Disassembly
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 2UZ-FE):
DISASSEMBLY
1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.
Maximum runout:
If the runout is greater than the maximum, replace the companion flange.
2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Using a dial indicator, measure the runout of the ring gear.
Maximum runout:
0.05 mm (0.00197 in.)
If the runout is greater than the maximum, replace the ring gear with a new one.
3. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the ring gear.
Standard backlash:
0.10 to 0.20 mm (0.00394 to 0.00788 in.)
HINT: Measure at 3 or more positions around the circumference of the ring gear.
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.
4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the case.
Standard backlash:
0.05 to 0.20 mm (0.00197 to 0.00788 in.)
If the backlash is not within the specified value, replace the side gear thrust washer with one of a different thickness.
5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Standard drive pinion preload (at starting):
0.85 to 1.37 Nm (9 to 13 kgf-cm, 8 to 12 in.-lbf)
If necessary, disassemble and inspect the differential.
6. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.
Standard total preload (at starting):
Standard drive pinion preload plus 0.24 to 0.46 Nm (3 to 4 kgf-cm, 3 to 4 in.-lbf)
If necessary, disassemble and inspect the differential.
7. REMOVE REAR DRIVE PINION NUT
(a) Using SST and a hammer, unstake the nut.
SST: 09930-00010
(b) Using SST to hold the companion flange, remove the nut.
SST: 09330-00021
09330-00030
8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09956-03030
SST: 09955-03050
9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST, a steel plate and press, press out the dust deflector.
SST: 09950-00020
NOTE: Do not drop the companion flange.
10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal.
SST: 09308-10010
11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the bearing (inner race).
SST: 09556-22010
(b) Remove the bearing spacer.
13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
(a) Remove the 2 bolts and 2 nut locks.
14. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY
(a) Place matchmarks on the bearing cap and differential carrier.
(b) Remove the 4 bolts and 2 differential bearing caps.
(c) Remove the differential case from the differential carrier.
HINT: Tag the 2 case bearing outer races to show the location for reassembly.
15. REMOVE REAR DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion and bearing spacer from the differential carrier.
16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press out the bearing (inner race).
SST: 09950-00020
If either the drive pinion or ring gear is damaged, replace them as a set.
17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using a brass bar and hammer, tap out the bearing (outer race).
If the bearing is damaged during removal, replace it.
19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using a brass bar and hammer, tap out the bearing (outer race).
If the bearing is damaged during removal, replace it.
20. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
21. INSPECT REAR DIFFERENTIAL CASE ASSEMBLY RUNOUT
HINT: If the ring gear runout is within the specified value (see "INSPECT RUNOUT OF DIFFERENTIAL RING GEAR" procedure), this inspection is not necessary.
(a) Install the differential case to the differential carrier.
(b) Inspect the differential case runout.
Maximum runout:
0.04 mm (0.00158 in.)
(c) Remove the differential case from the differential carrier.
22. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Using SST, remove the 2 bearings.
SST: 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00480
HINT: Fix the claws of SST to the notches in the differential case.
23. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, tap out the straight pin.
(b) Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear thrust washers.
24. REMOVE REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck)
(a) Remove the bolt, washer and dynamic damper.