Page 1849 of 2543

DIFFERENTIAL CARRIER INSPECTION
1. CHECK DRIVE PINION SHAFT RUNOUT
Measure the drive pinion shaft runout at a position 10 mm
(0.39 in.) from the end of the shaft.
Maximum runout:
0.08 mm (0.0031 in.)
If the runout is greater than the maximum, replace the drive
pinion and/or ring gear.
2. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 8 bolts from the carrier cover.
(b) Using a brass bar and hammer, separate the cover and
carrier.
3. CHECK RING GEAR RUNOUT
Maximum runout:
2JZ±GTE M/T
0.08 mm (0.0031 in.)
Except 2JZ±GTE M/T
0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the drive
pinion, ring gear and/or differential case.
4. CHECK RING GEAR BACKLASH
Measure the backlash of the ring gear and drive pinion at 3
points (minimum) and check that the average value is within
the specification.
Backlash (average value):
0.08±0.13 mm (0.0031±0.0051 in.)
NOTICE: The difference between the maximum and minimum
measured values must be less than 0.05 mm (0.0020 in.).
If the backlash is not within the specification, adjust the ring
gear backlash.
(See page SA±74) SA±64
± SUSPENSION AND AXLEREAR DIFFERENTIAL
Page 1850 of 2543

5. MEASURE DRIVE PINION PRELOAD
Using SST (or a 36 mm deep socket) and a torque wrench,
measure the drive pinion preload using the backlash of the
drive pinion and ring gear.
SST 09229±55010
Preload (at start):
2JZ±GTE M/T
1.0±1.2 NVm (10±12 kgfVcm, 8.9±10.6 in.Vlbf)
Except 2JZ±GTE M/T
0.5±0.8 NVm (5±8 kgfVcm, 4.3±6.9 in.Vlbf)
6. CHECK TOTAL PRELOAD
Using SST (or a 36 mm deep socket) and a torque wrench,
measure the total preload.
SST 09229±55010
Total preload (at start):
In addition to drive pinion preload
2JZ±GTE M/T
0.4±0.6 NVm (4±6 kgfVcm, 3.4±5.2 in.Vlbf)
Except 2JZ±GTE M/T
0.5±0.8 NVm (5±8 kgfVcm, 4.3±6.9 in.Vlbf)
If necessary, disassemble and inspect the differential
7. CONVENTIONAL TYPE ONLY:
CHECK PINION GEAR BACKLASH
Measure the pinion gear backlash while holding one side
gear toward the case.
Backlash:
0.05±0.20 mm (0.0020±0.0079 in.)
If the backlash is not within the specification, install the cor-
rect thrust washer.
(See page SA±70)
8. CHECK TOOTH CONTACT PATTERN
(See page SA±75)
DIFFERENTIAL CARRIER DISASSEMBLY
HINT: When fastening the differential carrier to an overhaul
stand, etc., fasten it at the 4 places on the ring gear side
shown in the illustration.
± SUSPENSION AND AXLEREAR DIFFERENTIALSA±65
Page 1851 of 2543
1. REMOVE SIDE GEAR SHAFT
(a) 2JZ±GTE M/T only:
Equally tighten both bolts at the same time and pull out the
side gear shaft.
NOTICE: Pull out the side gear shaft until a nut can fit be-
hind the shaft. Pulling the shaft out too far will damage
the dust cover.
(b) Using SST and 2 bolts, nuts, remove the side gear shaft.
SST 09520±24010
(c) Using a screwdriver, remove the snap ring from the side gear
shaft.
2. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the oil seal.
SST 09308±00010
3. REMOVE DIFFERENTIAL CARRIER RETAINER (AND
ADJUSTING PLATE WASHER)
(a) Remove the 8 bolts.
(b) 2JZ±GTE M/T:
Using SST, remove the carrier retainer and adjusting plate
washer.
SST 09550±10012 (09558±10010),
09950±40010
Except 2JZ±GTE M/T:
Using 2 screwdrivers, remove the carrier retainer.
(c) Using a screwdriver, remove the O±ring from the carrier
retainer. SA±66
± SUSPENSION AND AXLEREAR DIFFERENTIAL
Page 1852 of 2543
4. REMOVE DIFFERENTIAL CASE
Take the differential case out of the carrier while lifting the ring
gear side, as shown in the illustration.
5. REMOVE SIDE BEARING OUTER RACE (AND
ADJUSTING PLATE WASHER)
2JZ±GTE M/T:
Using a brass bar and hammer, drive out the outer race.
Except 2JZ±GTE M/T:
Using SST and a press, press out the outer race and adjust-
ing plate washer.
SST 09608±35014 (09608±06020, 09608±06110)
6. REMOVE DRIVE PINION, (OIL SLINGER), SPACER AND
COMPANION FLANGE
(a) Using a hammer and chisel, loosen the staked part of the nut.
(b) Using SST (and a 36 mm deep socket wrench), remove the
nut.
SST 09229±55010 (Except 2JZ±GTE M/T only),
09330±00021
(c) Using a press, press out the drive pinion with the rear bearing
and spacer.
NOTICE: Be careful not to drop the drive pinion.
(d) Remove the companion flange.
(e) Remove the oil slinger (2JZ±GTE M/T only) and spacer from
the drive pinion.
± SUSPENSION AND AXLEREAR DIFFERENTIALSA±67
Page 1853 of 2543

7. REMOVE OIL SEAL
Using SST, remove the oil seal.
SST 09308±00010
8. REMOVE (OIL SLINGER AND) FRONT BEARING
Remove the oil slinger (Except 2JZ±GTE M/T only) and front
bearing by hand.
9. REMOVE REAR BEARING FROM DRIVE PINION
Using SST and a press, remove the rear bearing from the
drive pinion.
SST 09950±00020
10. REMOVE FRONT AND REAR BEARING OUTER RACES
AND ADJUSTING PLATE WASHER
Using a brass bar and hammer, drive out the outer races and
adjusting plate washer from the differential carrier.
HINT: Measure the adjusting plate washer thickness and
make a note of it for reassembly.
11. REMOVE LH AND RH SIDE BEARINGS
Using SST, remove the LH and RH side bearings from the dif-
ferential case.
SST 09550±10012 (09558±10010), 09950±40010
12. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to separate it
from the differential case. SA±68
± SUSPENSION AND AXLEREAR DIFFERENTIAL
Page 1854 of 2543
13. CONVENTIONAL DIFFERENTIAL ONLY: DISASSEMBLE
DIFFERENTIAL CASE
NOTICE: If equipped with Torque Sensing LSD, do not
disassemble the differential case.
(a) Using a hammer and pin punch, drive out the straight pin.
(b) Remove these parts from the differential case.
wPinion shaft
wDifferential pinion
wPinion thrust washer
wSide gear
wSide gears thrust washer
DUST DEFLECTOR AND DUST COVER
REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09608±35014 (09608±06090),
09950±00020
(b) Using SST and a press, install a new dust deflector.
2JZ±GTE M/T:
SST 09608±35014 (09608±06020, 09608±06100),
09631±32020
Except 2JZ±GTE M/T:
SST 09316±60010 (09316±00010)
2. REPLACE SIDE GEAR SHAFT DUST COVER
(a) Using a screwdriver, remove the dust cover.
(b) Using SST and a press, install a new dust cover.
SST 09502±24010, 09608±35014 (09608±06020,
09608±06120)
± SUSPENSION AND AXLEREAR DIFFERENTIALSA±69
Page 1855 of 2543

DIFFERENTIAL CARRIER ASSEMBLY
1. CONVENTIONAL DIFFERENTIAL ONLY:
ADJUST DIFFERENTIAL PINION GEAR BACKLASH
(a) Install the proper thrust washers on the side gears.
HINT: Using the table below, select thrust washers which will
ensure that the backlash is within specification.
Thrust washer thickness
Thickness mm (in.) Thickness mm (in.)
1.6 (0.063)
1.8 (0.071)
1.7 (0.067) ±±
(b) Install the side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT: Align the holes of the differential case and pinion shaft.
(c) Push the side gear shafts gently into the differential case by
hand and install them.
(d) Measure the pinion gear backlash while holding one side
gear toward the case.
Backlash:
0.05±0.20 mm (0.0020±0.0079 in.)
If the backlash is not within the specification, install different
thickness side gear thrust washers.
(e) Remove the side gear shaft.
2. CONVENTIONAL DIFFERENTIAL ONLY: INSTALL RING
GEAR ON DIFFERENTIAL CASE
(a) Using a hammer and pin punch, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Stake the differential case.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the boiling water. SA±70
± SUSPENSION AND AXLEREAR DIFFERENTIAL
Page 1856 of 2543

(d) 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 differen-
tial case.
(e) Temporarily tighten the 2 bolts so that the bolt holes in the ring
gear and differential case are not misaligned.
NOTICE: The ring gear set bolts should not be tightened
until the ring gear has cooled sufficiently.
4. INSTALL RING GEAR SET BOLTS
(a) After the ring gear has cooled sufficiently, install new ring
gear set bolts to which thread lock has been applied.
Thread lock:
Part No. 08833±00100, THREE BOND 1360 K or
equivalent.
NOTICE: New ring gear set bolts should be used in every
case.
(b) Torque the set bolts uniformly and a little at a time.
Torque: 64 NVm (650 kgfVcm, 47 ftVlbf)
(c) Tighten the bolts an additional 60±90°.
NOTICE: Tighten the bolts in diagonally opposite pairs.
5. INSTALL SIDE BEARINGS
Using SST and a press, install the side bearings.
2JZ±GTE M/T:
SST 09608±35014 (09608±06020),
09710±30050, 09726±36010
Except 2JZ±GTE M/T:
SST 09608±35014 (09608±06020,
09608±06100), 09710±30050
6. INSTALL DRIVE PINION BEARING OUTER RACES AND
ADJUSTING PLATE WASHER
NOTICE: Always reassemble with a new adjusting plate
washer.
HINT: The adjusting plate washer is used for adjusting the
tooth contact pattern. 42 types of washer with differential
thicknesses are available.
First fit a washer with the same thickness as the washer
which was removed, then after checking the tooth contact
pattern, replace the washer with one of a different thickness
if necessary.
± SUSPENSION AND AXLEREAR DIFFERENTIALSA±71