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

REMOVE REAR DIFFERENTIAL BREATHER PLUG
1. Remove the breather plug from the differential carrier cover.
  
  Fig 1: Identifying Rear Differential Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CARRIER COVER
1. Remove the 8 bolts from the differential carrier cover.
  
  Fig 2: Identifying Carrier Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, lightly tap the rib of the side bearing retainer to remove it.
  
  Fig 3: Tapping Rib Of Side Bearing Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not damage the sealing surface of the differential carrier.
REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Remove the bolt and oil deflector from the differential carrier cover.
  
  Fig 4: Locating Rear Differential Breather Plug Oil Deflector & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SECURE REAR DIFFERENTIAL CARRIER
1. Set the differential carrier to an overhaul stand, etc., as shown in the illustration.
  
  Fig 5: Securing Rear Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RUNOUT OF DIFFERENTIAL RING GEAR See step 1
INSPECT DIFFERENTIAL RING GEAR BACKLASH See step 2
INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION See step 9
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH See step 4
INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE See step 5
INSPECT DIFFERENTIAL DRIVE PINION PRELOAD See step 6
INSPECT TOTAL PRELOAD See step 7
REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Using SST, remove the 2 oil seals.
  
  Fig 6: Removing Rear Differential Side Gear Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09308-00010
REMOVE REAR DRIVE PINION NUT
1. Using SST and a hammer, unstake the staked part of the drive pinion nut.
  
  Fig 7: Unstaking Staked Part Of Drive Pinion Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09930-00010
  NOTE:
  - Be sure to use SST with the tapered surface facing the shaft.
  - Do not grind the tip of the SST with a grinder, etc.
  - Completely loosen the staked part of the nut when removing it.
  - Do not damage the threads of the drive pinion.
2. Using SST to hold the flange, remove the drive pinion nut.
  
  Fig 8: Removing Drive Pinion Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09330-00021
REMOVE REAR DRIVE PINION COMPANION FLANGE
1. Using SST, remove the companion flange.
  
  Fig 9: Removing Companion Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-30012
    - 09951-03010
    - 09953-03010
    - 09954-03010
    - 09955-03030
    - 09956-03030
  NOTE:
  Apply grease to the threads and tip of the SST center bolt before use.
REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
HINT:

Perform this procedure only when the dust deflector is damaged.
1. Using SST and a press, remove the dust deflector.
  
  Fig 10: Removing Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-00020
  - SST: 09950-60010
    - 09951-00380
  - SST: 09950-70010
    - 09951-07100
  NOTE:
  Do not drop the companion flange.
REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
1. Using SST, remove the oil seal from the differential carrier.
  
  Fig 11: Removing Oil Seal From Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09308-00010
REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Remove the drive pinion oil slinger.
  
  Fig 12: Identifying Drive Pinion Oil Slinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.
  
  Fig 13: Removing Inner Race Of Rear Drive Pinion Front Tapered Roller Bearing From Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09556-22010
  NOTE:
  Apply grease to the threads and tip of the SST center bolt before use.
REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Remove the drive pinion bearing spacer.
  
  Fig 14: Identifying Drive Pinion Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL CASE ASSEMBLY
1. Put matchmarks on either set of the bearing cap and differential carrier.
  
  Fig 15: Identifying Bearing Caps Bolts & Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
3. Using SST and a hammer, remove the 2 side gear shaft plate washers.
  
  Fig 16: Removing Side Gear Shaft Plate Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09504-22011
  NOTE:
  Put identification marks on the side gear shaft plate washer to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
  
  HINT:
  
  Measure the thickness of the plate washers and note it.
4. Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.
  
  Fig 17: Identifying Case Bearing Outer Races LH And RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not damage the differential case bearing or ring gear.
  - 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 REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Remove the drive pinion from the differential carrier.
2. Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.
  
  Fig 18: Removing Inner Race Of Rear Drive Pinion Rear Tapered Roller Bearing From Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-00020
  NOTE:
  Do not drop the drive pinion.
  
  HINT:
  
  If either the drive pinion or ring gear is damaged, replace both as a set.
3. Remove the drive pinion plate washer from the drive pinion.
  HINT:
  
  Measure the thickness of the plate washer and note it.
4. Using a brass bar and a hammer, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.
  
  Fig 19: Removing Outer Race Of Rear Drive Pinion Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using a brass bar and a hammer, remove the outer race of the rear drive pinion rear tapered roller bearing from the differential carrier.
  
  Fig 20: Removing Outer Race Of Rear Drive Pinion Rear Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.
REMOVE DIFFERENTIAL RING GEAR
1. Hold the differential case in a vise between aluminum plates.
  
  Fig 21: Identifying Differential Ring Gear, Differential Case, Lock Plates, Bolts, & Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not overtighten the vise.
2. Put matchmarks on the ring gear and differential case.
3. Using a chisel and a hammer, unstake the 5 lock plates.
4. Remove the 10 ring gear set bolts and 5 lock plates.
  
  Fig 22: Identifying Ring Gear Set Bolts And Lock Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
  
  Fig 23: Tapping On Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use cloth to prevent damage to the ring gear teeth.
INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY See step 8
REMOVE REAR DIFFERENTIAL CASE BEARING
HINT:

Perform this procedure only when replacing the case bearing or differential case.
1. Hold the differential case in a vise between aluminum plates.
  
  Fig 24: Removing Case Bearing Inner Races
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not overtighten the vise.
2. Using SST, remove the case bearing inner races LH and RH from the differential case.
  - SST: 09950-40011
    - 09951-04020
    - 09952-04010
    - 09953-04030
    - 09954-04010
    - 09955-04061
    - 09957-04010
    - 09958-04011
  - SST: 09950-60010
    - 09951-00480
    - 09951-00350
    - 09952-06010
  NOTE:
  - Do not deform the bearing cage if the bearing is to be reused.
  - Hook the SST claw from the dent of the differential case to the bearing inner race.
  - Apply grease to the threads and tip of the SST center bolt before use.