Rear Differential Carrier Assembly (For 3Gr-Fe) Disassembly

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.
   

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.
   

Remove the breather plug from the differential carrier cover.

Remove the 8 bolts from the differential carrier cover.

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

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

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

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

Rotate the ring gear and measure the runout.

Maximum runout:

0.07 mm (0.0028 in.)

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.)

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.)

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

Maximum runout:

0.09 mm (0.0035 in.)

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)

Using SST, remove the 2 oil seals.

SST

09308-00010

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.
   

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

SST

09330-00021

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.

Using SST and a press, remove the dust deflector.

SST

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

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.

Remove the drive pinion oil slinger.

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.

Remove the drive pinion bearing spacer.

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

Remove the 4 bolts and 2 bearing caps.

NOTICE:

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

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.

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.
   

Remove the drive pinion from the differential carrier.

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.

Remove the drive pinion plate washer from the drive pinion.

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

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

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Put matchmarks on the ring gear and differential case.

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

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

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

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.

Install the differential case to the differential carrier.

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.

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

Torque:

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

Using a dial indicator, measure the differential case runout.

Maximum case runout:

0.07 mm (0.0028 in.)

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

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

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.
   

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

Remove the differential pinion shaft. [A]

Remove the 2 differential pinion gears. [B]

Remove the 2 differential pinion thrust washers. [C]

Remove the 2 side gears. [D]

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

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.

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