REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • The procedure listed below is for w/o LSD.

  • Use the same procedure for w/ and w/o LSD, unless otherwise specified.

PROCEDURE


  1. INSTALL DIFFERENTIAL RING GEAR


    1. Clean the contact surfaces of the rear differential case sub-assembly and differential ring gear.

    2. Clean the ring gear set bolt hole.

    3. Heat the differential ring gear to approximately 100°C (212°F) in boiling water.

    4. Carefully take the differential ring gear out of the boiling water.

      CAUTION:

      Use thick gloves to protect your hands as the differential ring gear is hot.

    5. Secure the rear differential case sub-assembly between aluminum plates in a vise.

      Note

      Do not overtighten the vise.

    6. B000VWBC01
      *a Matchmark
      *b Thread Lock

      After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the rear differential case sub-assembly.

    7. Align the matchmarks on the differential ring gear and rear differential case sub-assembly.

    8. After the differential ring gear has cooled sufficiently, install 12 new bolts to which thread lock has been applied.

      Adhesive
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent.

      Note


      • New ring gear set bolts should be used every time the differential ring gear is installed.

      • Do not allow oil to adhere to the ring gear set bolts during installation.

    9. Temporarily install the 12 bolts.

    10. B000UZK

      After the differential ring gear cools down, tighten the 12 bolts.

      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note

      Tighten diametrically opposite ring gear set bolts in pairs.

    11. B000Z09C01
      *a Paint Mark
      *b 60° to 90°

      Tighten the 12 set bolts an additional 60° to 90°.

      Note

      Tighten diametrically opposite ring gear set bolts in pairs.

  2. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. Using SST and a press, install the rear differential case bearing (inner races) LH and RH to the rear differential case sub-assembly.

      SST
      09550-60010
      09950-60010   ( 09951-00540 )
      B000XPIC02
      *A for RH Side *B for LH Side

      Note


      • Do not apply hypoid gear oil to a new bearing.

      • Do not deform the bearing cage. Set SST to the center of the rear differential case sub-assembly.

      • If the bearing is replaced, replace it and its outer race as a set.

  3. INSTALL REAR DRIVE PINION REAR BEARING


    1. B000VBBN01

      Using SST and a press, install the rear drive pinion rear bearing (inner race) to the differential drive pinion.

      SST
      09308-14010

      Note

      Do not apply hypoid gear oil to a new bearing.

    2. B000V3F

      Install the 2 rear drive pinion rear bearings (ball bearing) to the differential drive pinion.

    3. B000VRTC01
      *1 Rear Drive Pinion Rear Bearing (Outer Race)
      *2 Rear Differential Drive Pinion Plate Washer
      *3 Differential Oil Storage Ring

      Using SST and a press, install a new differential oil storage ring, a new rear differential drive pinion plate washer and rear drive pinion rear bearing (outer race).

      SST
      09951-01000
      09950-70010   ( 09951-07200 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Select a rear differential drive pinion plate washer of the same thickness as the removed one.

  4. INSTALL REAR DRIVE PINION FRONT BEARING


    1. B000X0HC01
      *1 Rear Drive Pinion Front Bearing (Outer Race)

      Using SST and a press, install the rear drive pinion front bearing (outer race).

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

      Note

      Do not apply hypoid gear oil to a new bearing.

    2. B000URO

      Install the rear drive pinion front bearing (inner race) to the rear differential carrier.

      Note

      Do not apply hypoid gear oil to a new bearing.

  5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when replacing the rear differential dust deflector.


    1. B000VESN01

      Using SST and a press, insert a new rear differential dust deflector to the rear drive pinion companion flange.

      SST
      09316-20011
      09513-36040

      Note


      • Slowly press in the rear differential dust deflector. Do not press it excessively.

      • If any burrs remain after pressing in the rear differential dust deflector, remove them.

  6. INSTALL DIFFERENTIAL DRIVE PINION


    1. B000W47N01

      Using SST and a press, install the differential drive pinion.

      SST
      09308-14010
      09316-60011   ( 09316-00051 )
      09513-36040

      Tech Tips

      Install the rear differential drive pinion bearing spacer and rear differential carrier oil seal after adjusting the tooth contact pattern.

  7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. B000VLN

      Install the rear differential drive pinion oil slinger.

  8. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B000UZTC01
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note


      • Install the rear drive pinion companion flange so that there is a slight looseness in the differential drive pinion because the rear differential drive pinion bearing spacer is not yet installed.

      • Apply molybdenum grease to the threads of the SST center bolt (09953-03010) before use.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 40 mm.

    2. Coat the threads of the rear drive pinion nut with hypoid gear oil LSD.

    3. B000WTSC01
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and temporary install the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

      CAUTION:

      Hold the overhaul attachment during the operation.

      Note


      • Apply hypoid gear oil LSD to the rear drive pinion nut and the threads of the differential drive pinion.

      • As there is no rear differential drive pinion bearing spacer, tighten the rear drive pinion nut a little at a time. Do not overtighten it.

      Tech Tips

      Tighten the nut approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. Turn the bearing clockwise and counterclockwise several times to stabilize it.

    2. B000VH5N01

      Using SST and a torque wrench, measure the preload.

      SST
      09229-55010
      Differential drive pinion preload (at starting)
      Item Specified Condition
      New bearing 0.37 to 0.80 N*m (3.8 to 8.1 kgf*cm, 3.3 to 7.0 in.*lbf)
      Reused bearing 0.28 to 0.51 N*m (2.9 to 5.2 kgf*cm, 2.5 to 4.5 in.*lbf)

      • If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.

        Torque
        550 N*m (5608 kgf*cm, 406 ft.*lbf) or less

  10. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. B000XBG

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing or differential ring gear.

  11. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. B000UOHC01
      *a Groove

      Using SST and a hammer, install the differential side bearing (outer race) RH to the differential ring gear tooth side.

      SST
      09527-17011
      09950-60020   ( 09951-00810, 09951-01030, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Tap in the rear differential case bearing (outer race) RH until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    2. B000TZ1C01
      *a Disc

      Install SST to the differential carrier with the 2 bolts (A) so that the center of the SST disc is at the center of the rear differential case bearing (outer race).

      SST
      09571-10200   ( 09571-01220, 09571-01230 )

    3. Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing (outer race) RH.

    4. B000XHSN01

      Using SST and a hammer, install the rear differential case bearing (outer race) LH to the differential ring gear back surface side.

      SST
      09527-17011
      09950-60020   ( 09951-00810, 09951-01030, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Tap in the rear differential case bearing (outer race) LH until it touches the rear differential case bearing inner race roller.

  12. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. B000XIBN01

      Using SST, install the thinnest rear differential side gear shaft snap ring to the back surface of the differential ring gear.

      SST
      09905-00031

      Tech Tips


      • If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are new, select a thinner rear differential side gear shaft snap ring and install it.

      • If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are reused, install a rear differential side gear shaft snap ring with the same thickness as the removed one.

    2. B000YGDN01

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    3. Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      SST
      09571-10200   ( 09571-01220, 09571-01230 )

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

      Tech Tips

      Tighten the SST bolt to apply the preload to the rear differential case bearing.

    4. Turn the differential ring gear clockwise and counterclockwise several times.

    5. B000UC8

      Using a dial indicator, measure the backlash of the differential ring gear at 3 positions.

      Backlash
      0.09 to 0.145 mm (0.00355 to 0.00570 in.)

      Note

      The difference between the maximum and minimum values must be within 0.05 mm (0.00197 in.).

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft snap ring.

      • If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the differential ring gear tooth side with a rear differential side gear shaft snap ring of a different thickness as described in the following procedure.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft snap ring.

    6. Loosen the SST bolt and separate the SST disc from the rear differential case bearing (outer race) RH.

      Note

      Do not remove SST.

    7. B000XHSN01

      Using SST and a hammer, create a clearance between the rear differential side gear shaft snap ring on the differential ring gear back surface side and the rear differential case bearing outer race LH.

      SST
      09527-17011
      09950-60020   ( 09951-00810, 09951-01030, 09952-06010 )
      09950-70010   ( 09951-07150 )
    8. B000XIBN01

      Using SST, remove the rear differential side gear shaft snap ring from the differential ring gear back surface side.

      SST
      09905-00031
    9. B000XIBN01

      Using SST, install a rear differential side gear shaft snap ring with a different thickness.

      SST
      09905-00031

      Tech Tips

      When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash also changes by 0.02 mm (0.000787 in.).

      Rear Differential Side Gear Shaft Snap Ring Thickness
      Part No. Thickness Part No. Thickness
      90521-99149 3.5075 to 3.5325 mm ( 0.1381 to 0.1390 in.) 90521-99169 3.9075 to 3.9325 mm ( 0.1539 to 0.1548 in.)
      90521-99150 3.5275 to 3.5525 mm ( 0.1389 to 0.1398 in.) 90521-99170 3.9275 to 3.9525 mm ( 0.1547 to 0.1556 in.)
      90521-99151 3.5475 to 3.5725 mm ( 0.1397 to 0.1406 in.) 90521-99171 3.9475 to 3.9725 mm ( 0.1555 to 0.1563 in.)
      90521-99152 3.5675 to 3.5925 mm ( 0.1405 to 0.1414 in.) 90521-99172 3.9675 to 3.9925 mm ( 0.1563 to 0.1571 in.)
      90521-99153 3.5875 to 3.6125 mm ( 0.1413 to 0.1422 in.) 90521-99173 3.9875 to 4.0125 mm ( 0.1570 to 0.1579 in.)
      90521-99154 3.6075 to 3.6325 mm ( 0.1421 to 0.1430 in.) 90521-99174 4.0075 to 4.0325 mm ( 0.1578 to 0.1587 in.)
      90521-99155 3.6275 to 3.6525 mm ( 0.1429 to 0.1437 in.) 90521-99175 4.0275 to 4.0525 mm ( 0.1586 to 0.1595 in.)
      90521-99156 3.6475 to 3.6725 mm ( 0.1437 to 0.1445 in.) 90521-99176 4.0475 to 4.0725 mm ( 0.1594 to 0.1603 in.)
      90521-99157 3.6675 to 3.6925 mm ( 0.1444 to 0.1453 in.) 90521-99177 4.0675 to 4.0925 mm ( 0.1602 to 0.1611 in.)
      90521-99158 3.6875 to 3.7125 mm ( 0.1452 to 0.1461 in.) 90521-99178 4.0875 to 4.1125 mm ( 0.1610 to 0.1619 in.)
      90521-99159 3.7075 to 3.7325 mm ( 0.1460 to 0.1469 in.) 90521-99179 4.1075 to 4.1325 mm ( 0.1618 to 0.1626 in.)
      90521-99160 3.7275 to 3.7525 mm ( 0.1468 to 0.1477 in.) 90521-99180 4.1275 to 4.1525 mm ( 0.1625 to 0.1634 in.)
      90521-99161 3.7475 to 3.7725 mm ( 0.1476 to 0.1485 in.) 90521-99181 4.1475 to 4.1725 mm ( 0.1633 to 0.1642 in.)
      90521-99162 3.7675 to 3.7925 mm ( 0.1484 to 0.1493 in.) 90521-99182 4.1675 to 4.1925 mm ( 0.1641 to 0.1650 in.)
      90521-99163 3.7875 to 3.8125 mm ( 0.1492 to 0.1500 in.) 90521-99183 4.1875 to 4.2125 mm ( 0.1649 to 0.1658 in.)
      90521-99164 3.8075 to 3.8325 mm ( 0.1500 to 0.1508 in.) 90521-99184 4.2075 to 4.2325 mm ( 0.1657 to 0.1666 in.)
      90521-99165 3.8275 to 3.8525 mm ( 0.1507 to 0.1516 in.) 90521-99185 4.2275 to 4.2525 mm ( 0.1665 to 0.1674 in.)
      90521-99166 3.8475 to 3.8725 mm ( 0.1515 to 0.1524 in.) 90521-99186 4.2475 to 4.2725 mm ( 0.1673 to 0.1682 in.)
      90521-99167 3.8675 to 3.8925 mm ( 0.1523 to 0.1532 in.) 90521-99187 4.2675 to 4.2925 mm ( 0.1681 to 0.1689 in.)
      90521-99168 3.8875 to 3.9125 mm ( 0.1531 to 0.1540 in.) - -
    10. B000TWN

      Using a plastic-faced hammer, lightly tap the differential ring gear tooth side of the rear differential carrier.

    11. B000YGDC01
      *a Turn

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    12. Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      SST
      09571-10200   ( 09571-01220, 09571-01230 )

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    13. B000UC8

      Using a dial indicator, measure the backlash of the differential ring gear at 3 positions.

      Backlash
      0.09 to 0.145 mm (0.00355 to 0.00570 in.)

      If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the back surface of the differential ring gear with one of a different thickness.

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft snap ring.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft snap ring.

  13. ADJUST REAR DIFFERENTIAL CASE BEARING PRELOAD


    1. B000YGDC01
      *a Turn

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    2. Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      SST
      09571-10200   ( 09571-01220, 09571-01230 )

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    3. B000UFVN01

      Using SST, install the thinnest rear differential side gear shaft snap ring to the differential ring gear tooth side.

      SST
      09905-00031
    4. B000V45C01
      *a Disc

      Remove the dial indicator and loosen the bolt until the SST disc is separated from the rear differential case bearing (outer race) RH on the differential ring gear tooth side.

    5. B000TWN

      Using a plastic-faced hammer, lightly tap the differential ring gear tooth side of the rear differential carrier to stabilize the rear differential case bearing.

    6. B000UC8

      Using a dial indicator, measure the backlash of the differential ring gear at 3 positions. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the rear differential side gear shaft snap ring on the differential ring gear tooth side with a thicker one.

      Backlash
      0.09 to 0.145 mm (0.00355 to 0.00570 in.)

      Tech Tips

      If the value is not within the specified range, replace the snap ring with one of a different thickness in the following procedure.

    7. B000U03N01

      Remove the 2 bolts and SST.

  14. ADJUST TOTAL PRELOAD


    1. B000VH5N01

      Using SST and a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09229-55010
      Total Preload (at Starting)
      Item Specified Condition
      New bearing 0.96 to 2.09 N*m (9.8 to 21.3 kgf*cm, 8.5 to 18.4 in.*lbf)
      Reused bearing 0.79 to 1.59 N*m (8.1 to 16.2 kgf*cm, 7.0 to 14.0 in.*lbf)

      Note


      • If the measured preload is less than the specified value, replace the rear differential side gear shaft snap ring of the differential ring gear tooth surface side with a thicker one.

      • If the measured preload is more than the specified value, replace the rear differential side gear shaft snap ring of the differential ring gear tooth surface side with a thinner one.

      Tech Tips

      When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 1 in.*lbf).

    2. B000WRY

      Set a dial indicator to the end of the differential ring gear face.

    3. While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Backlash
      0.09 to 0.145 mm (0.00355 to 0.00570 in.)

      Note


      • If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both the right and left rear differential side gear shaft snap rings equally.

      • When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash will also change by approximately 0.02 mm (0.000787 in.).

    4. Recheck the total preload.

  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. B000WNY

      Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.

    2. Rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      B000YT1C07
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion away from the ring gear (*e, *f) - -

      Note

      Check the tooth contact pattern at 4 or more positions around the circumference of the differential ring gear.

    4. B000WESC01
      *1 Rear Differential Drive Pinion Plate Washer

      If the teeth are not contacting properly, use the following table to select a proper rear differential drive pinion plate washer for correction.

      Tech Tips


      • 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 rear differential drive pinion plate washer has been changed, adjust the backlash and measure the total preload.

      Rear Differential Drive Pinion Plate Washer Thickness
      Part No. Thickness Part No. Thickness
      90560-62001 1.81 to 1.83 mm ( 0.0713 to 0.0720 in.) 90560-62012 2.03 to 2.05 mm ( 0.0800 to 0.0807 in.)
      90560-62002 1.83 to 1.85 mm ( 0.0721 to 0.0728 in.) 90560-62013 2.05 to 2.07 mm ( 0.0808 to 0.0814 in.)
      90560-62003 1.85 to 1.87 mm ( 0.0729 to 0.0736 in.) 90560-62014 2.07 to 2.09 mm ( 0.0815 to 0.0822 in.)
      90560-62004 1.87 to 1.89 mm ( 0.0737 to 0.0744 in.) 90560-62015 2.09 to 2.11 mm ( 0.0823 to 0.0830 in.)
      90560-62005 1.89 to 1.91 mm ( 0.0745 to 0.0751 in.) 90560-62016 2.11 to 2.13 mm ( 0.0831 to 0.0838 in.)
      90560-62006 1.91 to 1.93 mm ( 0.0752 to 0.0759 in.) 90560-62017 2.13 to 2.15 mm ( 0.0839 to 0.0846 in.)
      90560-62007 1.93 to 1.95 mm ( 0.0760 to 0.0767 in.) 90560-62018 2.15 to 2.17 mm ( 0.0847 to 0.0854 in.)
      90560-62008 1.95 to 1.97 mm ( 0.0768 to 0.0775 in.) 90560-62019 2.17 to 2.19 mm ( 0.0855 to 0.0862 in.)
      90560-62009 1.97 to 1.99 mm ( 0.0776 to 0.0783 in.) 90560-62020 2.19 to 2.21 mm ( 0.0863 to 0.0870 in.)
      90560-62010 1.99 to 2.01 mm ( 0.0784 to 0.0791 in.) 90560-62021 2.21 to 2.23 mm ( 0.0871 to 0.0877 in.)
      90560-62011 2.01 to 2.03 mm ( 0.0792 to 0.0799 in.) - -

  16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for RH Side)

    Click here

  17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for LH Side)

    Click here

  18. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Click here

  19. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)

    Click here

  20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Click here

  21. REMOVE REAR DRIVE PINION NUT


    1. B000VRNC01
      *a Turn
      *b Hold

      Using SST to hold the rear drive pinion companion flange, remove the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )

      CAUTION:

      Hold the overhaul attachment during the operation.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 45 mm.

  22. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  24. REMOVE DIFFERENTIAL DRIVE PINION

    Click here

  25. REMOVE REAR DRIVE PINION FRONT BEARING


    1. B000URO

      Remove the rear drive pinion front bearing (inner race) from the rear differential carrier.

  26. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B000TUL

      Install a new rear differential drive pinion bearing spacer to the differential drive pinion.

      Note

      Install the rear differential drive pinion bearing spacer with the larger diameter side facing toward the differential drive pinion.

  27. INSTALL REAR DRIVE PINION FRONT BEARING


    1. B000URO

      Install the rear drive pinion front bearing (inner race) to the rear differential carrier.

  28. INSTALL DIFFERENTIAL DRIVE PINION


    1. B000W47N01

      Using SST and a press, install the differential drive pinion to the rear differential carrier.

      SST
      09308-14010
      09316-60011   ( 09316-00051 )
      09513-36040

  29. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. B000VLN

      Install the rear differential drive pinion oil slinger.

  30. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  31. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B000UZTC01
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange to the differential drive pinion.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note

      Apply molybdenum grease to the threads of the SST center bolt (09953-03010) before use.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 45 mm.

    2. Coat the threads of a new rear drive pinion nut with hypoid gear oil LSD.

    3. B000WTSC01
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and temporary tighten the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

      CAUTION:

      Hold the overhaul attachment during the operation.

      Note


      • Do not tighten the nut excessively, otherwise the threads will be stripped.

      • Apply hypoid gear oil LSD to the threads of the drive pinion nut and differential drive pinion.

      Tech Tips

      Tighten the drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and then tighten it further while observing the preload.

  32. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. B000XBG

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing and differential ring gear.

  33. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. B000UOHC01
      *a Groove

      Using SST and a hammer, install the rear differential case bearing (outer race) RH to the differential ring gear tooth side.

      SST
      09527-17011
      09950-60020   ( 09951-00810, 09951-01030, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Tech Tips

      Tap in the rear differential case bearing (outer race) until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    2. B000TZ1C01
      *a Disc

      Install SST to the differential carrier with the 2 bolts (A) so that the center of the SST disc is at the center of the rear differential case bearing (outer race).

      SST
      09571-10200   ( 09571-01220, 09571-01230 )

    3. Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing (outer race) RH.

    4. B000XHSN01

      Using SST and a hammer, install the rear differential case bearing (outer race) LH to the differential ring gear back surface side.

      SST
      09527-17011
      09950-60020   ( 09951-00810, 09951-01030, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Tech Tips

      Tap in the rear differential case bearing outer race until it touches the rear differential case bearing inner race roller.

  34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. B000XIBN01

      Using SST, install the rear differential side gear shaft snap ring to the rear differential carrier on the differential ring gear back surface side.

      SST
      09905-00031

      Tech Tips

      Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.

    2. B000YGDC01
      *a Turn

      Set a dial indicator on the rear differential carrier.

    3. Tighten the SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    4. B000UFVN01

      Using SST, install the rear differential side gear shaft snap ring to the differential ring gear tooth side.

      SST
      09905-00031

      Tech Tips

      Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.

    5. B000TWN

      Remove the dial indicator and tap the rear differential carrier on the differential ring gear tooth side using a plastic-faced hammer to stabilize the rear differential case bearing.

    6. B000U03N01

      Remove the 2 bolts and SST.

  35. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. B000VH5N01

      Using SST and a torque wrench, measure the starting torque of the differential drive pinion.

      SST
      09229-55010
      Differential drive pinion preload (at starting)
      Item Specified Condition
      New bearing 0.52 to 0.95 N*m (5.4 to 9.6 kgf*cm, 4.7 to 8.4 in.*lbf)
      Reused bearing 0.43 to 0.66 N*m (4.4 to 6.7 kgf*cm, 3.9 to 5.8 in.*lbf)

      • If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut 5 to 10°.

        Torque
        550 N*m (5608 kgf*cm, 406 ft.*lbf) or less

      • If the preload is less than the specified minimum value even when the tightening torque of the rear drive pinion nut is more than the specified maximum value, loosen the rear drive pinion nut and check that the threads of the drive pinion nut and differential drive pinion are not stripped.

      • If the threads are not stripped, replace the rear differential drive pinion bearing spacer. Apply hypoid gear oil LSD to the threads of the differential drive pinion and repeat the procedure.

      Tech Tips


      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

  36. INSPECT TOTAL PRELOAD


    1. B000VH5N01

      Using SST and a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09229-55010
      Total Preload (at Starting)
      Item Specified Condition
      New bearing 1.11 to 2.24 N*m (11.4 to 22.8 kgf*cm, 9.9 to 19.8 in.*lbf)
      Reused bearing 0.94 to 1.74 N*m (9.6 to 17.7 kgf*cm, 8.4 to 15.4 in.*lbf)

  37. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. B000WRY

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Standard backlash
      0.09 to 0.145 mm (0.00355 to 0.00570 in.)

      If the backlash is not within the specified range, adjust the backlash or perform repairs as necessary.

  38. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. B000X38C01
      *a 10 mm (0.394 in.)

      Using a dial indicator, measure the runout of the differential drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.

      Maximum runout
      0.08 mm (0.00315 in.)

      If the runout is more than the maximum, replace the differential drive pinion and differential ring gear.

  39. STAKE REAR DRIVE PINION NUT


    1. B000XC0N01

      Using SST and a hammer, stake the rear drive pinion nut.

      SST
      09930-00010

  40. INSTALL REAR DRIVE SHAFT OIL SEAL LH


    1. B000XMVC01
      *1 Rear Drive Shaft Oil Seal LH
      *a Oil Seal Installation Depth

      Using SST and a hammer, install a new rear drive shaft oil seal LH.

      SST
      09518-36030
      09950-70010   ( 09951-07150 )
      Oil seal installation depth
      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      Note


      • Make sure to check the identification marks on the rear differential side gear shaft oil seals before installation because the part numbers differ between the left and right sides.

      • To ensure a proper seal, evenly tap in the rear drive shaft oil seal LH.

      • When installing the rear drive shaft oil seal LH, tap them in until the outer surface of each seal is flush with the rear differential carrier.

      • Make sure the difference between the maximum and minimum measured values is less than 0.85 mm (0.0335 in.), as a greater difference may lead to oil leaks.

  41. INSTALL REAR DRIVE SHAFT OIL SEAL RH

    Tech Tips

    Perform the same procedure as for the LH side.

  42. INSTALL REAR DIFFERENTIAL DRAIN PLUG


    1. Using a 10 mm socket hexagon wrench, install the differential drain plug together with a new gasket.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  43. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. B000YYG

      Remove the 4 bolts and rear differential carrier from the overhaul stand.

      Note

      Clean the fitting surface between the rear differential carrier and rear differential carrier cover.

  44. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. B000V8BC01
      *a Stoppers

      Clean the seal packing attached to the rear differential carrier and rear differential carrier cover using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.

      Note

      Do not scratch the sealing surface.

    2. Install the rear differential breather plug oil deflector with the bolt while contacting it with the stoppers on the rear differential carrier cover.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  45. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN

    Tech Tips

    It is not necessary to remove a rear differential carrier straight pin unless it is being replaced.


    1. B000XY7C01
      *a Protrusion

      Using a plastic-faced hammer, install the 2 rear differential carrier straight pins to the rear differential carrier cover.

      Protrusion
      10 to 12 mm (0.394 to 0.472 in.)

  46. INSTALL REAR DIFFERENTIAL CARRIER COVER


    1. B000YYSC01
      *a Seal Packing
      *b 2 to 3 mm (0.0788 to 0.1181 in.)

      Apply seal packing 1281 to the rear differential carrier as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent

      Note


      • Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.1181 in.) in diameter.

      • Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and end of application.

      • Install the rear differential carrier cover within 3 minutes of application.

    2. B000Y1J

      Install the rear differential carrier cover with the 8 bolts.

      Torque:
      46.6 N*m  { 475 kgf*cm, 34 ft.*lbf }

      Note

      Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.

  47. INSTALL REAR DIFFERENTIAL BREATHER PLUG


    1. B000VMR

      Install the rear differential breather plug to the rear differential carrier cover.

      Torque:
      20.6 N*m  { 210 kgf*cm, 15 ft.*lbf }

  48. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER


    1. B000YSK

      Using a 12 mm socket hexagon wrench, install the rear differential dynamic damper to the rear differential carrier cover with the bolt.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }