DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY


  1. INSTALL DIFFERENTIAL RING GEAR


    1. Clean the differential ring gear set bolt hole.

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

      CAUTION:

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

    3. Carefully take the ring gear out of the boiling water.

    4. A01GM16E02
      Text in Illustration
      *a Matchmark

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

      Tech Tips

      Align the rear differential case bolt holes and differential ring gear screw holes.

    5. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    6. A01GJQTE09
      Text in Illustration
      *1 Thread Lock

      Apply thread lock adhesive to the threads and flanges of 10 new differential case bolts.

      Note

      As the differential case bolts are plastic region tightening bolts, do not reuse them.

    7. A01GLRR

      Temporarily tighten the 10 differential case bolts uniformly in several passes, and then tighten them to the torque specification.

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

      Note


      • Tighten the bolts after the ring gear has sufficiently cooled down.

      • Install the differential case bolts by tightening diametrically opposite pairs uniformly in several passes.

    8. A01GMIPE04
      Text in Illustration
      *a 60° to 90°

      Tighten the bolts further by 60° to 90°.

      Note

      Tighten the bolts in diametrically opposite pairs.

  2. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. Using SST and a press, press in the case bearing inner race LH and RH to the differential case.

      SST
      09950-60010   ( 09951-00560, 09951-00570 )
      09950-70010   ( 09951-07100 )
      A01GJ9AE01

      Note


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

      • Do not deform the bearing cage. Set SST to the center of the differential case.

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

  3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01GHTNE02

      Using SST and a press, press in the rear drive pinion rear tapered roller bearing inner race to the drive pinion.

      SST
      09316-60011   ( 09316-00031 )
      09612-10093   ( 09613-22011 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Disassemble SST (09613-22011), and only use the pipe part.

    2. A01GL4JE02
      Text in Illustration
      *1 Differential Drive Pinion Washer

      Using SST and a press, press in the rear drive pinion rear tapered roller bearing outer race and drive pinion washer.

      SST
      09950-70010   ( 09951-07200 )
      09255-10012

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

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

  4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01GMT0E01

      Using SST and a press, press in the rear drive pinion front tapered roller bearing outer race.

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

      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 dust deflector.


    1. A01GIDME02

      Using SST and a press, insert a new dust deflector into the companion flange.

      SST
      09316-60011   ( 09316-00011 )

      Note


      • Slowly press in the dust deflector but not excessively.

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

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01GMJO

      Install the rear drive pinion front tapered roller bearing inner race from the differential carrier.

  7. INSTALL DIFFERENTIAL DRIVE PINION


    1. A01GMKSE01

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

      SST
      09316-60011   ( 09316-00011, 09316-00041 )
      09608-04031

      Note


      • Install the spacer and oil seal after performing the ring gear tooth contact pattern inspection adjustment.

      • Make sure the press, SST and drive pinion are in a straight line when pressing.

      • Do not forcefully press in the bearing.

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

  8. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GKPA

      Install the drive pinion oil slinger.

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01GNWEE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

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

      Note


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

      • Apply grease to the threads and tip of SST center bolt before use.

    2. A01GMLYE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST and a torque wrench, install a new drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )
      Maximum torque
      490 N*m (5000 kgf*cm, 361 ft.*lbf) or less

      Note


      • Tighten the nut with a force of 100 N*m (1020 kgf*cm) while checking the starting torque of the drive pinion.

      • As the bearing spacer is not installed, tighten the drive pinion nut little by little. Do not overtighten the nut.

      • Do not overtighten the nut, as the threads will become damaged.

      • Coat the threads the drive pinion nut and drive pinion with hypoid gear oil LSD.

      • Perform the removal while supporting the overhaul attachment.

    3. For a more accurate measurement, rotate the bearing forward and backward before the inspection.

    4. A01GMSQE02

      Using SST and a torque wrench, measure the preload.

      SST
      09229-55010
      Standard drive pinion preload (at starting)
      1.15 to 1.55 N*m (12 to 15 kgf*cm, 11 to 13 in.*lbf)

      Note

      Record the preload for total preload measurement.

  10. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GN7R

      Insert the differential case from the ring gear tooth side to install it.

      Note

      Do not damage the case bearing and ring gear.

  11. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01GNYQE01
      Text in Illustration
      *a Groove

      Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

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

    2. A01GK83E06
      Text in Illustration
      *1 Groove

      Install the 2 bolts and SST to the differential carrier.

      SST
      09571-50010

    3. Tighten SST bolt until SST disc lightly touches the case bearing outer race.

    4. A01GJF1E02

      Using SST and a hammer, tap in the ring gear back surface side case bearing outer race.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

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

  12. ADJUST DIFFERENTIAL RING GEAR BACKLASH


    1. A01GHQ7

      Using snap ring pliers, install a side gear shaft snap ring on the back surface of the ring gear.

      If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential side gear shaft snap ring first.

      If the differential case bearing, ring gear, or drive pinion are reused, select and install a differential side gear shaft snap ring with the same thickness as the one before the disassembly first.

    2. A01GM22E01

      Install a dial indicator to the differential carrier.

    3. Tighten SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

      SST
      09571-50010

      Note

      Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

      Tech Tips


      • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

      • Tighten SST bolt to apply the preload to the case bearing.

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

    5. A01GLW3

      Using a dial indicator, measure the backlash of the ring gear .

      Standard backlash
      0.08 to 0.13 mm (0.0031 to 0.0051 in.)

      Note

      Measure at 3 or more areas around the circumference of the ring gear.

      Tech Tips


      • Record the measured value, as it is used to select the differential side gear shaft snap ring.

      • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.

      If the measured value is not within the specified range, replace the ring gear side differential side gear shaft snap ring with one of a different thickness in the next step.

    6. A01GI40E03
      Text in Illustration
      *1 Disc
      *a Turn

      Loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

    7. A01GJF1E02

      Using SST and a hammer, tap the ring gear back surface side to create clearance between the differential case bearing outer race and the differential side gear shaft snap ring of the ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

    8. A01GHQ7

      Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

    9. A01GHQ7

      Using snap ring pliers, install a side gear shaft snap ring with a different thickness than the one removed.

      Tech Tips

      When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash also changes by 0.02 mm (0.0008 in.).

      Standard snap ring thickness
      Thickness Thickness Thickness
      3.66 mm (0.1441 in.) 3.92 mm (0.1543 in.) 4.18 mm (0.1646 in.)
      3.68 mm (0.1449 in.) 3.94 mm (0.1551 in.) 4.20 mm (0.1654 in.)
      3.70 mm (0.1457 in.) 3.69 mm (0.1559 in.) 4.22 mm (0.1661 in.)
      3.72 mm (0.1465 in.) 3.98 mm (0.1567 in.) 4.24 mm (0.1669 in.)
      3.74 mm (0.1472 in.) 4.00 mm (0.1575 in.) 4.26 mm (0.1677 in.)
      3.76 mm (0.1480 in.) 4.02 mm (0.1583 in.) 4.28 mm (0.1685 in.)
      3.78 mm (0.1488 in.) 4.04 mm (0.1591 in.) 4.30 mm (0.1693 in.)
      3.80 mm (0.1496 in.) 4.06 mm (0.1598 in.) 4.32 mm (0.1701 in.)
      3.82 mm (0.1503 in.) 4.08 mm (0.1606 in.) 4.34 mm (0.1709 in.)
      3.84 mm (0.1512 in.) 4.10 mm (0.1614 in.) 4.36 mm (0.1717 in.)
      3.86 mm (0.1520 in.) 4.12 mm (0.1622 in.) 4.38 mm (0.1724 in.)
      3.88 mm (0.1528 in.) 4.14 mm (0.1630 in.) 4.40 mm (0.1732 in.)
      3.90 mm (0.1535 in.) 4.16 mm (0.1638 in.) 4.42 mm (0.1740 in.)
    10. A01GL93

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

    11. A01GM22E02
      Text in Illustration
      *a Turn

      Install a dial indicator to the differential carrier.

    12. Tighten SST bolt to alter the differential carrier's shape approximately 0.1 mm (0.004 in.).

      SST
      09571-50010

      Note

      Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in).

      Tech Tips


      • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

      • Tighten SST bolt to apply the preload to the case bearing.

    13. A01GLW3E01

      Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.

    14. Fix the companion flange in place by hand, and measure the ring gear backlash.

      Standard backlash
      0.08 to 0.13 mm (0.0031 to 0.0051 in.)

      Note

      Measure the ring gear at 3 or more different places.

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

      Tech Tips


      • Record the measured value, as it is used to select the differential side gear shaft snap ring.

      • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.

      • When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.

  13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01GM22E02
      Text in Illustration
      *1 Turn

      Install a dial indicator to the differential carrier.

    2. Tighten SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

      SST
      09571-50010

      Note

      Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

      Tech Tips

      Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

    3. A01GN6Z

      Using snap ring pliers, install a side gear shaft snap ring on the ring gear tooth side.

      If the backlash is not within the specified range, adjust it to the specified range by increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings equally.

    4. A01GI40E04
      Text in Illustration
      *1 Turn
      *a Disc

      Remove the dial indicator and loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

      Tech Tips

      Do not remove SST.

    5. A01GL93

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

    6. A01GLW3E01

      Place a dial indicator on the tip of the ring gear tooth at a right angle.

    7. Fix the companion flange in place by hand, and measure the ring gear backlash.

      Standard backlash
      0.08 to 0.13 mm (0.0031 to 0.0051 in.)

      Note

      Measure at 3 or more areas around the circumference of the ring gear.

      If the backlash is small even in one place, replace the ring gear tooth side differential side gear shaft snap ring with a thicker one.

      Tech Tips


      • Record the measured value, as it is used to select the differential side gear shaft snap ring.

      • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.

      • When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.

    8. A01GK83E02

      Remove the 2 bolts and SST from the differential carrier.

  14. ADJUST TOTAL PRELOAD


    1. A01GMSQE01

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

      SST
      09229-55010
      Standard total preload (at starting)
      Item Specified Condition
      2WD New bearing 1.81 to 3.41 N*m (19 to 34 kgf*cm, 16 to 30 in.*lbf)
      Reused bearing 1.64 to 2.86 N*m (17 to 29 kgf*cm, 15 to 25 in.*lbf)
      AWD New bearing 1.77 to 3.29 N*m (18 to 33 kgf*cm, 16 to 29 in.*lbf)
      Reused bearing 1.61 to 2.77 N*m (17 to 28 kgf*cm, 15 to 24 in.*lbf)

      If the measured preload is below the standard value, replace the differential side gear shaft snap ring with a thicker one.

      If the measured preload is above the standard value, replace the differential side gear shaft snap ring with a thinner one.

      Note


      • If the thickness of the differential side gear shaft snap ring changes 0.02 mm, the total preload will change approximately 0.1 N*m (1.0 kgf*cm).

      • For reassembly purposes, record the measured value.

    2. A01GKM7E01

      Place a dial indicator on the tip of the ring gear tooth at a right angle.

    3. While holding the companion flange, rotate the ring gear and measure the backlash.

      Standard backlash
      0.08 to 0.13 mm (0.0031 to 0.0051 in.)

      Note

      Measure at 3 or more areas around the circumference of the ring gear.

      If the backlash is not within the specified range, adjust it to the specified range by increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings equally.

      Tech Tips


      • When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.

      • When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will also change by approximately 0.02 mm (0.0008).

      • Record the measured value, as it is used to select the differential side gear shaft snap ring.

      • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.

    4. Recheck the total preload.

  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01GNXO

      Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

    2. A01GIAN

      Rotate the companion flange several times in the forward and backward rotation directions.

    3. Inspect the tooth contact pattern.

      A01GKAYE02

      Note

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

      Tech Tips

      The patterns indicated by the Prussian blue are the tooth contact locations.

    4. A01GHZHE02
      Text in Illustration
      *1 Differential Drive Pinion Washer

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

      Note

      Make sure to always replace the drive pinion washer with a new one.

      Standard washer thickness
      Thickness No. Thickness No. Thickness No.
      1.87 mm (0.0736 in.) 87 2.01 mm (0.0791 in.) 01 2.15 mm (0.0846 in.) 15
      1.88 mm (0.0740 in.) 88 2.02 mm (0.0795 in.) 02 2.16 mm (0.0850 in.) 16
      1.89 mm (0.0744 in.) 89 2.03 mm (0.0799 in.) 03 2.17 mm (0.0854 in.) 17
      1.90 mm (0.0748 in.) 90 2.04 mm (0.0803 in.) 04 2.18 mm (0.0858 in.) 18
      1.91 mm (0.0752 in.) 91 2.05 mm (0.0807 in.) 05 2.19 mm (0.0862 in.) 19
      1.92 mm (0.0756 in.) 92 2.06 mm (0.0811 in.) 06 2.20 mm (0.0866 in.) 20
      1.93 mm (0.0760 in.) 93 2.07 mm (0.0815 in.) 07 2.21 mm (0.0870 in.) 21
      1.94 mm (0.0764 in.) 94 2.08 mm (0.0819 in.) 08 2.22 mm (0.0874 in.) 22
      1.95 mm (0.0768 in.) 95 2.09 mm (0.0823 in.) 09 2.23 mm (0.0878 in.) 23
      1.96 mm (0.0772 in.) 96 2.10 mm (0.0827 in.) 10 2.24 mm (0.0882 in.) 24
      1.97 mm (0.0776 in.) 97 2.11 mm (0.0831 in.) 11 2.25 mm (0.0886 in.) 25
      1.98 mm (0.0780 in.) 98 2.12 mm (0.0835 in.) 12 2.26 mm (0.0890 in.) 26
      1.99 mm (0.0783 in.) 99 2.13 mm (0.0839 in.) 13 2.27 mm (0.0894 in.) 27
      2.00 mm (0.0787 in.) 00 2.14 mm (0.0843 in.) 14 2.28 mm (0.0898 in.) 28

  16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01GK83E07
      Text in Illustration
      *1 Disc

      Install the 2 bolts and SST to the differential carrier.

      SST
      09571-50010

    2. Tighten SST bolt until SST disc lightly touches the case bearing outer race.

    3. A01GM22E01

      Install a dial indicator to the rear differential carrier.

    4. Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the case bearing outer race and side gear shaft snap ring.

      Note

      Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

      Tech Tips


      • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

      • The approximate 0.1 mm clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.

    5. A01GN6Z

      Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

      Tech Tips

      Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

    6. A01GI40E03
      Text in Illustration
      *1 Disc
      *a Turn

      Remove the dial indicator and loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

      Tech Tips

      Do not remove SST.

  17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01GKG5E02

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

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

    2. A01GHQ7

      Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.

      Tech Tips

      Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

  18. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01GJ4ZE03
      Text in Illustration
      *a Turn

      Tighten SST bolt and push out the case bearing outer race on the ring gear back surface side.

      SST
      09571-50010

      Note

      Do not drop the case bearing outer race.

      Tech Tips


      • For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring.

      • Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

    2. A01GK83E02

      Remove the 2 bolts and SST from the differential carrier.

  19. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01GIRXE01

      Raise the ring gear side of the differential case slightly and remove the ring gear tooth side case bearing outer race.

      Note

      Do not drop the case bearing outer race.

      Tech Tips


      • For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring.

      • Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

  20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GK2F

      Remove the rear differential case.

      Note

      Do not damage the case bearing.

  21. REMOVE REAR DRIVE PINION NUT


    1. A01GI63E04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, fix the companion flange in place.

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

    2. Using SST, remove the drive pinion nut from the differential carrier.

      SST
      09229-55010

      Tech Tips

      Perform the removal while supporting the overhaul attachment.

  22. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR


    1. A01GM1ZE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the companion flange.

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

      Note

      Before using SST center bolt (09953-03010), apply hypoid gear oil to its threads and tip.

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GKPA

      Remove the differential drive pinion oil slinger from the differential drive pinion.

  24. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01GIJU

      Using a press, press out the drive pinion from the differential carrier.

      Note

      Do not drop the drive pinion.

  25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01GMJO

      Remove the rear drive pinion front tapered roller bearing from the differential carrier.

  26. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01GJ9B

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

      Tech Tips

      The bearing spacer can be installed facing either direction.

  27. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01GMJO

      Install the rear drive pinion front tapered roller bearing inner race from the differential carrier.

  28. INSTALL DIFFERENTIAL DRIVE PINION


    1. A01GMKSE01

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

      SST
      09316-60011   ( 09316-00011, 09316-00041 )
      09608-04031

  29. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GKPA

      Install the differential drive pinion oil slinger to the differential drive pinion.

  30. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01GMKKE03

      Using SST and a hammer, tap in a new oil seal.

      SST
      09316-60011   ( 09316-00011 )
      09710-04101

      Note


      • Tap the oil seal uniformly so that the oil seal is straight.

      • Do not excessively tap the oil seal.

    2. Using a vernier caliper, measure the depth of the oil seal.

      Standard depth
      0 to 0.5 mm (0 to 0.020 in.)

      Note


      • Measure at 3 or more areas around the circumference of the oil seal.

      • Make sure difference between the maximum and minimum measured values is less than 0.65 mm, as a greater difference may lead to oil leaks.

  31. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR


    1. A01GNWEE01
      Text in Illustration
      *a Turn
      *b Hold

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

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

      Note


      • Perform this procedure after aligning the companion flange with the spline of the drive pinion.

      • Apply grease to the threads and tip of SST center bolt before use.

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

    3. A01GMLYE01
      Text in Illustration
      *a Turn
      *b Hold

      Use SST to hold the flange and torque the drive pinion nut.

      SST
      09950-30012   ( 09955-03040 )

    4. Using SST and a torque wrench, tighten the drive pinion nut while checking the starting torque of the drive pinion.

      SST
      09229-55010
      09330-00021
      Maximum torque
      490 N*m (5000 kgf*cm, 361 ft.*lbf) or less

      Note


      • Tighten the nut with a force of 100 N*m (1020 kgf*cm) while checking the starting torque of the drive pinion.

      • Do not overtighten the nut, as the threads will become damaged.

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

      Tech Tips

      Perform the removal while supporting the overhaul attachment.

  32. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GN7R

      Insert the differential case from the ring gear tooth side.

      Note

      Do not damage the case bearing inner race or ring gear.

  33. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01GNYQE01
      Text in Illustration
      *a Groove

      Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

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

    2. A01GK83E08
      Text in Illustration
      *1 Disc

      Install the 2 bolts and SST to the differential carrier.

      SST
      09571-50010

    3. Tighten SST bolt until SST disc lightly touches the case bearing outer race.

    4. A01GKG5E02

      Using SST and a hammer, tap in the ring gear back surface side case bearing outer race.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

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

  34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01GHQ7

      Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

      Note

      Check that the differential side gear shaft snap ring is securely fitted into the groove.

      Tech Tips

      Use the side gear shaft snap ring that was used during the tooth contact adjustment.

    2. A01GM22E01

      Install a dial indicator on the differential carrier.

    3. Tighten SST bolt, and push in the differential case.

      Note

      Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

      Tech Tips


      • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

      • The approximate 0.1 mm clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.

    4. A01GN6Z

      Remove the dial indicator and using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.

      Tech Tips

      Use the side gear shaft snap ring that was used during the tooth contact adjustment.

    5. A01GI40E03
      Text in Illustration
      *1 Disc
      *a Turn

      Loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

    6. A01GL93

      Tap the differential carrier on the ring gear tooth side using a plastic-faced hammer to stabilize the case bearing.

    7. A01GK83E02

      Remove the 2 bolts and SST from the differential carrier.

  35. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01GMSQE01

      Using SST and a torque wrench, measure the preload.

      SST
      09229-55010
      Standard total preload (at starting)
      1.25 to 1.65 N*m (13 to 16 kgf*cm, 11 to 14 in.*lbf)

      Note


      • For a more accurate measurement, rotate the flange forward and backward several times before the measurement.

      • Check the starting torque of the drive pinion for use with the total preload inspection.

      • The bearing spacer is made of plastic and changes shape when used. If the starting torque of the drive pinion is exceeded by mistake, make sure to replace the bearing spacer with a new one.

        If the starting torque of the drive pinion is exceeded, replace the bearing spacer.

        If the starting torque of the drive pinion is insufficient, tighten the drive pinion nut 5 to 10° at a time.

        Repeat the adjustment as necessary until the starting torque matches the specified torque.

      Maximum torque
      490 N*m (5000 kgf*cm, 361 ft.*lbf) or less

      Note


      • If the tightening torque of the pinion nut exceeds the specified torque but the drive pinion starting torque is still insufficient, loosen the pinion nut. Then check if the pinion nut and drive pinion threads are damaged.

      • If there are no problems, replace the bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

  36. INSPECT TOTAL PRELOAD


    1. A01GMSQE02

      Using SST and a torque wrench, measure the total preload.

      SST
      09229-55010
      Standard total preload (at starting)
      Item Specified Condition
      2WD New bearing 1.91 to 3.51 N*m (20 to 35 kgf*cm, 17 to 31 in.*lbf)
      Reused bearing 1.74 to 2.96 N*m (18 to 30 kgf*cm, 16 to 26 in.*lbf)
      AWD New bearing 1.87 to 3.39 N*m (19 to 34 kgf*cm, 17 to 30 in.*lbf)
      Reused bearing 1.71 to 2.87 N*m (18 to 29 kgf*cm, 16 to 25 in.*lbf)

  37. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01GKM7E01

      Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.

    2. Fix the companion flange in place, and measure the ring gear backlash.

      Standard backlash
      0.08 to 0.13 mm (0.0031 to 0.0051 in.)

      Note

      Measure at 3 or more areas around the circumference of the ring gear.

  38. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A01GIPRE01

      Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) from the end of the shaft.

      Maximum runout
      0.08 mm (0.0031 in.)

  39. INSTALL REAR DRIVE PINION NUT


    1. A01GM40E01

      Using a chisel and a hammer, stake the drive pinion nut.

      SST
      09930-00010

  40. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01GKNBE03

      Using SST and a hammer, install 2 new oil seals.

      SST
      09223-15030
      09950-70010   ( 09951-07150 )
      Standard depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

      Note


      • Tap the oil seal uniformly so that the oil seal is straight.

      • After the installation, check that the oil seal has been tapped securely onto the differential.

    2. Apply MP grease to the lips of the oil seal.

  41. INSTALL REAR DIFFERENTIAL DRAIN PLUG

    Tech Tips

    Perform this procedure as necessary.


    1. Using a 10 mm socket hexagon wrench, install a new gasket and drain plug to the rear differential carrier.

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

  42. INSTALL REAR DIFFERENTIAL FILLER PLUG

    Tech Tips

    Perform this procedure as necessary.


    1. Using a 10 mm socket hexagon wrench, install a new gasket and filler plug to the rear differential carrier.

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

  43. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A01GJ8XE01

      Remove the differential carrier from the overhaul attachment.

  44. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


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

      Note

      Do not scratch the fitting surface.

    2. A01GID2

      Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.

      Torque:
      7.0 N*m  { 72 kgf*cm, 62 ft.*lbf }

  45. INSTALL REAR DIFFERENTIAL CARRIER COVER


    1. A01GKSQE09
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the 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 (0.08 to 0.12 in.) in diameter.

      • Overlap the seal packing at least 10 mm at the beginning and the end of application.

      • A01GM3K

        Install the differential carrier cover within 3 minutes of application.

    2. Install the differential carrier cover with the 8 bolts.

      Torque:
      47 N*m  { 475 kgf*cm, 35 ft.*lbf }

      Note

      Do not fill the oil or drive 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.

  46. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A01GHSK

      Install the breather plug to the carrier cover.

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