the total preload is not within the specified range, adjust the total preload or repair as necessary.



27. INSTALL REAR DRIVE PINION NUT


    C051380

  1. Using a chisel and hammer, stake the drive pinion nut.



28. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    C108755E01

  1. Using SST and a hammer, install 2 new oil seals.

    SST
    09554-22010  

    Oil seal drive in depth:
    -0.5 to 0.5 mm (-0.020 to 0.020 in.)

  1. Apply MP grease to the oil seal lip.



29. REMOVE REAR DIFFERENTIAL CARRIER


    G021127E01

  1. Remove the differential carrier from the overhaul stand, etc.



30. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    C112933

  1. Install the oil deflector and bolt to the carrier cover.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }



31. INSTALL REAR DIFFERENTIAL CARRIER COVER

  1. Clean any residual FIPG material on the contact surfaces using gasoline or alcohol.



    C112930E01

  1. Apply FIPG to the carrier cover.

    FIPG:
    08826-00090, THREE BOND 1281 or equivalent

    HINT:
    1. Apply FIPG in drops, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter on the entire surface.
    2. Overlap FIPG at least 10 mm (0.39 in.) or more at the beginning and the end of application.
    3. Install the carrier cover within 3 minutes after applying FIPG.
    4. Do not add oil or drive the vehicle immediately after installing the cover. Leave it for at least an hour.
      Also, for at least 12 hours, avoid rapid acceleration/deceleration.



    G033000

  1. Install the carrier cover with the 8 bolts.

    Torque:
    47 N*m{ 480 kgf*cm , 35 ft.*lbf }



32. INSTALL REAR DIFFERENTIAL BREATHER PLUG


    G033076

  1. Install the breather plug to the carrier cover.

    Torque:
    21 N*m{ 210 kgf*cm , 15 ft.*lbf }



33. INSTALL REAR DIFFERENTIAL DRAIN PLUG

  1. Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }



34. INSTALL NO.1 REAR DIFFERENTIAL MOUNT CUSHION

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



    C108047E01

  1. Using SST, install a new No.1 rear differential mount cushion.

    SST
    09570-24010  

    NOTICE:
    1. Temporarily install the mount cushion to the member in order to prevent it from tilting and install the SST.
    2. Be sure to use the SST with the correct combination.
    3. Make sure that the SST contacts the entire circumference of the mount cushion.
    4. Be sure to install the mount cushion so that the identification rubber mark is at the bottom.



35. INSTALL NO.2 REAR DIFFERENTIAL MOUNT CUSHION

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



    C108048E02

  1. Using SST, install a new No.2 rear differential mount cushion.

    SST
    09570-24010  

    NOTICE:
    1. Temporarily install the mount cushion to the member in order to prevent it from tilting and install the SST.
    2. Be sure to use the SST with the correct combination.
    3. Make sure that the SST contacts the entire circumference of the mount cushion.
    4. Be sure to install the mount cushion so that the identification rubber marks are at the right and left.