Rear Differential Carrier Assembly (For 3Uz-Fe) Reassembly

Clean the contact surfaces of differential case and ring gear.

Clean the differential ring gear set bolt hole.

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

CAUTION:

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

Carefully take the ring gear out of the boiling water.

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

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

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

After the ring gear has been cooled sufficiently, install the new 10 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.

Torque the 10 set bolts uniformly, a little at a time.

Torque:

64 N*m{650 kgf*cm, 47 ft.*lbf}

Tighten the bolts further by 60° to 90°.

NOTICE:

Tighten the bolts, diagonally opposite of each other, in pairs.

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(09951-07200)

NOTICE:

1. Do not apply hypoid gear oil to a new bearing.
   
2. Do not deform the bearing cage. Set the SST to the center of the differential case.
   
3. If the bearing is replaced, replace it with the bearing outer race as a set.
   
4. The ring gear tooth (90366-50087) and back surfaces (90366-50027) have different bearings. Therefore, install the ring gear paying attention to part numbers.
   

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

SST

09502-24010

Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and plate washer.

SST

09950-70010(09951-07200)
09255-10012

HINT:

Select a plate washer of the same thickness as the one removed.

Using SST and a press, install the rear drive pinion front tapered roller bearing outer race.

SST

09950-60020(09951-00710)
09950-70010(09951-07200)

Using SST and a press, install the differential drive pinion.

SST

09316-60011(09316-00011)
09608-04031

HINT:

Assemble the spacer and oil seal after adjusting the tooth contact pattern.

Install the drive pinion oil slinger.

Using SST, install the companion flange.

SST

09950-30012(09951-03010,09954-03010,09956-03060,09955-03040)

NOTICE:

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

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

Using SST to hold the flange, torque the drive pinion nut.

SST

09229-55010
09330-00021

HINT:

Tighten the nut to 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.
   

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

Using SST and a torque wrench, measure the preload.

Drive pinion preload (at starting):

New bearing:

0.91 to 1.67 N*m (9.3 to 17.0 kgf*cm, 8.1 to 14.8 in.*lbf)

Reused bearing:

0.19 to 0.67 N*m (1.9 to 6.8 kgf*cm, 1.7 to 5.9 in.*lbf)

NOTICE:

Record the preload for total preload measurement.

Insert the differential case from the ring gear tooth side to install.

NOTICE:

Do not damage the case bearing and ring gear.

Using SST and a hammer, install the ring gear tooth side case bearing outer race.

SST

09608-32010
09950-70010(09951-07200)

HINT:

Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

Install SST to the differential carrier.

SST

09571-50010

Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.

Using SST and a hammer, install the ring gear back surfaces side case bearing outer race.

SST

09950-70010(09951-07200)
09608-32010

HINT:

Tap in the case bearing outer race until it touches the case bearing inner race roller.

Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.

Install a dial indicator to the differential carrier.

Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

SST

09571-50010

NOTICE:

Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT:

1. Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
   
2. Tighten the SST bolt to apply the preload to the case bearing.
   

Turn the ring gear clockwise and counterclockwise several times.

Using a dial indicator, measure the backlash of the ring gear at 3 positions.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:

The difference between the maximum and minimum values must be within 0.05 mm (0.002 in.)

HINT:

Write the values for reference to select a side gear shaft snap ring. If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

Loosen the SST bolt and separate the SST disc from the case bearing outer race on the ring gear tooth side.

Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear back surfaces side and case bearing outer race.

SST

09608-32010
09950-70010(09951-07200)

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.

Using snap ring pliers, install a side gear shaft snap ring with a different thickness.

HINT:

1. There are 39 different thicknesses of the side gear shaft snap ring available in 0.02 mm (0.0008 in.) increments.
   
2. When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash also changes by 0.02 mm (0.0008 in.).
   

Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.

Install a dial indicator to the differential carrier.

Tighten the SST bolt to alter the differential carrier's shape approximately 0.1 mm (0.004 in.).

SST

09571-50010

HINT:

Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.

Using a dial indicator, measure the backlash of the ring gear at 3 positions.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness.

Install a dial indicator to the differential carrier.

Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

SST

09571-50010

NOTICE:

Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT:

Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.

Using snap ring pliers, install the thinnest side gear shaft snap ring on the ring gear tooth side.

Remove the dial indicator and loosen the bolt until the SST disc is separated from the case bearing outer race.

Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.

Using a dial indicator, measure the backlash of the ring gear at 3 positions. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT:

If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

Loosen the SST bolt and separate the SST disc from the case bearing outer race on the ring gear tooth side.

Using SST and a hammer, create a clearance between the side gear shaft snap ring on the back surface of the ring gear and case bearing outer race.

Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.

Using snap ring pliers, install a side gear shaft snap ring with a different thickness.

HINT:

1. There are 39 different thicknesses of the side gear shaft snap ring available in 0.02 mm (0.0008 in.) increments.
   
2. When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash also changes by 0.02 mm (0.0008 in.).
   

Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.

Check the backlash around the ring gear. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one.

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT:

If a value is not within the specified range, replace it with one of a different thickness in the same procedure.

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

SST

09229-55010

Total preload (at starting):

Drive pinion preload plus 0.48 to 1.43 N*m (4.89 to 14.58 kgf*cm, 4.25 to 12.66 in.*lbf)

NOTICE:

1. If the measured preload is less than the specification, replace the rear differential side gear shaft snap ring of the ring gear's tooth surface side with a thicker one.
   
2. If the preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thinner one.
   

HINT:

When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 0.9 in.*lbf).

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

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

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:

1. 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 snap rings equally.
   
2. When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will also change by approximately 0.02 mm (0.0008 in.).
   

Recheck the total preload.

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

Rotate the ring gear in both directions.

Inspect the tooth contact pattern.

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

NOTICE:

Make sure to always replace the plate washer with a new one.

HINT:

There are 42 thicknesses of the rear differential drive pinion plate washers available in 0.01 mm (0.04 in.) increments.

Install the SST to the rear differential carrier.

SST

09571-50010

Install a dial indicator to the rear differential carrier.

Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the case bearing outer race and side gear shaft snap ring.

NOTICE:

Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT:

1. Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.
   
2. Approximately 0.1 mm (0.004 in.) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly.
   

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

Remove the dial indicator and loosen the SST bolt.

NOTICE:

Do not remove the SST.

Using SST and a hammer, create a clearance between the case bearing outer race on the ring gear and side gear shaft snap ring.

SST

09608-32010
09950-70010(09951-07200)

HINT:

The clearance is not visible, but tapping the SST with a hammer three or four times should be enough.

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.

Tighten the SST bolt and push out the case bearing outer race on the ring gear back surfaces side.

SST

09571-50010

NOTICE:

Do not drop the case bearing outer race.

Remove the SST.

Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.

HINT:

For reassembly, check the installation position of the case bearing outer race and of the side gear shaft snap ring before removing the case bearing outer race. Write down the result.

Remove rear differential case assembly.

NOTICE:

Do not damage the case bearing.

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

SST

09229-55010
09330-00021
09950-30012(09955-03040)

Using SST, remove the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03040,09956-03060)

Remove the differential drive pinion oil slinger.

Using a press, remove the drive pinion from the differential carrier.

NOTICE:

Do not drop the drive pinion.

Remove the rear drive pinion front tapered roller bearing from the differential carrier.

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

Using SST and a press, install the differential drive pinion to the differential carrier.

SST

09316-60011(09316-00011)
09608-04031

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

Using SST and a press, insert a new dust deflector into the companion flange.

SST

09316-60011(09316-00011)

NOTICE:

1. Slowly press in the dust deflector but not excessively.
   
2. If any burrs remain after pressing in the deflector, remove them.
   

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

SST

09316-60011(09316-00011)
09710-30012(09710-04101)

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Apply MP grease to the oil seal lip.

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

SST

09950-30012(09951-03010,09953-03010,09954-03010,09956-03060,09955-03040)

NOTICE:

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

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

Use SST to hold the flange and torque the drive pinion nut.

SST

09950-30012(09955-03040)
09229-55010
09330-00021

Torque:

98 to 490 N*m{1,000 to 5,000 kgf*cm, 72 to 361 ft.*lbf}

NOTICE:

1. Do not tighten excessively, otherwise the threads will be stripped.
   
2. Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
   

HINT:

Tighten the nut using approximately 98 N*m (1,000 kgf*cm, 72 ft.*lbf) of force, then tighten it further while observing the preload.

Using SST and a torque wrench, measure the preload.

SST

09229-55010

Drive pinion preload (at starting):

New bearing:

1.2 to 1.8 N*m (12.2 to 18.4 kgf*cm, 10.6 to 15.9 in.*lbf)

Reused bearing:

0.5 to 0.8 N*m (5 to 8 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°.
   
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.
   

Insert the differential case from the ring gear tooth side.

NOTICE:

Do not damage the case bearing inner race or ring gear.

Using SST and a hammer, install the ring gear tooth side case bearing outer race.

SST

09608-32010
09950-70010(09951-07200)

HINT:

Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

Install SST to the differential carrier.

SST

09571-50010

Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.

Using SST and a hammer, install the ring gear back surface side case bearing outer race.

SST

09950-70010(09951-07200)
09608-32010

HINT:

Tap in the case bearing outer race until it touches the case bearing inner race roller.

Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

HINT:

Use the side gear shaft snap ring installed when performing tooth contact adjustment.

Set a dial indicator on the differential carrier.

Tighten the SST bolt to alter the differential carrier's shape.

Shaped limit:

0.20 mm (0.0079 in.)

NOTICE:

Do not alter the shape excessively.

Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.

HINT:

Use the side gear shaft snap ring installed when performing tooth contact adjustment.

Remove the dial indicator, tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.

Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) away from the end of the shaft.

Maximum runout:

0.08 mm (0.0031 in.)

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

SST

09223-15030
09950-70010(09951-07200)

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Apply MP grease to the oil seal lips.

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

SST

09229-55010

Total preload (at starting):

Drive pinion preload plus 0.48 to 1.43 N*m (4.89 to 14.58 kgf*cm, 4.25 to 12.66 in.*lbf)

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

Remove the differential carrier from the overhaul attachment.

NOTICE:

Clean the fitting surface between the differential carrier and carrier cover.

Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.

NOTICE:

Do not scratch the fitting surface.

Install the rear differential breather plug oil deflector to the rear differential carrier cover.

Torque:

7.0 N*m{70 kgf*cm, 62 ft.*lbf}

Apply FIPG to the differential carrier at the position shown in the illustration.

FIPG:

08826-00090, THREE BOND 1281 or equivalent

NOTICE:

1. Apply the seal packing in drops, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter entirely.
   
2. Overlap the seal packing at least 10 mm at the beginning and the end of application.
   
3. Install the differential carrier cover within 3 minutes of application.
   

Install the differential carrier cover with the 8 bolts.

Torque:

47 N*m{475 kgf*cm, 35 ft.*lbf}

NOTICE:

Do not fill the 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.

Install the breather plug to the carrier cover.

Torque:

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

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}

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.
   

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.