Differential: Removal & Installation Lexus SC II рестайлинг

REPLACEMENT

HINT

1. Use the same procedures for the RH side and LH side.
2. The procedures listed below are for the LH side.

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1. REMOVE REAR WHEEL
2. REMOVE REAR DIFFERENTIAL FILLER PLUG Using a 10 mm hexagon wrench, remove the filler plug and gasket.
3. REMOVE REAR DIFFERENTIAL DRAIN PLUG Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain the differential oil.
4. REMOVE REAR SUSPENSION MEMBER BRACE RH
5. DISCONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S29240530602008041900000) )
6. DISCONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S25531146682008041900000) )
7. DISCONNECT REAR SPEED SENSOR LH (See «INSTALLATION»(ref-283150-S04945892262008041900000) )
8. DISCONNECT REAR DRIVE SHAFT ASSEMBLY LH (See «REMOVAL»(ref-283176-S14516349372008041900000) )
9. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST, tap out the oil seal. SST 09308-10010 (Scheme 2): Tapping Oil Seal
10. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (Scheme 3): Installing Rear Differential Side Gear Shaft Oil Seal Using SST and a hammer, tap in a new oil seal. SST 09223-15030, 09950-70010 (09951-07200) Apply MP grease to the oil seal lip.
11. INSTALL REAR DRIVE SHAFT ASSEMBLY LH (See «INSTALLATION»(ref-283176-S03716466732008041900000) )
12. CONNECT REAR SPEED SENSOR LH (See «INSTALLATION»(ref-283150-S04945892262008041900000) )
13. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S29240530602008041900000) )
14. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S25531146682008041900000) )
15. INSTALL REAR WHEEL
16. INSTALL REAR DIFFERENTIAL DRAIN PLUG (See «REPLACEMENT»(ref-283163-S28948870152008041900000) )
17. ADD DIFFERENTIAL OIL (See «REPLACEMENT»(ref-283163-S28948870152008041900000) )
18. INSPECT DIFFERENTIAL OIL (See «REPLACEMENT»(ref-283163-S28948870152008041900000) )
19. INSTALL REAR DIFFERENTIAL FILLER PLUG (See «REPLACEMENT»(ref-283163-S28948870152008041900000) )
20. STABILIZE SUSPENSION (See «INSTALLATION»(ref-283147-S11824451992008041900000) )
21. INSTALL REAR SUSPENSION MEMBER BRACE RH
22. TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S29240530602008041900000) )
23. TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S25531146682008041900000) )
24. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Inspect and adjust the rear wheel alignment (see «REAR WHEEL ALIGNMENT»(ref-283147-S07828615012008041900000) ).
25. CHECK SPEED SENSOR SIGNAL Check the speed sensor signal (see «DIAGNOSIS SYSTEM»(ref-283150-S35591510232008041900000) ).

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1. REMOVE REAR WHEEL
2. REMOVE FRONT FLOOR BRACE CENTER
3. REMOVE REAR SUSPENSION MEMBER BRACE REAR LOWER LH Remove the 2 bolts and brace.
4. REMOVE REAR SUSPENSION MEMBER BRACE REAR LOWER RH Remove the 2 bolts and brace.
5. REMOVE HEATED OXYGEN SENSOR
6. REMOVE TAILPIPE ASSEMBLY (See «REMOVAL»(ref-283175-S10954038012008041900000) )
7. REMOVE FRONT FLOOR BRACE CENTER (See «REMOVAL»(ref-283173-S21457504642008041900000) >
8. REMOVE EXHAUST CENTER PIPE ASSEMBLY (See «REMOVAL»(ref-283175-S10954038012008041900000) )
9. REMOVE EXHAUST FRONT PIPE ASSEMBLY (See «REMOVAL»(ref-283175-S10954038012008041900000) )
10. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR (See «REMOVAL»(ref-283173-S21457504642008041900000) )
11. REMOVE PARKING BRAKE CABLE HEAT INSULATOR (See «REMOVAL»(ref-283173-S21457504642008041900000) )
12. REMOVE REAR END BODY MOUNTING SET PLATE LH
13. REMOVE REAR END BODY MOUNTING SET PLATE RH
14. REMOVE MAIN MUFFLER HEAT INSULATOR
15. REMOVE BODY REAR END MOUNTING BRACKET SUB-ASSEMBLY
16. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See «REMOVAL»(ref-283173-S21457504642008041900000) )
17. REMOVE REAR DIFFERENTIAL FILLER PLUG Using a 10 mm hexagon wrench, remove the filler plug and gasket.
18. REMOVE REAR DIFFERENTIAL DRAIN PLUG Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain the differential oil.
19. REMOVE REAR SUSPENSION MEMBER BRACE LH
20. REMOVE REAR SUSPENSION MEMBER BRACE RH
21. DISCONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S25531146682008041900000) )
22. DISCONNECT REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Use the same procedures described for the LH side.
23. DISCONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S29240530602008041900000) )
24. DISCONNECT REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Use the same procedures described for the LH side.
25. DISCONNECT REAR DRIVE SHAFT ASSEMBLY LH (See «REMOVAL»(ref-283176-S14516349372008041900000) )
26. DISCONNECT REAR DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedures described for the LH side.
27. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY Support the differential carrier with a jack. Using a 12 mm hexagon wrench, remove the 3 hexagon bolts. (Scheme 4): Locating Hexagon Bolts Remove the 2 bolts and 2 lower mount stoppers. Remove the differential. Remove the 2 upper mount stoppers from the differential carrier. (Scheme 5): Locating Lower Mount Stoppers And Bolts
28. REMOVE REAR NO. 1 DIFFERENTIAL MOUNT CUSHION Pass SST bolts through the area shown in the illustration, and remove the No. 1 mount cushion. SST 09570-24011, 09316-12010 NOTE: When removing the No. 1 mount cushion, do not connect SST (09316-12010) to the rear suspension member. Be sure to combine SST properly. Do not install SST bolts at an angle. Make sure the SST bolts are tightened equally. (Scheme 6): Removing Rear No. 1 Differential Mount Cushion
29. REMOVE REAR NO. 2 DIFFERENTIAL MOUNT CUSHION Pass SST bolts through the area shown in the illustration, and remove the No. 2 mount cushion. SST 09570-24011, 09316-12010 NOTE: When removing the No. 2 mount cushion, do not connect SST (09316-12010) to the rear suspension member. Be sure to combine SST properly. Do not install SST bolts at an angle. Make sure the SST bolts are tightened equally. (Scheme 7): Removing Rear No. 2 Differential Mount Cushion

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1. REMOVE REAR DIFFERENTIAL CARRIER COVER Remove the 8 bolts from the carrier cover. (Scheme 8): Locating Carrier Cover Bolts Using a brass bar and hammer, tap out the cover from carrier. if necessary, remove the breather plug from the differential carrier cover. (Scheme 9): Removing Breather Plug To Differential Carrier Cover Remove the bolt and oil deflector from the differential carrier cover. (Scheme 10): Locating Differential Carrier Cover Bolts
2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY (Scheme 11): Identifying Fix Rear Differential Carrier Assembly
3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Using a dial indicator, measure the runout of the ring gear. Maximum runout: 0.05 mm (0.0020 in.) If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case. (Scheme 12): Measuring Runout Of Ring Gear
4. INSPECT DIFFERENTIAL RING GEAR BACKLASH Using a dial indicator, measure the backlash of the ring gear. HINT: Perform the measurements at 3 or more positions around the side bearing preload. Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) (Scheme 13): Measuring Backlash Of Ring Gear NOTE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 in.). If the backlash is not as specified, adjust the backlash.
5. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue. Hold the companion flange firmly and rotate the ring gear in both directions. Inspect the tooth contact pattern. (Scheme 14): Identifying Tooth Contact Pattern If the tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing. NOTE: Make sure to always replace the adjusting washer with a new one. HINT: Refer to the adjusting washer table on the next page. (Scheme 15): Tooth Contact Pattern Examples HINT: Rear differential drive pinion plate washers are available in 42 sizes, each with a 0.01 mm (0.0004 in.) thickness difference. Standard plate washer thickness THICKNESS SPECIFICATION Part No. Thickness mm (in.) No. Part No. Thickness mm (in.) No. 90201-70001 1.87 (0.0736) 87 90201-70022 2.08 (0.0819) 08 90201-70002 1.88 (0.0740) 88 90201-70023 2.09 (0.0823) 09 90201-70003 1.89 (0.0744) 89 90201-70024 2.10 (0.0827) 10 90201-70004 1.90 (0.0748) 90 90201-70025 2.11 (0.0831) 11 90201-70005 1.91 (0.0752) 91 90201-70026 2.12 (0.0835) 12 90201-70006 1.92 (0.0756) 92 90201-70027 2.13 (0.0839) 13 90201-70007 1.93 (0.0760) 93 90201-70028 2.14 (0.0843) 14 90201-70008 1.94 (0.0764) 94 90201-70029 2.15 (0.0846) 15 90201-70009 1.95 (0.0768) 95 90201-70030 2.16 (0.0850) 16 90201-70010 1.96 (0.0772) 96 90201-70031 2.17 (0.0854) 17 90201-70011 1.97 (0.0776) 97 90201-70032 2.18 (0.0858) 18 90201-70012 1.98 (0.0780) 98 96201-70033 2.19 (0.0862) 19 90201-70013 1.99 (0.0783) 99 90201-70034 2.20 (0.0866) 20 90201-70014 2.00 (0.0787) 00 90201-70035 2.21 (0.0870) 21 90201-70015 2.01 (0.0791) 01 90201-70036 2.22 (0.0874) 22 90201-70016 2.02 (0.0795) 02 90201-70037 2.23 (0.0878) 23 90201-70017 2.03 (0.0799) 03 90201-70038 2.24 (0.0882) 24 90201-70018 2.04 (0.0803) 04 90201-70039 2.25 (0.0886) 25 90201-70019 2.05 (0.0807) 05 90201-70040 2.26 (0.0890) 26 90201-70020 2.06 (0.0811) 06 90201-70041 2.27 (0.0894) 27 90201-70021 2.07 (0.0815) 07 90201-70042 2.28 (0.0898) 28
6. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Using a vise, hold the differential case between 2 aluminum plates. Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.). If the backlash is not within the specification, replace the rear differential case sub-assembly with a new one. (Scheme 16): Inspecting Differential Side Gear Backlash
7. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) from the end of the shaft. Maximum runout: 0.08 mm (0.0031 in.) HINT: If the runout is greater than the maximum, replace the drive pinion and ring gear. (Scheme 17): Measuring Runout Of Drive Pinion Shaft
8. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Using SST and a torque wrench, measure the preload of backlash between the drive pinion and ring gear. SST 09229-55010 Standard preload (at starting): 0.5 to 0.8 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) HINT: If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary. (Scheme 18): Inspecting Differential Drive Pinion Preload
9. INSPECT TOTAL PRELOAD Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. SST 09229-55010 Standard total preload: Standard drive pinion preload plus 0.46 to 1.37 N*m (4.69 to 13.97 kgf*cm, 4.07 to 12.13 in.*lbf) If necessary, disassemble and inspect the differential. (Scheme 19): Measuring Preload With Teeth Of Drive Pinion And Ring Gear
10. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST, tap out the 2 oil seals. SST 09308-00010 (Scheme 20): Tapping Oil Seals With SST
11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for Except ring gear side position) Install SST to the rear differential carrier. SST 09571-50010 (Scheme 21): Identifying Rear Differential Carrier With SST Install a dial indicator to the rear differential carrier. Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and side gear shaft snap ring. (Scheme 22): Installing Dial Indicator To Rear Differential Carrier NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.0008 in.). HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side gear shaft oil seal is tapped in. Approximately 0.1 mm (0.004 in.) of clearance between the side bearing (outer race) and the side gear shaft snap ring is sufficient for the washer to move slightly. Using snap ring pliers, remove the snap ring on the drive pinion side. HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result. Remove the dial indicator and loosen the SST bolt. NOTE: Do not remove SST. (Scheme 23): Removing Snap Ring On Drive Pinion Side
12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for Ring gear side position) Using SST and a hammer, create a clearance between the side bearing (outer) on the ring gear and side gear shaft snap ring. SST 09608-32010, 09950-70010 (09951-07200) HINT: The clearance cannot be seen, but tapping SST with a hammer 3 or 4 times should be enough. (Scheme 24): Removing Rear Differential Side Gear Shaft Using snap ring pliers, remove the snap ring on the ring gear side. HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result. (Scheme 25): Removing Snap Ring On Ring Gear Side
13. REMOVE REAR DIFFERENTIAL CASE BEARING (for Ring gear side position) Tighten the SST bolt and push out the outer race on the ring gear side. SST 09571-50010 NOTE: Do not drop the side bearing (outer race). Remove SST. (Scheme 26): Pushing Outer Race On Ring Gear Side
14. REMOVE REAR DIFFERENTIAL CASE BEARING (for Except ring gear side position) Raise the ring gear of the differential case slightly to remove the drive pinion side outer race. HINT: For reassembly, check the installation position of the outer race and the side gear shaft snap ring before removing the outer race. Write down the result. (Scheme 27): Removing Drive Pinion Side Outer Race
15. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY NOTE: Be careful not to damage the case bearing. (Scheme 28): Removing Rear Differential Case Sub-Assembly
16. REMOVE REAR DRIVE PINION NUT Using a chisel and hammer, loosen the staked part of the nut. (Scheme 29): Loosening Staked Part Of Nut Using SST to hold the drive pinion companion flange, remove the nut. SST 09229-55010, 09950-30012 (09955-03040), 09330-00021 (09330-00030) (Scheme 30): Holding Drive Pinion Companion Flange
17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Using SST, remove the companion flange. (Scheme 31): Removing Companion Flange SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
18. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
19. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal from the differential carrier. SST 09308-10010
20. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Using a magnet hand, remove the differential drive pinion oil slinger. (Scheme 32): Removing Differential Drive Pinion Oil Slinger
21. REMOVE DIFFERENTIAL DRIVE PINION Using a press, press out the drive pinion with the rear bearing from the differential carrier. NOTE: Be careful not to drop the drive pinion. (Scheme 33): Pressing Drive Pinion With Rear Bearing From Differential Carrier
22. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Remove the spacer from the drive pinion. (Scheme 34): Identifying Spacer To Drive Pinion
23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Remove the front bearing from the differential carrier. (Scheme 35): Identifying Front Bearing To Differential Carrier Using a brass bar and hammer, tap out the front bearing outer race. (Scheme 36): Tapping Front Bearing Outer Race
24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, press out the rear bearing from the drive pinion. SST 09950-00020 NOTE: Do not drop the drive pinion. HINT: If the drive pinion or ring gear is damaged, replace them as a set. (Scheme 37): Pressing Rear Bearing To Drive Pinion Using a brass bar and hammer, tap out the rear bearing outer race. Remove the plate washer. (Scheme 38): Tapping Rear Bearing Outer Race
25. REMOVE DIFFERENTIAL RING GEAR Place matchmarks on the ring gear and differential case. (Scheme 39): Identifying Matchmarks On Ring Gear And Differential Case Remove the 10 ring gear set bolts. (Scheme 40): Removing Ring Gear Set Bolts Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
26. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY NOTE: This inspection is not necessary if the ring gear runout is within specified value Maximum runout: 0.05 mm (0.0020 in.) (Scheme 41): Inspecting Runout Of Rear Differential Case Sub-Assembly Install the differential case as shown in the illustration. (Scheme 42): Installing Differential Case Using SST and a hammer, tap in the outer race on the drive pinion side. SST 09608-32010, 09950-70010 (09951-07200) HINT: Tap in the outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen. (Scheme 43): Tapping Outer Race On Drive Pinion Side Place SST on the differential carrier. SST 09571-50010 Tighten the SST bolt until the SST disc lightly touches the case bearing (outer race). (Scheme 44): Identifying SST Bolt Using SST and a hammer, tap in the outer race on the ring gear side. SST 09608-32010, 09950-70010 (09951-07200) HINT: Tap in the outer race until it touches the case bearing roller. Place a dial indicator on the differential case flange surface at a right angle. (Scheme 45): Tapping Outer Race On Ring Gear Side Using a dial indicator, measure the differential case runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout is greater than the maximum, replace the rear differential case sub-assembly with a new one. (Scheme 46): Measuring Differential Case Runout
27. REMOVE REAR DIFFERENTIAL CASE BEARING (for Ring gear side position) Tighten the SST bolt to push out the ring gear side outer race. SST 09571-50010 NOTE: Do not drop the side bearing (outer race). Remove SST. (Scheme 47): Removing Rear Differential Case Bearing
28. REMOVE REAR DIFFERENTIAL CASE BEARING (for Except ring gear side position) Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race. (Scheme 48): Removing Drive Pinion Side Outer Race
29. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY NOTE: Be careful not to damage the side bearing. (Scheme 49): Removing Rear Differential Case Sub-Assembly
30. REMOVE REAR DIFFERENTIAL CASE BEARING Using SST, remove the 2 differential case bearings from the differential case. SST 09950-60010 (09951 -00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011) (Scheme 50): Removing Differential Case Bearings To Differential Case HINT: Do not remove the case bearing when not replacing the differential case. NOTE: Do not deform the bearing case. Hook the claws of SST to the bearing inner race of the differential case.
31. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, press out the dust deflector. SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100) NOTE: Do not drop the differential carrier. (Scheme 51): Pressing Dust Deflector
32. INSPECT DIFFERENTIAL PINION GEAR BACKLASH Using a vise, hold the differential case between 2 aluminum plates. Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.). If the backlash is not as specified, replace the rear differential case with a new one. (Scheme 52): Inspecting Differential Pinion Gear Backlash

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1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR HINT: Perform this procedure only when replacing the dust deflector. (Scheme 53): Installing Rear Differential Dust Deflector Using SST and a press, press a new dust deflector into the companion flange. SST 09316-60011 (09316-00011) NOTE: Slowly press a new dust deflector into the companion flange while observing the dust deflector. Do not press excessively. If necessary, remove any burrs after inserting the new dust deflector.
2. INSTALL DIFFERENTIAL RING GEAR Clean the contact surfaces of the differential case and ring gear. Heat the ring gear in boiling water that is approximately 100°C (212°F). Carefully take the ring gear out of the boiling water. (Scheme 54): Heating Ring Gear After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the ring gear and the differential case. Temporarily install 2 new ring gear set bolts so that the bolt holes in the ring gear and differential case are not misaligned. (Scheme 55): Identifying Matchmarks On Ring Gear NOTE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.
3. INSTALL REAR DIFFERENTIAL CASE BOLT Clean the differential ring gear set bolt holes. Wait until the ring gear has cooled sufficiently. Apply thread lock to 8 new ring gear set bolts. Seal Packing: Toyota Genuine thread lock 1360, Three Bond 1360 or equivalent NOTE: Always use new ring gear set bolts. (Scheme 56): Pressing Rear Bearing With SST Install the 8 ring gear set bolts to the ring gear. Torque the 10 set bolts uniformly and a little at a time. NOTE: Tighten the bolts in diametrically opposite pairs. Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) Tighten the bolts further by 60 to 90°. (Scheme 57): Tightening Bolts Further
4. INSTALL REAR DIFFERENTIAL CASE BEARING Using SST and a press, press in the 2 differential case bearings. SST 09950-60010 (09951-00560), 09950-60020 (09951-00810), 09950-70010 (09951-07100,09951-07200) (Scheme 58): Identifying Differential Case Bearings SST NOTE: Align SST with the center of the differential case. Replace the bearing outer race when bearing is replaced. Be careful as the 2 bearings are different. The ring gear tooth side's bearing is part No. 90366-50087 and the other side's bearing is part No. 90366-50027.
5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, press in the rear bearing. SST 09502-24010 (Scheme 59): Identifying Rear Bearing With SST Using SST and a press, press in the rear bearing outer race and adjusting washer. SST 09255-10012, 09950-70010 (09951-07100) HINT: Select a thrust shim of the same thickness as the removed one. (Scheme 60): Pressing Rear Bearing Outer Race And Adjusting Washer
6. INSTALL DIFFERENTIAL DRIVE PINION Using SST and a press, press in the front bearing outer race. SST 09950-60020 (09951-00710), 09950-70010 (09951-07200) Install the drive pinion in the differential carrier. (Scheme 61): Pressing Front Bearing Outer Race With SST Using SST and a press, press the front bearing into the drive pinion. SST 09316-60011 (09316-00011), 09608-04031 HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern. (Scheme 62): Pressing Front Bearing Into Drive Pinion With SST
7. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD Using SST, install the companion flange onto the differential carrier. SST SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060) NOTE: Because the spacer is not installed, maintain a little looseness between the companion flange and the drive pinion when installing. Adjust the drive pinion preload by tightening the companion flange nut. 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 to hold the flange, tighten the nut. SST 09229-55010 (09955-03040), 09330-00021 (09330-00030) Using SST and a torque wrench, measure the preload. SST 09229-55010 Standard preload (at starting) BEARING SPECIFICATION Bearing Specified Condition New bearing 1.5 to 2.0 N*m (15 to 21 kgf*cm, 13.0 to 17.8 in.*lbf) Reused bearing 0.5 to 0.8 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) (Scheme 63): Measuring Preload With SST HINT: Do not apply hypoid gear oil if a new bearing is used. If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary. NOTE: For a more accurate measurement, rotate the bearing forward and backward several times before measuring.
8. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY Insert the differential case from the ring gear tooth side to install it. NOTE: Do not damage the case bearing and ring gear. (Scheme 64): Identifying Rear Differential Case Sub-Assembly
9. INSTALL REAR DIFFERENTIAL CASE BEARING Using SST and a hammer, tap in the drive pinion side outer race. SST 09608-32010, 09950-70010 (09951-07200) HINT: Tap in the outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen. (Scheme 65): Tapping Drive Pinion Side Outer Race Install SST to the differential carrier. SST 09571-50010 Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race). (Scheme 66): Identifying Differential Carrier With SST Using SST and a hammer, tap in the ring gear side outer race. SST 09950-70010 (09951-07200), 09608-32010 HINT: Tap in the outer race until it touches the case bearing roller. (Scheme 67): Tapping Ring Gear Side Outer Race With SST
10. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for Ring gear side position) HINT: This procedure is required only when the final gear set (drive pinion and ring gear) is replaced. Using snap ring pliers, install the thinnest side gear shaft snap ring on the ring gear side. Install a dial indicator to the differential carrier. (Scheme 68): Installing Rear Differential Side Gear Shaft Snap Ring Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.). SST 09571-50010 NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.). (Scheme 69): Tightening SST Bolt HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side gear shaft oil seal is tapped in. 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. HINT: Perform the measurements at 3 or more positions around the side bearing preload. (Scheme 70): Measuring Backlash Of Ring Gear Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) NOTE: The difference between the maximum and minimum values must be within 0.05 mm (0.0020 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 drive pinion. Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear side and outer race. SST 09608-32010, 09950-70010 (09951-07200) (Scheme 71): Removing Rear Differential Side Gear Shaft Using snap ring pliers, remove the snap ring on the ring gear side. Using snap ring pliers, install a snap ring with a different thickness. HINT: Side gear shaft snap rings are available in 39 sizes, each with a 0.02 mm (0.0008 in.) thickness difference. When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash changes by 0.02 mm (0.0008 in.). (Scheme 72): Installing Rear Differential Side Gear Shaft Snap Ring Standard snap ring thickness SNAP RING THICKNESS SPECIFICATION Parts No. Thickness mm (in.) Parts No. Thickness mm (in.) 90521-99062 3.66 (0.1441) 90521-99084 4.06 (0.1598) 90521-99063 3.68 (0.1449) 90521-99085 4.08 (0.1606) 90521-99064 3.70 (0.1457) 90521-99086 4.10 (0.1614) 90521-99065 3.72 (0.1465) 90521-99087 4.12 (0.1622) 90521-99066 3.74 (0.1472) 90521-99088 4.14 (0.1630) 90521-99067 3.76 (0.1480) 90521-99089 4.16 (0.1638) 90521-99068 3.78 (0.1488) 90521-99090 4.18 (0.1646) 90521-99070 3.80 (0.1496) 90521-99091 4.20 (0.1654) 90521-99071 3.82 (0.1503) 90521-99092 4.22 (0.1661) 90521-99072 3.84 (0.1512) 90521-99095 4.24 (0.1669) 90521-99073 3.86 (0.1520) 90521-99096 4.26 (0.1677) 90521-99074 3.88 (0.1528) 90521-99097 4.28 (0.1685) 90521-99075 3.90 (0.1535) 90521-99100 4.30 (0.1693) 90521-99076 3.92 (0.1543) 90521-99101 4.32 (0.1701) 90521-99077 3.94 (0.1551) 90521-99102 4.34 (0.1709) 90521-99078 3.96 (0.1559) 90521-99103 4.36 (0.1717) 90521-99079 3.98 (0.1567) 30521-99104 4.38 (0.1724) 90521-99081 4.00 (0.1575) 90521-99105 4.40 (0.1732) 90521-99082 4.02 (0.1583) 90521-99107 4.42 (0.1740) 90521-99083 4.04 (0.1591) - - Using a plastic-faced hammer, lightly tap the drive pinion side of the differential carrier. (Scheme 73): Tapping Drive Pinion Side Of Differential Carrier Install a dial indicator onto 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 HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal is tapped in. (Scheme 74): Installing Dial Indicator To Rear Differential Carrier Using a dial indicator, measure the ring gear backlash. Standard 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 ring gear side with one of a different thickness. (Scheme 75): Measuring Backlash Of Ring Gear
11. ADJUST DIFFERENTIAL RING GEAR BACKLASH 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 HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal is tapped in. (Scheme 76): Installing Dial Indicator To Rear Differential Carrier Using snap ring pliers, install the thinnest side gear shaft snap ring on the drive pinion side. Remove the dial indicator and loosen the bolt until the SST disc is separated from the outer race. (Scheme 77): Removing Snap Ring On Drive Pinion Side Using a plastic-faced hammer, lightly tap the drive pinion side of the differential carrier. (Scheme 78): Tapping Drive Pinion Side Of Differential Carrier Check the backlash around the ring gear. Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) NOTE: The difference between the maximum and minimum values must be within 0.05 mm (0.0020 in.). (Scheme 79): Measuring Backlash Of Ring Gear If a value is not within the specified range, replace the snap ring with one of a different thickness (proceed to the next step). Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion. Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear side and outer race. SST 09608-32010, 09950-70010 (09951 -07200) (Scheme 80): Removing Rear Differential Side Gear Shaft Using snap ring pliers, remove the side gear shaft snap ring on the ring gear side. Using snap ring pliers, install a side gear shaft snap ring with different thickness. HINT: Side gear shaft snap rings are available in 39 sizes, each with a 0.02 mm (0.0008 in.) thickness difference. When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash changes by 0.02 mm (0.0008 in.). (Scheme 81): Installing Rear Differential Side Gear Shaft Snap Ring Standard snap ring thickness SNAP RING THICKNESS SPECIFICATION Part No. Thickness mm (in.) Part No. Thickness mm (in.) 90521-99062 3.66 (0.1441) 90521-99084 4.06 (0.1598) 90521-99063 3.68 (0.1449) 90521-99085 4.08 (0.1606) 90521-99064 3.70 (0.1457) 90521-99086 4.10 (0.1614) 90521-99065 3.72 (0.1465) 90521-99087 4.12 (0.1622) 90521-99066 3.74 (0.1472) 90521-99088 4.14 (0.1630) 90521-99067 3.76 (0.1480) 90521-99089 4.16 (0.1638) 90521-99068 3.78 (0.1488) 90521-99090 4.18 (0.1646) 90521-99070 3.80 (0.1496) 90521-99091 4.20 (0.1654) 90521-99071 3.82 (0.1503) 90521-99092 4.22 (0.1661) 90521-99072 3.84 (0.1512) 90521-99095 4.24 (0.1669) 90521-99073 3.86 (0.1520) 90521-99096 4.26 (0.1677) 90521-99074 3.88 (0.1528) 90521-99097 4.28 (0.1685) 90521-99075 3.90 (0.1535) 90521-99100 4.30 (0.1693) 90521-99076 3.92 (0.1543) 90521-99101 4.32 (0.1701) 90521-99077 3.94 (0.1551) 90521-99102 4.34 (0.1709) 90521-99078 3.96 (0.1559) 90521-99103 4.36 (0.1717) 90521-99079 3.98 (0.1567) 90521-99104 4.38 (0.1724) 90521-99081 4.00 (0.1575) 90521-99105 4.40 (0.1732) 90521-99082 4.02 (0.1583) 90521-99107 4.42 (0.1740) 90521-99083 4.04 (0.1591) - - Using a plastic-faced hammer, lightly tap the drive pinion side of the differential carrier. (Scheme 82): Tapping Drive Pinion Side Of Differential Carrier Check the backlash around the ring gear. Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) NOTE: The difference between the maximum and minimum values must be within 0.05 mm (0.0020 in.). If a value is not within the specified range, replace it with one of a different thickness in the same procedure. (Scheme 83): Measuring Backlash Of Ring Gear
12. ADJUST TOTAL PRELOAD Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. SST 09229-55010 Standard total preload (at starting): Drive pinion preload plus 0.46 to 1.37 N*m (4.69 to 13.97 kgf*cm, 4.07 to 12.13 in.*lbf) (Scheme 84): Measuring Preload With SST 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. If the preload is greater than the specification, replace the rear differential side gear shaft snap ring of the ring gear's 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 differential ring gear and measure the backlash. (Scheme 85): Measuring Backlash Of Ring Gear Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) If the measured value is not as specified, adjust it by increasing or decreasing the thickness of the right and left side gear shaft snap ring equally. NOTE: When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will change by approximately 0.02 mm (0.0008 in.). Recheck the total preload.
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue. Hold the companion flange firmly and rotate the ring gear in both directions. Inspect the tooth contact pattern. (Scheme 86): Identifying Tooth Contact Pattern If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing. NOTE: Make sure to always replace the adjusting washer with a new one. HINT: Refer to the adjusting washer table on the next page. (Scheme 87): Identifying Drive Pinion Rear Bearing (Scheme 88): Tooth Contact Pattern Examples HINT: Rear differential drive pinion plate washers are available in 42 sizes, each with a 0.01 mm (0.0004 in.) thickness difference. Standard drive pinion plate washers THICKNESS SPECIFICATION Part No. Thickness mm (in.) No. Part No. Thickness mm (in.) No. 90201-70001 1.87 (0.0736) 87 90201-70022 2.08 (0.0819) 08 90201-70002 1.88 (0.0740) 88 90201-70023 2.09 (0.0823) 09 90201-70003 1.89 (0.0744) 89 90201-70024 2.10 (0.0827) 10 90201-70004 1.90 (0.0748) 90 90201-70025 2.11 (0.0831) 11 90201-70005 1.91 (0.0752) 91 90201-70026 2.12 (0.0835) 12 90201-70006 1.92 (0.0756) 92 90201-70027 2.13 (0.0839) 13 90201-70007 1.93 (0.0760) 93 90201-70028 2.14 (0.0843) 14 90201-70008 1.94 (0.0764) 94 90201-70029 2.15 (0.0846) 15 90201-70009 1.95 (0.0768) 95 90201-70030 2.16 (0.0850) 16 90201-70010 1.96 (0.0772) 96 90201-70031 2.17 (0.0854) 17 90201-70011 1.97 (0.0776) 97 90201-70032 2.18 (0.0858) 18 90201-70012 1.98 (0.0780) 98 90201-70033 2.19 (0.0862) 19 90201-70013 1.99 (0.0783) 99 90201-70034 2.20 (0.0866) 20 90201-70014 2.00 (0.0787) 00 90201-70035 2.21 (0.0870) 21 90201-70015 2.01 (0.0791) 01 90201-70036 2.22 (0.0874) 22 90201-70016 2.02 (0.0795) 02 90201-70037 2.23 (0.0878) 23 90201-70017 2.03 (0.0799) 03 90201-70038 2.24 (0.0882) 24 90201-70018 2.04 (0.0803) 04 90201-70039 2.25 (0.0886) 25 90201-70019 2.05 (0.0807) 05 90201-70040 2.26 (0.0890) 26 90201-70020 2.06 (0.0811) 06 90201-70041 2.27 (0.0894) 27 90201-70021 2.07 (0.0815) 07 90201-70042 2.28 (0.0898) 28
14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for Except ring gear side position) Install SST to the rear differential carrier. (Scheme 89): Identifying Rear Differential Carrier With SST 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 side bearing (outer race) and snap ring. SST (Scheme 90): Installing Dial Indicator To Rear Differential Carrier NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.0008 in.). HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal is tapped in. Approximately 0.1 mm (0.0004 in.) clearance between the side bearing (outer race) and the snap ring is sufficient for the washer to move slightly. Using snap ring pliers, remove the snap ring on the drive pinion side. HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result. Remove the dial indicator and loosen the SST bolt. NOTE: Do not remove SST. (Scheme 91): Removing Snap Ring On Drive Pinion Side
15. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for Ring gear side position) Using SST and a hammer, create a clearance between the side bearing (outer) on the ring gear and snap ring. SST 09608-32010, 09950-70010 (09951-07200) HINT: The clearance cannot be seen, but tapping SST with a hammer 3 or 4 times should be enough. (Scheme 92): Removing Rear Differential Side Gear Shaft Using snap ring pliers, remove the snap ring on the ring gear side. HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result. (Scheme 93): Installing Rear Differential Side Gear Shaft Snap Ring
16. REMOVE REAR DIFFERENTIAL CASE BEARING (for Ring gear side position) Tighten the SST bolt and push out the outer race on the ring gear side. SST 09571-50010 NOTE: Do not drop the side bearing (outer race). Remove SST. (Scheme 94): Pushing Outer Race On Ring Gear Side
17. REMOVE REAR DIFFERENTIAL CASE BEARING (for Except ring gear side position) Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race. HINT: For reassembly, check the installation position of the outer race and of the side gear shaft snap ring before removing the outer race. Write down the result. (Scheme 95): Removing Drive Pinion Side Outer Race
18. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY NOTE: Be careful not to damage the case bearing. (Scheme 96): Removing Rear Differential Case Sub-Assembly
19. REMOVE REAR DRIVE PINION NUT Using SST to hold the flange, remove the nut. SST 09229-55010, 09330-00021 (09330-00030), 09950-30012 (09955-03040) (Scheme 97): Holding Drive Pinion Companion Flange
20. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)
21. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Using a magnet hand, remove the differential drive pinion oil slinger. (Scheme 98): Removing Companion Flange
22. REMOVE DIFFERENTIAL DRIVE PINION Using a press, press out the drive pinion with the rear bearing from the differential carrier. NOTE: Be careful not to drop the drive pinion. (Scheme 99): Pressing Drive Pinion With Rear Bearing From Differential Carrier
23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Remove the front bearing from the differential carrier. (Scheme 100): Identifying Front Bearing To Differential Carrier
24. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Install the spacer to the drive pinion. (Scheme 101): Identifying Spacer To Drive Pinion
25. INSTALL DIFFERENTIAL DRIVE PINION Using SST and a press, press the drive pinion (rear bearing rear inner race) and rear drive pinion tapered roller bearing front inner race into the differential carrier. SST 09316-60011 (09316-00011), 09608-04031 (Scheme 102): Pressing Front Bearing Into Drive Pinion With SST
26. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Install the rear differential drive pinion oil slinger to the differential drive pinion.
27. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Apply a small amount of MP grease to a new oil seal lip. Using SST and a hammer, tap the oil seal into the rear differential carrier. SST 09316-60011 (09316-00011), 09710-04101 Standard oil seal depth: 0 +-0.5 mm (0 +-0.020 in.) NOTE: Be sure that the oil seal is straight during insertion. (Scheme 103): Installing Rear Differential Carrier Oil Seal
28. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Using SST, install the companion flange to the differential carrier. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060, 09956-03060) Apply hypoid gear oil LSD to the threads of a new nut. (Scheme 104): Installing Companion Flange To Differential Carrier Using SST, hold the flange and tighten the nut while observing the preload with SST and torque wrench. SST 09229-55010 (09955-03040), 09330-00021 (09330-00030) Torque: 98 to 490 N*m (1,000 to 5,000 kgf*cm, 72 to 361 ft.*lbf) (Scheme 105): Holding Drive Pinion Companion Flange NOTE: Do not tighten excessively, otherwise the threads will be stripped. SST 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.
29. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY Install the differential case from the ring gear tooth side to install. NOTE: Do not damage the case bearing or ring gear. (Scheme 106): Identifying Rear Differential Case Sub-Assembly
30. INSTALL REAR DIFFERENTIAL CASE BEARING Using SST and a hammer, tap in the drive pinion side outer race. SST 09608-32010, 09950-70010 (09951-07200) HINT: Tap in the outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen. (Scheme 107): Tapping Drive Pinion Side Outer Race Install SST to the differential carrier. SST 09571-50010 Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race). (Scheme 108): Identifying Differential Carrier With SST Using SST and a hammer, tap in the ring gear side outer race. SST 09608-32010, 09950-70010 (09951-07200) HINT: Tap in the outer race until it touches the case bearing roller. (Scheme 109): Tapping Outer Race On Ring Gear Side
31. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING Using snap ring pliers, install the snap ring in the differential carrier on the ring gear side. HINT: Use the side gear shaft snap ring installed when the tooth contact adjustment was performed. (Scheme 110): Installing Rear Differential Side Gear Shaft Snap Ring Set a dial indicator on the differential carrier. Shaped limit: 0.2 mm (0.008 in.) Tighten the SST bolt to alter the differential carrier's shape. SST 09571-50010 NOTE: Do not alter the shape excessively. (Scheme 111): Installing Dial Indicator To Rear Differential Carrier Using snap ring pliers, install the side gear shaft snap ring on the drive pinion side. HINT: Use the side gear shaft snap ring installed when the tooth contact adjustment was performed. (Scheme 112): Removing Snap Ring On Drive Pinion Side Remove the dial indicator, and tap the differential carrier on the drive pinion side using a plastic-faced hammer to stabilize the case bearing. (Scheme 113): Tapping Drive Pinion Side Of Differential Carrier
32. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD NOTE: Rotate the flange clockwise and counterclockwise several times to stabilize the bearing before measuring the differential drive pinion preload. Using SST and a torque wrench, measure the preload. (Scheme 114): Measuring Preload With SST SST 09229-55010 Standard preload (at starting) BEARING SPECIFICATION Bearing Specified Condition New bearing 1.44 to 2.01 N*m (14.8 to 20.5 kgf*cm, 12.7 to 17.8 in.*lbf) Reused bearing 0.5 to 0.8 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If the preload is greater than the specified maximum value, replace the bearing spacer. NOTE: Because the bearing spacer deforms with use, replace the bearing spacer with a new one if the drive pinion preload is greater than the maximum value. If the preload is less than the specified minimum value, check the preload while retightening the nut by 5 to 10 degrees to adjust it into the specified value range. Torque: 98 to 490 N*m (1,000 to 5,000 kgf*cm, 72 to 361 ft.*lbf) 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. NOTE: In some cases, the nut torque is greater than the specified value but the preload is still less than the specified minimum value. If not, proceed to step INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION. Loosen the nut and check that the threads of the nut and drive pinion are not damaged. If the threads are not stripped, replace the spacer and apply hypoid gear oil LSD to the threads. Then repeat step INSPECT DRIVE PINION PRELOAD.
33. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Place a dial indicator where 10 mm (0.39 in.) away from the drive pinion shaft tip at a right angle. Measure the shaft runout. Maximum runout: 0.08 mm (0.0031 in.) (Scheme 115): Measuring Runout Of Drive Pinion Shaft
34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Apply MP grease to the lips of 2 new oil seal. Using SST and a hammer, tap in the oil seal until their faces become flush with the differential carrier surface. SST 09223-15030, 09950-70010 (09951-07200) (Scheme 116): Installing Rear Differential Side Gear Shaft Oil Seal
35. INSPECT TOTAL PRELOAD Using SST and a torque wrench, measure the preload (at starting) with the drive pinion and ring gear teeth in contact. SST SST 09229-55010 Standard total preload (at starting): Drive pinion preload plus 0.46 to 1.37 N*m (4.69 to 13.97 kgf*cm, 4.07 to 12.13 in.*lbf) (Scheme 117): Measuring Preload With Drive Pinion And Ring Gear Teeth
36. INSTALL REAR DRIVE PINION NUT Using a chisel and hammer, stake the nut. (Scheme 118): Installing Rear Drive Pinion Nut
37. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY Remove the differential carrier from the overhaul attachment. NOTE: Clean the fitting surface between the differential carrier and carrier cover. (Scheme 119): Identifying Fix Rear Differential Carrier Assembly
38. INSTALL REAR DIFFERENTIAL CARRIER COVER Clean the FIPG attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent. NOTE: Be careful not to scratch the fitting surface. Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt. Torque: 7.0 N*m (70 kgf*cm, 62 in.*lbf) (Scheme 120): Locating Rear Differential Carrier Cover Apply a continuous bead of seal packing to the differential carrier (diameter: 2 to 3 mm (0.080 to 0.120 in.)) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent (Scheme 121): Identifying Seal Packing NOTE: Overlap the seal packing at least 10 mm at the beginning and the end of application. Install the differential carrier cover within 3 minutes of application. Install the differential carrier cover with the 8 bolts. NOTE: After installing the cover, do not expose the seal to engine oil or start the engine for at least 1 hour, and avoid sudden acceleration or deceleration for at least 12 hours. If rear differential breather plug was removed: Install the breather plug. Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf) (Scheme 122): Locating Carrier Cover Bolts

INSTALLATION

HINT

A bolt without a torque specification is shown in the standard bolt chart (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. INSTALL REAR NO. 1 DIFFERENTIAL MOUNT CUSHION Pass SST bolts through the area shown in the illustration, and install the mount cushion. SST 09570-24011, 09316-12010 NOTE: Make sure the mount cushion installation angle misalignment is not over +- 3°. Make sure the mount cushion is not at an angle by first temporarily installing the mount cushion to the member before installing SST. Be sure to combine SST properly. Confirm that SST contacts the entire bush surface of the mount cushion. (Scheme 123): Identifying Rear No. 1 Differential Mount Cushion
2. INSTALL REAR NO. 2 DIFFERENTIAL MOUNT CUSHION Pass SST bolt through the area shown in the illustration, and install the mount cushion. SST 09570-24011, 09316-12010 NOTE: Make sure the mount cushion installation angle misalignment is not over +- 3°. Make sure the mount cushion is not at an angle by first temporarily installing the mount cushion to the member before installing SST. Be sure to combine SST properly. Confirm that SST contacts the entire bush surface of the mount cushion. (Scheme 124): Identifying Rear No. 2 Differential Mount Cushion
3. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY Install the 2 upper mount stoppers on the rear differential carrier. HINT: Use the upper mount stopper which was removed. Support the rear differential carrier with a jack and temporary install the lower mount stoppers and 2 new front side set bolts. NOTE: Do not let the rear differential carrier interfere with the drive shaft. (Scheme 125): Locating Lower Mount Stoppers And Bolts Using a 12 mm hexagon wrench, install the 3 rear side set hexagon bolts. Torque: 142 N*m (1,450 kgf*cm, 105 ft.*lbf) Torque the 2 front side set bolts. Torque: 123 N*m (1,250 kgf*cm, 90 ft.*lbf) Lower the jack. (Scheme 126): Locating Differential Carrier To Suspension Member With Bolts
4. INSTALL REAR DIFFERENTIAL DRAIN PLUG Using a 10 mm hexagon wrench, install the drain plug with a new gasket. Torque: 49 N*m (500 kgf*cm, 39 ft.*lbf)
5. ADD DIFFERENTIAL OIL (See «REPLACEMENT»(ref-283163-S28948870152008041900000) )
6. INSPECT DIFFERENTIAL OIL (See «REPLACEMENT»(ref-283163-S28948870152008041900000) )
7. INSTALL REAR DIFFERENTIAL FILLER PLUG Using a 10 mm hexagon wrench, install the filler plug with a new gasket. Torque: 49 N*m (500 kgf*cm, 39 ft.*lbf)
8. INSTALL REAR DRIVE SHAFT ASSEMBLY LH (See «INSTALLATION»(ref-283176-S03716466732008041900000) )
9. INSTALL REAR DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedures described for the LH side.
10. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S29240530602008041900000) )
11. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Use the same procedures described for the LH side.
12. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S25531146682008041900000) )
13. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Use the same procedures described for the LH side.
14. INSTALL REAR SUSPENSION MEMBER BRACE LH Install the rear suspension member with the 2 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
15. INSTALL REAR SUSPENSION MEMBER BRACE RH HINT: Use the same procedures described for the LH side.
16. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR Install the insulator with the 4 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
17. INSTALL PARKING BRAKE CABLE HEAT INSULATOR Install the insulator with the 4 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
18. INSTALL REAR WHEEL Install the rear wheel with the 5 nuts. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) Install the ornament with the 10 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
19. STABILIZE SUSPENSION (See «INSTALLATION»(ref-283147-S11824451992008041900000) )
20. TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (See «INSTALLATION»(ref-283147-S29240530602008041900000) )
21. TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH HINT: Use the same procedures described for the LH side.
22. TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY (See «INSTALLATION»(ref-283147-S25531146682008041900000) )
23. TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH HINT: Use the same procedures described for the LH side.
24. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See «INSTALLATION»(ref-283173-S00154937922008041900000) )
25. INSTALL EXHAUST FRONT PIPE ASSEMBLY (See «INSTALLATION»(ref-283175-S09779970882008041900000) )
26. INSTALL EXHAUST CENTER PIPE ASSEMBLY (See «INSTALLATION»(ref-283175-S09779970882008041900000) )
27. INSTALL TAILPIPE ASSEMBLY (See «INSTALLATION»(ref-283175-S09779970882008041900000) )
28. INSTALL HEATED OXYGEN SENSOR
29. INSTALL REAR SUSPENSION MEMBER BRACE REAR LOWER LH Install the rear suspension member brace rear lower with the 2 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
30. INSTALL REAR SUSPENSION MEMBER BRACE REAR LOWER RH HINT: Use the same procedures described for the LH side.
31. INSTALL REAR END BODY MOUNTING SET PLATE LH Install the rear end body mounting set plate with the 4 bolts. Torque: 56 N*m (570 kgf*cm, 41 ft.*lbf)
32. INSTALL REAR END BODY MOUNTING SET PLATE RH HINT: Use the same procedures described for the LH side.
33. INSTALL FRONT FLOOR BRACE CENTER Install the floor brace center with the 4 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
34. INSPECT AND ADJUST REAR WHEEL ALIGNMENT Inspect and adjust the rear wheel alignment (see «REAR WHEEL ALIGNMENT»(ref-283147-S07828615012008041900000) ).
35. CHECK FOR EXHAUST GAS LEAK (See «INSTALLATION»(ref-283175-S09779970882008041900000) )