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REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): Inspection

  1. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR 
    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.

    Fig 1: Measuring Runout Of Ring Gear Using Dial Indicator
    G04047111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH 
    1. Set the dial indicator perpendicular to the end of the ring gear face.
    2. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

      Backlash: 

      DIFFERENTIAL RING GEAR BACKLASH

      Specifications Backlash
      2WD  0.13 to 0.18 mm (0.0051 to 0.0071 in.) 
      4WD  0.10 to 0.15 mm (0.0039 to 0.0059 in.) 
      Fig 2: Inspecting And Adjusting Differential Ring Gear Backlash
      G04047112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
      • Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
    3. 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.
      Fig 3: Selecting Side Gear Shaft Plate Washer
      G04047113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Washer thickness (2WD) 

      WASHER THICKNESS SPECIFICATION (2WD)

      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) -

      Washer thickness (4WD) 

      WASHER THICKNESS SPECIFICATION (4WD)

      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      2.57 to 2.59 (0.1012 to 0.1020) 2.81 to 2.83 (0.1106 to 0.1114) 3.05 to 3.07 (0.1201 to 0.1209)
      2.59 to 2.61 (0.1020 to 0.1028) 2.83 to 2.85 (0.1114 to 0.1122) 3.07 to 3.09 (0.1209 to 0.1217)
      2.61 to 2.63 (0.1028 to 0.1035) 2.85 to 2.87 (0.1122 to 0.1130) 3.09 to 3.11 (0.1217 to 0.1224)
      2.63 to 2.65 (0.1035 to 0.1043) 2.87 to 2.89 (0.1130 to 0.1138) 3.11 to 3.13 (0.1224 to 0.1232)
      2.65 to 2.67 (0.1043 to 0.1051) 2.89 to 2.91 (0.1138 to 0.1146) 3.13 to 3.15 (0.1232 to 0.1240)
      2.67 to 2.69 (0.1051 to 0.1059) 2.91 to 2.93 (0.1146 to 0.1154) 3.15 to 3.17 (0.1240 to 0.1248)
      2.69 to 2.71 (0.1059 to 0.1067) 2.93 to 2.95 (0.1154 to 0.1161) 3.17 to 3.19 (0.1248 to 0.1256)
      2.71 to 2.73 (0.1067 to 0.1075) 2.95 to 2.97 (0.1161 to 0.1169) 3.19 to 3.21 (0.1256 to 0.1264)
      2.73 to 2.75 (0.1075 to 0.1083) 2.97 to 2.99 (0.1169 to 0.1177) 3.21 to 3.23 (0.1264 to 0.1271)
      2.75 to 2.77 (0.1083 to 0.1091) 2.99 to 3.01 (0.1177 to 0.1185) 3.23 to 3.25 (0.1271 to 0.1280)
      2.77 to 2.79 (0.1091 to 0.1098) 3.01 to 3.03 (0.1185 to 0.1193) -
      2.79 to 2.81 (0.1098 to 0.1106) 3.03 to 3.05 (0.1193 to 0.1201) -
    4. Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.
      Fig 4: Tapping On Ring Gear With Plastic Hammer
      G04047114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Set the dial indicator perpendicular to the end of the ring gear face.
      Fig 5: Setting Dial Indicator Perpendicular To End Of Ring Gear Face
      G04047115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

      Backlash: 

      BACKLASH SPECIFICATION

      Specifications Backlash
      2WD  0.13 to 0.18 mm (0.0051 to 0.0071 in.) 
      4WD  0.10 to 0.15 mm (0.0039 to 0.0059 in.) 
    7. 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.
      Fig 6: Selecting Side Gear Shaft Plate Washer
      G04047116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. 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 zero or close to zero.
      Fig 7: Identifying Thicker Side Gear Shaft Plate Washer
      G04047117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.
      Fig 8: Tapping On Ring Gear With Plastic Hammer
      G04047118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Set the dial indicator perpendicular to the end of the ring gear face.
      Fig 9: Setting Dial Indicator To End Of Ring Gear Face
      G04047119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

    Backlash: 

    BACKLASH SPECIFICATION

    Specifications Backlash
    2WD  0.13 to 0.18 mm (0.0051 to 0.0071 in.) 
    4WD  0.10 to 0.15 mm (0.0039 to 0.0059 in.) 

    If the 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.

  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2WD) 
    1. 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 not, replace the rear differential case sub-assembly with a new one.

    Fig 10: Inspecting Differential Side Gear Backlash
    G04047120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 4WD) 
    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 new side gear thrust washers that have a differential thickness than the current thrust washers. The new left and right thrust washers should be the same thickness as each other.

    Fig 11: Inspecting Differential Side Gear Backlash (For 4WD)
    G04047121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2WD) 
    1. Hold the differential case in a vise between aluminum plates.
      NOTE: Do not overtighten the vise.
    2. 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 not, replace the rear differential case sub-assembly with a new one.

    Fig 12: Inspecting Differential Side Gear Backlash (For 2WD)
    G04047122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 4WD) 
    1. Hold the differential case in a vise between aluminum plates.
      NOTE: Do not overtighten the vise.
      Fig 13: Holding Differential Case In Vise
      G04047123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 new side gear thrust washers that have a differential thickness than the current thrust washers. The new left and right thrust washers should be the same thickness as each other.

    HINT:

    Refer to Fig 13 to select the 2 No. 1 side gear thrust washers.

    Thrust washer thickness 

    WASHER THICKNESS SPECIFICATION TABLE

    Thickness mm (in.)  Thickness mm (in.) 
    0.96 to 1.04 (0.0378 to 0.0409) 1.16 to 1.24 (0.0457 to 0.0488)
    WASHER THICKNESS SPECIFICATION

    Thickness mm (in.) Thickness mm (in.)
    1.06 to 1.14 (0.0417 to 0.0449)  1.26 to 1.34 (0.0496 to 0.0528) 
  7. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE 
    1. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

    Maximum runout: 0.09 mm (0.0035 in.) 

    If the runout is greater than the maximum value, replace the rear drive pinion companion flange sub-assembly.

    Fig 14: Inspecting Runout Of Rear Drive Pinion Companion Flange
    G04047124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT DRIVE PINION PRELOAD 
    1. Using a torque wrench, measure the preload of the drive pinion.

    Preload (at starting) 

    New bearing: 

    DRIVE PINION SPECIFICATION (NEW BEARING)

    Specifications Drive pinion preload
    2WD  1.49 to 2.59 N*m (15.2 to 26.4 kgf*cm, 13.2 to 22.9 in.*lbf) 
    4WD  1.40 to 2.00 N*m (14.3 to 20.4 kgf*cm, 12.4 to 17.7 in.*lbf) 

    Reused bearing 

    DRIVE PINION SPECIFICATION (REUSED BEARING)

    Specifications Drive pinion preload
    2WD  .11 to 1.91 N*m (11.3 to 19.5 kgf*cm, 9.8 to 16.9 in.*lbf) 
    4WD  0.51 to 0.76 N*m (5.2 to 7.7 kgf*cm, 4.5 to 6.7 in.*lbf) 

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

    Fig 15: Inspecting Drive Pinion Preload
    G04047125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT TOTAL PRELOAD 
    1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
    Fig 16: Inspecting Total Preload
    G04047126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Preload (at starting) New differential case bearing: 

    PRELOAD (AT STARTING) NEW DIFFERENTIAL CASE BEARING

    Specifications New drive pinion tapered roller bearing Reused drive pinion tapered roller bearing
    4WD  2.57 to 4.26 N*m (26.2 to 43.4 kgf*cm, 22.7 to 37.7 in.*lbf)  2.19 to 3.58 N*m (22.3 to 36.5 kgf*cm, 19.4 to 31.7 in.*lbf) 
    4WD  1.63 to 2.40 N*m (16.6 to 24.5 kgf*cm, 14.4 to 21.2 in.*lbf)  0.74 to 1.16 N*m (7.5 to 11.8 kgf*cm, 6.5 to 10.3 in.*lbf) 

    Reused differential case bearing 

    REUSED DIFFERENTIAL CASE BEARING

    Specifications New drive pinion tapered roller bearing Reused drive pinion tapered roller bearing
    2WD  1.98 to 3.37 N*m (20.2 to 34.4 kgf*cm, 17.5 to 29.8 in.*lbf)  1.60 to 2.69 N*m (16.3 to 27.4 kgf*cm, 14.2 to 23.8 in.*lbf) 
    4WD  1.56 to 2.31 N*m (15.9 to 23.1 kgf*cm, 13.8 to 20.4 in.*lbf)  0.77 to 1.17 N*m (7.9 to 11.9 kgf*cm, 6.8 to 10.4 in.*lbf) 

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

  10. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY 

    HINT:

    Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.

    1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.
      NOTE:
      • Be sure to install the bearing outer races in each correct position.
      • Do not damage the differential case bearing or ring gear.
    2. Install the differential case to the differential carrier.
      Fig 17: Installing Differential Case To Differential Carrier
      G04047127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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.
      Fig 18: Identifying Right & Left (Back Side & Teeth Side) Side Gear Shaft Plate Washers
      G04047128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.
      NOTE: Make sure that the right and left bearing caps are not interchanged.
    5. Tighten both bearing caps with the 4 bolts.

      Torque: 85 N*m (870 kgf*cm, 63 ft.*lbf) 

      Fig 19: Aligning Matchmarks On Bearing Cap & Differential Carrier
      G04047129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a dial indicator, measure the differential case runout.

      Maximum case runout: 0.07 mm (0.0028 in.) 

      If the runout is greater than the maximum value, replace the differential case assembly with a new one.

      Fig 20: Measuring Differential Case Runout
      G04047130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 4 bolts and 2 bearing caps.
      NOTE: Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.
    8. Remove the right and left bearing caps, 2 side gear shaft plate washers and differential case.
    NOTE: Do not damage the differential case bearing or ring gear.
  11. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
      Fig 21: Coating Teeth With Red Lead Primer
      G04047131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the ring gear in both directions.
    3. Inspect the tooth contact pattern.
      4. Fig 22: Inspecting Tooth Contact Between Ring Gear & Drive Pinion
      G04047132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. If the teeth are not contacting properly, use the following table to select a proper washer for correction.
    NOTE:
    • If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
    • If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.
    Fig 23: Identifying Plate Washer
    G04047133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Washer thickness: 

    WASHER THICKNESS SPECIFICATION

    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 to 2.28 (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) -
  12. INSPECT DIFFERENTIAL PINION AND SIDE GEAR (for 4WD) 
    1. 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.

  13. INSPECT DIFFERENTIAL CASE (for 4WD) 
    1. Check that there is no damage to the differential case.

    If the differential case is damaged, replace it.

  14. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR 
    1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.
      NOTE: Be sure to install the bearing outer races in each correct position.
    2. Install the differential case to the differential carrier.
    3. 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.
      Fig 24: Installing Differential Case To Differential Carrier (1 Of 2)
      G04047134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 25: Installing Differential Case To Differential Carrier (2 Of 2)
      G04047135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • If the case bearing is new, select a thinner side gear shaft plate washer and install it.
      • If the case bearing is reused, install a side gear shaft plate washer with the same thickness as the removed one.
    4. Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.
      NOTE: Make sure that the right and left bearing caps are not interchanged.
    5. Tighten both bearing caps with the 4 bolts.

      Torque: 85 N*m (870 kgf*cm, 63 ft.*lbf) 

      Fig 26: Tightening Both Bearing Caps Bolts
      G04047136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. 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.

      Fig 27: Measuring Runout Of Ring Gear Using Dial Indicator
      G04047137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 4 bolts and 2 bearing caps.
      NOTE: Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.
      Fig 28: Identifying Bolts and Bearing Caps
      G04047138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 side gear shaft plate washers.
      Fig 29: Identifying Side Gear Shaft Plate Washers
      G04047139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the right and left bearing caps, 2 side gear shaft plate washers and differential case.
    Fig 30: Identifying Right & Left Bearing Caps Side Gear Shaft Plate Washers & Differential Case
    G04047140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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