DIFFERENTIAL CARRIER ASSEMBLY (for LSD) REASSEMBLY

INSTALL DIFFERENTIAL RING GEAR
1. Clean the contact surfaces of the differential case and ring gear.
2. Clean the differential ring gear set bolt hole.
3. Heat the ring gear to approximately 100°C (212°F) in boiling water.
  
  CAUTION:
  
  Use thick gloves to protect your hands as the ring gear is hot.
4. Carefully take the ring gear out of the boiling water.
5. Secure the differential case between aluminum plates in a vise.
  
  Note
  
  Do not overtighten the vise.
6. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
7. Align the matchmarks on the ring gear and the differential case.
  
  Text in Illustration
  
  *1 Thread Lock
  
  *a Matchmark
8. After the ring gear has cooled sufficiently, install 10 ring gear set 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 ring gear is installed.
  - Do not allow oil to adhere to the ring gear set bolt during installation.
9. Tighten the 10 set bolts uniformly, a little at a time.
  
  Torque:
  
  64 N*m { 650 kgf*cm, 47 ft.*lbf }
10. Text in Illustration
  
  *a 60° to 90°
  
  Tighten the bolts further 60° to 90°.
  
  Note
  
  Tighten diagonally opposite bolts in pairs.
INSTALL REAR DIFFERENTIAL CASE BEARING
1. Using SST and a press, install the case bearing inner races LH and RH to the differential case.
  
  SST
  
  09950-60010 ( 09951-00560, 09951-00570 )
  
  09950-70010 ( 09951-07100 )
  
  Text in Illustration
  
  *A LH Side *B RH 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 differential case.
  
  If the bearing is replaced, replace it and its outer race as a set.

Text in Illustration
*1	Thread Lock
*a	Matchmark

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

Text in Illustration
*a	60° to 90°

Text in Illustration
*A	LH Side	*B	RH Side

INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

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

SST

09316-60011 ( 09316-00031 )

09612-24014 ( 09613-22011 )

Text in Illustration
*1	Outer Race
*2	Rear Differential Drive Pinion Plate Washer

Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and a new rear differential drive pinion plate washer.

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

Tech Tips

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

INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the rear drive pinion front tapered roller bearing outer race.
  
  SST
  
  09950-60020 ( 09951-00710 )
  
  09950-70010 ( 09951-07100 )
2. Install the rear drive pinion front tapered roller bearing to the differential carrier.
INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
Tech Tips

Perform this procedure only when replacing the dust deflector.
1. Using SST and a press, insert a new dust deflector to the companion flange.
  
  SST
  
  09316-60011 ( 09316-00011 )
  Note
  
  Slowly press in the dust deflector but not press it excessively.
  
  If any burrs remain after pressing in the deflector, remove them.
INSTALL DIFFERENTIAL DRIVE PINION
1. Using SST and a press, install the differential drive pinion.
  
  SST
  
  09316-60011 ( 09316-00011, 09316-00041 )
  
  09608-04031
  
  Tech Tips
  
  Install the rear differential drive pinion bearing spacer and oil seal after adjusting the tooth contact pattern.
INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Install the drive pinion oil slinger.
ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
1. Text in Illustration
  
  *a Turn
  
  *b Hold
  
  Using SST, install the companion flange.
  
  SST
  
  09950-30012 ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )
  Note
  
  Install the companion flange so that there is a slight looseness in 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. Coat the threads of the drive pinion nut with hypoid gear oil LSD.
3. Text in Illustration
  
  *a Turn
  
  *b Hold
  
  Using SST to hold the flange, tighten the drive pinion nut.
  
  SST
  
  09229-55010
  
  09330-00021
  
  09950-30012 ( 09955-03040 )
  
  Tech Tips
  
  Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
  Note
  
  Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
  
  As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.
4. Turn the bearing clockwise and counterclockwise several times to stabilize it.
5. Using SST and a torque wrench, measure the preload.
  
  SST
  
  09229-55010
  
  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.
  
  If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary.
INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
1. Insert the differential case from the ring gear tooth side to install the differential case.
  
  Note
  
  Do not damage the case bearing and ring gear.
INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE RH
1. Text in Illustration
  
  *a Groove
  
  Using SST and a hammer, install the ring gear tooth side differential side bearing outer race RH.
  
  SST
  
  09608-32010
  
  09950-70010 ( 09951-07200 )
  
  Tech Tips
  
  Tap in the differential side bearing outer race RH until half of the side gear shaft snap ring groove of the differential carrier can be seen.
INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE LH
1. Text in Illustration
  
  *1 Disc
  
  Install SST to the differential carrier with the 2 bolts.
  
  SST
  
  09571-50010
2. Tighten SST bolt (A) until SST disc lightly touches the differential side bearing outer race LH.
3. Using SST and a hammer, install the ring gear back surface side differential side bearing outer race LH.
  
  SST
  
  09608-32010
  
  09950-70010 ( 09951-07200 )
  
  Tech Tips
  
  Tap in the differential side bearing outer race LH until it touches the case bearing inner race roller.

Text in Illustration
*a	Turn
*b	Hold

Text in Illustration
*a	Turn
*b	Hold

Drive pinion preload (at starting)
1.15 to 1.55 Nm (12 to 15 kgfcm, 11 to 13 in.*lbf)

Text in Illustration
*a	Groove

Text in Illustration
*1	Disc

INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.
Tech Tips
- If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft snap ring and install it.
- If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft snap ring with the same thickness as the removed one.
Install a dial indicator to the differential carrier.
Tighten SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.00394 in.).

SST

09571-50010

Text in Illustration

*a Turn

Note

Observe the dial indicator to ensure that the clearance does not change more than 0.2 mm (0.00787 in.).
Tech Tips
- Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
- Tighten SST bolt to apply the preload to the case bearing.
Turn the ring gear clockwise and counterclockwise several times.
Using a dial indicator, measure the backlash of the ring gear at 3 positions.

Backlash

0.08 to 0.13 mm (0.00315 to 0.00512 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 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 ring gear tooth side with a snap ring of different thickness as described in the following procedure.
- Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
Loosen SST bolt and separate SST disc from the differential side bearing outer race RH on the ring gear tooth side.
Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear back surface side and differential side bearing outer race LH.

SST

09608-32010

09950-70010 ( 09951-07200 )
Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

Text in Illustration
*a	Turn

Backlash
0.08 to 0.13 mm (0.00315 to 0.00512 in.)

Using snap ring pliers, install a side gear shaft snap ring with a different thickness.

Tech Tips

When the 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.).

Snap Ring Thickness
Thickness	Thickness	Thickness
3.66 mm (0.14409 in.)	3.92 mm (0.15433 in.)	4.18 mm (0.16457 in.)
3.68 mm (0.14488 in.)	3.94 mm (0.15512 in.)	4.20 mm (0.16535 in.)
3.70 mm (0.14567 in.)	3.96 mm (0.15591 in.)	4.22 mm (0.16614 in.)
3.72 mm (0.14646 in.)	3.98 mm (0.15669 in.)	4.24 mm (0.16693 in.)
3.74 mm (0.14724 in.)	4.00 mm (0.15748 in.)	4.26 mm (0.16772 in.)
3.76 mm (0.14803 in.)	4.02 mm (0.15827 in.)	4.28 mm (0.16850 in.)
3.78 mm (0.14882 in.)	4.04 mm (0.15905 in.)	4.30 mm (0.16929 in.)
3.80 mm (0.14961 in.)	4.06 mm (0.15984 in.)	4.32 mm (0.17008 in.)
3.82 mm (0.15039 in.)	4.08 mm (0.16063 in.)	4.34 mm (0.17087 in.)
3.84 mm (0.15118 in.)	4.10 mm (0.16142 in.)	4.36 mm (0.17165 in.)
3.86 mm (0.15197 in.)	4.12 mm (0.16220 in.)	4.38 mm (0.17244 in.)
3.88 mm (0.15276 in.)	4.14 mm (0.16299 in.)	4.40 mm (0.17323 in.)
3.90 mm (0.15354 in.)	4.16 mm (0.16378 in.)	4.42 mm (0.17402 in.)

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

*a Turn

Install a dial indicator to the differential carrier.
Tighten SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.

SST

09571-50010

Tech Tips

Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
Using a dial indicator, measure the backlash of the ring gear at 3 positions.

Backlash

0.08 to 0.13 mm (0.00315 to 0.00512 in.)
If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness.
Tech Tips
- Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
- Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
1. Text in Illustration
  
  *a Turn
  
  Install a dial indicator to the differential carrier.
2. Tighten SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.
  
  SST
  
  09571-50010
  
  Note
  
  Observe the dial indicator to ensure that the clearance does not change more than 0.2 mm (0.00787 in.).
  
  Tech Tips
  
  Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
3. Using snap ring pliers, install the thinnest side gear shaft snap ring on the ring gear tooth side.
4. Text in Illustration
  
  *1 Disc
  
  Remove the dial indicator and loosen the bolt until SST disc is separated from the differential side bearing outer race RH.
5. Using a plastic-faced hammer, lightly tap the ring gear tooth side of the differential carrier.
6. Using a dial indicator, measure the backlash of the 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 side gear shaft snap ring on the ring gear tooth side with a thicker one.
  
  Backlash
  
  0.08 to 0.13 mm (0.00315 to 0.00512 in.)
  
  Tech Tips
  
  If a value is not within the specified range, replace it with one of a different thickness in the following procedure.
7. Loosen 2 SST bolts and separate SST disc from the differential side bearing outer race RH on the ring gear tooth side.

Text in Illustration
*a	Turn

Backlash
0.08 to 0.13 mm (0.00315 to 0.00512 in.)

Text in Illustration
*a	Turn

Text in Illustration
*1	Disc

Backlash
0.08 to 0.13 mm (0.00315 to 0.00512 in.)

ADJUST TOTAL PRELOAD

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

SST: 09229-55010

Total preload (at starting)

Item	Specified Condition
New bearing	1.81 to 3.41 Nm (19 to 34 kgfcm, 16 to 30 in.*lbf)
Reused bearing	1.64 to 2.86 Nm (17 to 29 kgfcm, 15 to 25 in.*lbf)

Note

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

Set a dial indicator to the end of the differential ring gear face.
While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash

0.08 to 0.13 mm (0.00315 to 0.00512 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 side gear shaft snap rings equally.
- When the 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.).
Recheck the total preload.

Backlash
0.08 to 0.13 mm (0.00315 to 0.00512 in.)

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.
Rotate the ring gear in both directions.

Inspect the tooth contact pattern.

Text in Illustration
*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 to the ring gear (e, f)	-	-

Text in Illustration
*1	Rear Differential Drive Pinion Plate Washer

If the teeth are not contacting properly, use the following table to select a proper 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 drive pinion washer has been changed, adjust the backlash and measure the total preload.

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

REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
1. Text in Illustration
  
  *1 Disc
  
  Install SST to the rear differential carrier with the 2 bolts.
  
  SST
  
  09571-50010
2. Install a dial indicator to the rear differential carrier.
3. Tighten SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH 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 (0.00787 in.).
  Tech Tips
  - Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
  - Approximately 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and the side gear shaft snap ring is sufficient for the washer to move slightly.
4. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.
5. Remove the dial indicator and loosen SST bolt.
  
  Note
  
  Do not remove SST.
REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
1. Using SST and a hammer, create a clearance between the differential side bearing outer race LH 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. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH
1. Text in Illustration
  
  *a Turn
  
  Tighten SST bolt and push out the differential side bearing outer race LH on the ring gear back surface side.
  
  SST
  
  09571-50010
  
  Note
  
  Do not drop the side bearing outer race.
  Tech Tips
  
  To use as a reference for installation, clearly write the installation positions (back side or teeth side) of the differential side bearing outer race and the rear differential side gear shaft snap ring.
  
  Put identification marks on the differential side bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
2. Remove the 2 bolts and SST.
REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH
1. Raise the ring gear side of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.
  Tech Tips
  
  For reassembly, check the installation position of the differential side bearing outer race and the side gear shaft snap ring before removing the differential side bearing outer race. Write down the result.
  
  Put identification marks on the differential side 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 DIFFERENTIAL CASE SUB-ASSEMBLY
1. Remove the rear differential case sub-assembly.
  
  Note
  
  Do not damage the case bearing.
REMOVE REAR DRIVE PINION NUT
1. Text in Illustration
  
  *a Turn
  
  *b Hold
  
  Using SST to hold the flange, remove the drive pinion nut.
  
  SST
  
  09229-55010
  
  09330-00021
  
  09950-30012 ( 09955-03040 )
REMOVE REAR DRIVE PINION COMPANION FLANGE
1. 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
  
  Apply grease to the threads and tip of SST center bolt before use.
REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Remove the differential drive pinion oil slinger.
REMOVE DIFFERENTIAL DRIVE PINION
1. Using a press, remove the drive pinion from the differential carrier.
  
  Note
  
  Do not drop the drive pinion.
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Remove the rear drive pinion front tapered roller bearing from the differential carrier.
INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Install a new drive pinion bearing spacer to the drive pinion.
  
  Note
  
  Make sure to install the bearing spacer with the larger inner diameter facing the differential drive pinion and the smaller inner diameter facing the rear drive pinion companion flange.
INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Install the rear drive pinion front tapered roller bearing to the differential carrier.
INSTALL DIFFERENTIAL DRIVE PINION
1. Using SST and a press, install the differential drive pinion to the differential carrier.
  
  SST
  
  09316-60011 ( 09316-00011, 09316-00041 )
  
  09608-04031
INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Install the differential drive pinion oil slinger to the differential drive pinion.
INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
1. Using SST and a hammer, install a new rear differential carrier oil seal.
  
  SST
  
  09316-60011 ( 09316-00011 )
  
  09710-30012 ( 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
  
  -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
  Note
  - Measure at 3 or more areas around the circumference of the oil seal.
  - Make sure the difference between the maximum and minimum measured values is less than 0.65 mm (0.0256 in.), as a greater difference may lead to oil leaks.
INSTALL REAR DRIVE PINION COMPANION FLANGE
1. 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
  
  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. Text in Illustration
  
  *a Turn
  
  *b Hold
  
  Using SST and a torque wrench, hold the flange and tighten the drive pinion nut.
  
  SST
  
  09229-55010
  
  09330-00021
  
  09950-30012 ( 09955-03040 )
  
  Torque
  
  490 N*m (5000 kgf*cm, 361 ft.*lbf) or less
  Note
  - Do not tighten excessively, otherwise the threads will be stripped.
  - Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
  Tech Tips
  
  Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.
INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
1. Insert the differential case from the ring gear tooth side.
  
  Note
  
  Do not damage the case bearing inner race or ring gear.
INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE RH
1. Text in Illustration
  
  *a Groove
  
  Using SST and a hammer, install the ring gear tooth side differential side bearing outer race RH.
  
  SST
  
  09608-32010
  
  09950-70010 ( 09951-07200 )
  
  Tech Tips
  
  Tap in the differential side bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.
INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE LH
1. Text in Illustration
  
  *1 Disc
  
  Install SST to the differential carrier with the 2 bolts.
  
  SST
  
  09571-50010
2. Tighten SST bolt (A) until SST disc lightly touches the differential side bearing outer race RH.
3. Using SST and a hammer, install the ring gear back surface side differential side bearing outer race LH.
  
  SST
  
  09608-32010
  
  09950-70010 ( 09951-07200 )
  
  Tech Tips
  
  Tap in the differential side bearing outer race until it touches the case bearing inner race roller.
INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
1. Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
  
  Tech Tips
  
  Use the side gear shaft snap ring installed when performing tooth contact adjustment.
2. Text in Illustration
  
  *1 Turn
  
  Set a dial indicator on the differential carrier.
3. Tighten SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.
  
  Note
  
  Observe the dial indicator to ensure that the clearance does not change more than 0.2 mm (0.00787 in.).
4. 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 installed when performing tooth contact adjustment.
5. Remove the dial indicator and tap the differential carrier on the ring gear tooth side using a plastic-faced hammer to stabilize the case bearing.
6. Remove the 2 bolts and SST.
ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
1. Using SST and a torque wrench, measure the preload.
  
  SST
  
  09229-55010
  
  Drive pinion preload (at starting)
  
  1.25 to 1.65 N*m (13 to 16 kgf*cm, 11 to 14 in.*lbf)
  - If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut 5 to 10°.
    
    Torque
    
    490 N*m (5000 kgf*cm, 361 ft.*lbf) or less
  - If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
  - If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

Text in Illustration
*1	Disc

Text in Illustration
*a	Turn

Text in Illustration
*a	Turn
*b	Hold

Text in Illustration
*a	Turn
*b	Hold

Standard depth
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

Text in Illustration
*a	Turn
*b	Hold

Text in Illustration
*a	Turn
*b	Hold

Torque
490 Nm (5000 kgfcm, 361 ft.*lbf) or less

Text in Illustration
*a	Groove

Text in Illustration
*1	Disc

Text in Illustration
*1	Turn

Drive pinion preload (at starting)
1.25 to 1.65 Nm (13 to 16 kgfcm, 11 to 14 in.*lbf)

Torque
490 Nm (5000 kgfcm, 361 ft.*lbf) or less

INSPECT TOTAL PRELOAD

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

SST: 09229-55010

Total preload (at starting)

Item	Specified Condition
New bearing	1.91 to 3.51 Nm (20 to 35 kgfcm, 17 to 31 in.*lbf)
Reused bearing	1.74 to 2.96 Nm (18 to 30 kgfcm, 16 to 26 in.*lbf)

INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.
  
  Backlash
  
  0.08 to 0.13 mm (0.00315 to 0.00512 in.)
  
  If the backlash is not within the specified range, adjust the backlash or repair as necessary.
INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
1. Using a dial indicator, measure the runout of the 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 drive pinion and ring gear.
STAKE REAR DRIVE PINION NUT
1. Using SST and a hammer, stake the drive pinion nut.
  
  SST
  
  09930-00010
INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Text in Illustration
  
  *a -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
  
  Using SST and a hammer, install 2 new oil seals.
  
  SST
  
  09223-15030
  
  09950-70010 ( 09951-07200 )
  
  Oil seal installation depth
  
  -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
  Tech Tips
  - Make sure to check the identification marks on the 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 differential side gear shaft oil seals.
  - After installing both oil seals, tap them in until both surfaces are flush with the rear differential carrier.
INSTALL REAR DIFFERENTIAL DRAIN PLUG
1. Using a 10 mm hexagon wrench, install the differential drain plug with a new gasket.
  
  Torque:
  
  49 N*m { 500 kgf*cm, 36 ft.*lbf }
TEMPORARILY INSTALL REAR DIFFERENTIAL FILLER PLUG
1. Using a 10 mm hexagon wrench, temporarily install the differential filler plug.
  
  Tech Tips
  
  Add differential oil before installing the gasket and fully tightening the rear differential filler plug.
REMOVE REAR DIFFERENTIAL CARRIER
1. Remove the 4 bolts and differential carrier from the overhaul attachment.
  
  Note
  
  Clean the fitting surface between the differential carrier and carrier cover.
INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Install the rear differential breather plug oil deflector to the rear differential carrier cover.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
INSTALL REAR DIFFERENTIAL CARRIER COVER
1. Clean the seal packing attached on the differential carrier and 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. Text in Illustration
  
  *1 Seal Packing
  
  *a 2 to 3 mm
  
  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 (0.0787 to 0.118 in.) in diameter.
  
  Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.
  
  Install the differential carrier cover within 3 minutes of application.
3. Install the differential carrier cover with the 8 bolts and 2 pins.
  
  Torque:
  
  47 N*m { 479 kgf*cm, 35 ft.*lbf }
  
  Note
  
  Do not add 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 72 hours after application.
INSTALL REAR DIFFERENTIAL BREATHER PLUG
1. Install the breather plug to the differential carrier cover.
  
  Torque:
  
  21 N*m { 210 kgf*cm, 15 ft.*lbf }