FRONT DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH
1. Using SST and a press, press in the shaft bearing.
  
  SST
  
  09223-00010
2. Using a snap ring expander, install the snap ring.
  
  Tech Tips
  
  Install the snap ring securely.
INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
1. Install the shaft to the differential tube.
2. Using needle nose pliers, install the snap ring.
  
  Tech Tips
  
  Install the snap ring securely.
INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Coat the lip of a new oil seal with MP grease.
  
  Standard oil seal depth
  
  4.8 to 5.8 mm (0.189 to 0.229 in.)
2. Using SST and a plastic-faced hammer, tap in the oil seal.
  
  SST
  
  09223-15020

Standard oil seal depth
4.8 to 5.8 mm (0.189 to 0.229 in.)

INSTALL DIFFERENTIAL CASE ASSEMBLY

Install the 2 thrust washers to the 2 side gears.

Standard Thrust Washer

Thickness	Thickness
1.48 to 1.52 mm (0.0583 to 0.0598 in.)	1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)	1.78 to 1.82 mm (0.0701 to 0.0717 in.)
1.58 to 1.62 mm (0.0622 to 0.0638in.)	1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)	1.88 to 1.92 mm (0.0740 to 0.0756 in.)
1.68 to 1.72 mm (0.0661 to 0.0677 in.)	-

Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion thrust washers and pinion shaft to the differential case.

Tech Tips

Align the holes of the differential case and pinion shaft.
Measure the side gear backlash.
1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
  
  Standard backlash
  
  0.15 mm (0.00591 in.) or less
  - If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.
Using a 5 mm pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.
Stake the differential case.

INSTALL DIFFERENTIAL RING GEAR
1. Clean the contact surfaces of the differential case and ring gear.
2. Heat the ring gear in water that is approximately 100°C (212°F).
3. Carefully remove the ring gear from the boiling water.
4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
5. Text in Illustration
  
  *a Matchmark
  
  Align the matchmarks on the ring gear with those of the differential case.
6. After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.
  
  Adhesive
  
  Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
  
  Torque:
  
  115 N*m { 1173 kgf*cm, 85 ft.*lbf }
INSTALL FRONT DIFFERENTIAL CASE BEARING
1. Using SST and a press, press the 2 bearings (inner) into the differential case.
  
  SST
  
  09950-60010 ( 09951-00520, 09951-00610 )
  
  09950-70010 ( 09951-07150 )
INSTALL FRONT DIFFERENTIAL CASE BEARING

Tech Tips

When replacing the 3 differential case bearings, install the 2 thinnest new washers onto each bearing. When reusing the bearings, install the new case washers to the same places they were removed from.
1. Text in Illustration
  
  *a Case Washer
  
  Using SST and a press, press the case bearing (outer race) into the differential case bearing retainer.
  
  SST
  
  09950-60020 ( 09951-00810 )
  
  09950-70010 ( 09951-07150 )
2. Text in Illustration
  
  *a Case Washer
  
  Using SST and a press, press the case bearing (outer) into the differential carrier.
  
  SST
  
  09950-60020 ( 09951-00810 )
  
  09950-70010 ( 09951-07150 )
INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)
1. Using SST, install the front drive pinion rear tapered roller bearing (outer race).
  
  SST
  
  09950-00020 ( 09951-00890, 09951-00680 )
INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using a brass bar and hammer, tap in the oil storage ring.
2. Using SST, install the front drive pinion front tapered roller bearing (outer race).
  
  SST
  
  09950-00020 ( 09951-00890, 09951-00680 )
  
  Text in Illustration
  
  *A for Rear
  
  *B for Front
INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Install the washer to the drive pinion.
  
  Tech Tips
  
  First, install a washer that has the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.
2. Using SST and a press, press the front bearing onto the drive pinion.
  
  SST
  
  09506-30012

Standard backlash
0.15 mm (0.00591 in.) or less

Text in Illustration
*a	Matchmark

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

Text in Illustration
*a	Case Washer

Text in Illustration
*a	Case Washer

Text in Illustration
*A	for Rear
*B	for Front

INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

Install the drive pinion, roller bearing and oil slinger to the differential case.

Tech Tips

Install the spacer, oil storage ring and oil seal after adjusting the gear contact pattern.
Using SST, install the companion flange.

SST

09950-30012 ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )

Note

Before using SST (center bolt), apply hypoid gear oil to its threads and tip.
Adjust the drive pinion preload by tightening the companion flange nut.
Using SST to hold the flange in place, tighten the nut.

SST

09330-00021

Torque:

370 N*m { 3770 kgf*cm, 273 ft.*lbf, or less }
Note
- As there is no spacer, tighten the nut a little at a time. Be careful not to overtighten it.
- Apply hypoid gear oil to the nut.

Using a torque wrench, measure the preload.

Standard Preload (at Starting)

Item	Specified Condition
New bearing	0.98 to 1.57 Nm (10 to 16 kgfcm, 8.7 to 14 in.*lbf)
Used bearing	0.49 to 0.78 Nm (5 to 8 kgfcm, 4.3 to 6.9 in.*lbf)

Note

For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

INSTALL DIFFERENTIAL CASE ASSEMBLY

ADJUST DIFFERENTIAL RING GEAR BACKLASH

Install the side bearing retainer with the 10 bolts.

Torque:

50 N*m { 510 kgf*cm, 37 ft.*lbf }

Using SST and a dial indicator, measure the ring gear backlash.

SST: 09564-32011

Standard backlash
0.11 to 0.21 mm (0.00433 to 0.00827 in.)

If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.

Tech Tips

There should be no clearance between the plate washer and case. Make sure that the ring gear has backlash.

Standard Washer

Thickness	Thickness	Thickness
1.57 to 1.59 mm (0.0618 to 0.0626 in.)	1.79 to 1.81 mm (0.0705 to 0.0713 in.)	1.99 to 2.01 mm (0.0783 to 0.0791 in.)
1.59 to 1.61 mm (0.0626 to 0.0634 in.)	1.81 to 1.83 mm (0.0713 to 0.0720 in.)	2.01 to 2.03 mm (0.0791 to 0.0799 in.)
1.61 to 1.63 mm (0.0634 to 0.0642 in.)	1.83 to 1.85 mm (0.0720 to 0.0728 in.)	2.03 to 2.05 mm (0.0791 to 0.0807 in.)
1.63 to 1.65 mm (0.0642 to 0.0650 in.)	1.85 to 1.87 mm (0.0728 to 0.0736 in.)	2.05 to 2.07 mm (0.0807 to 0.0815 in.)
1.65 to 1.67 mm (0.0650 to 0.0657 in.)	1.87 to 1.89 mm (0.0736 to 0.0744 in.)	2.07 to 2.09 mm (0.0815 to 0.0822 in.)
1.67 to 1.69 mm (0.0657 to 0.0665 in.)	1.89 to 2.01 mm (0.0744 to 0.0791 in.)	2.09 to 2.11 mm (0.0822 to 0.0830 in.)
1.69 to 1.71 mm (0.0665 to 0.0673 in.)	1.89 to 1.91 mm (0.0744 to 0.0752 in.)	2.11 to 2.13 mm (0.0830 to 0.0839 in.)
1.71 to 1.73 mm (0.0673 to 0.0681 in.)	1.91 to 1.93 mm (0.0752 to 0.0760 in.)	2.13 to 2.15 mm (0.0839 to 0.0846 in.)
1.73 to 1.75 mm (0.0681 to 0.0689 in.)	1.93 to 1.95 mm (0.0760 to 0.0768 in.)	2.15 to 2.17 mm (0.0846 to 0.0854 in.)
1.75 to 1.77 mm (0.0689 to 0.0697 in.)	1.95 to 1.97 mm (0.0768 to 0.0776 in.)	-
1.77 to 1.79 mm (0.0697 to 0.0705 in.)	1.97 to 1.99 mm (0.0776 to 0.0783 in.)	-

INSPECT TOTAL PRELOAD

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

Standard Total Preload (at Starting)

Item	Specified Condition
New bearing	1.2 to 2.45 Nm (12 to 25 kgfcm, 10.6 to 21.7 in.*lbf)
Used bearing	0.71 to 1.66 Nm (7.2 to 17 kgfcm, 6.3 to 14.7 in.*lbf)

If necessary, disassemble and inspect the differential.

ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Remove the differential case bearing retainer and differential case.
Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.
Install the differential case and differential case bearing retainer.

Torque:

50 N*m { 510 kgf*cm, 37 ft.*lbf }
Hold the companion flange firmly in place and rotate the ring gear in both directions.
Remove the differential case bearing retainer and differential case.
Inspect the tooth contact pattern.

Text in Illustration
*1	Drive Pinion Washer

If the teeth are not contacting properly, use the following chart to select an appropriate washer.

Standard Washer

Thickness	Thickness	Thickness
1.69 to 1.71 mm (0.0665 to 0.0673 in.)	1.93 to 1.95 mm (0.0760 to 0.0768 in.)	2.17 to 2.19 mm (0.0854 to 0.0862 in.)
1.72 to 1.74 mm (0.0677 to 0.0685 in.)	1.96 to 1.98 mm (0.0772 to 0.0780 in.)	2.20 to 2.22 mm (0.0866 to 0.0874 in.)
1.75 to 1.77 mm (0.0689 to 0.0697 in.)	1.99 to 2.01 mm (0.0783 to 0.0791 in.)	2.23 to 2.25 mm (0.0878 to 0.0886 in.)
1.78 to 1.80 mm (0.0700 to 0.0709 in.)	2.02 to 2.04 mm (0.0795 to 0.0803 in.)	2.26 to 2.28 mm (0.0890 to 0.0898 in.)
1.81 to 1.83 mm (0.0713 to 0.0720 in.)	2.05 to 2.07 mm (0.0807 to 0.0815 in.)	2.29 to 2.31 mm (0.0902 to 0.0909 in.)
1.84 to 1.86 mm (0.0724 to 0.0732 in.)	2.08 to 2.10 mm (0.0819 to 0.0827 in.)	2.32 to 2.34 mm (0.0913 to 0.0921 in.)
1.87 to 1.89 mm (0.0736 to 0.0744 in.)	2.11 to 2.13 mm (0.0831 to 0.0839 in.)	-
1.90 to 1.92 mm (0.0748 to 0.0756 in.)	2.14 to 2.16 mm (0.0843 to 0.0850 in.)	-

REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT
1. Using SST and a hammer, unstake the nut.
  
  SST
  
  09930-00010
2. Using SST to hold the companion flange, remove the nut.
  
  SST
  
  09330-00021
REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
Text in Illustration

*a Hold

*b Turn
1. Using SST, remove the companion flange.
  
  SST
  
  09950-30012 ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )
  
  Note
  
  Before using SST (center bolt), apply hypoid gear oil to its threads and tip.
REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)
1. Using SST and a press, remove the rear tapered roller bearing (inner) and washer from the drive pinion.
  
  SST
  
  09950-00020
  
  Tech Tips
  
  If the drive gear or ring gear is damaged, replace them as a set.
  
  Note
  
  Do not drop the drive pinion.
REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)
1. Using a brass bar and hammer, remove the rear tapered roller bearing (outer).
INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Install the bearing spacer.
INSTALL FRONT DIFFERENTIAL OIL STORAGE RING
1. Using a brass bar and hammer, tap in a new oil storage ring.
  
  Note
  
  Be careful not to damage the oil storage ring.
INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)
1. Using SST and a hammer, install the roller bearing (outer).
  
  SST
  
  09316-60011 ( 09316-00011, 09316-00021 )
INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)
1. Install the roller bearing (inner).
INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
1. Apply MP grease to the lip of a new oil seal.
2. Using SST and a hammer, tap in the oil seal.
  
  SST
  
  09554-22010
  
  Standard oil seal depth
  
  3.9 to 4.8 mm (0.154 to 0.189 in.)
INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
Text in Illustration

*1 Plate
1. Using a steel plate and press, press in a new dust deflector.
  
  Note
  
  Do not damage the dust deflector.
INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
1. Place the companion flange on the drive pinion.
2. Coat the threads of a new nut with hypoid gear oil.
3. Using SST, install the companion flange.
  
  SST
  
  09950-30012 ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )
  
  Note
  
  Before using SST (center bolt), apply hypoid gear oil to its threads and tip.
4. Using SST to hold the companion flange in place, tighten the nut to the correct torque.
  
  SST
  
  09330-00021 ( 09330-00030 )
  
  Torque:
  
  370 N*m { 3770 kgf*cm, 273 ft.*lbf, or less }
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
1. Remove any old FIPG material from the side bearing retainer.
  
  Note
  
  Do not drop oil on the contact surfaces of the differential carrier and side bearing retainer.
2. Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.
3. Text in Illustration
  
  *1 Seal Packing
  
  Apply seal packing to the side bearing retainer as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Tech Tips
  
  Install the side bearing retainer within 10 minutes of applying seal packing.
4. Install the side bearing retainer with the 10 bolts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }

Text in Illustration
*a	Hold
*b	Turn

Standard oil seal depth
3.9 to 4.8 mm (0.154 to 0.189 in.)

Text in Illustration
*1	Plate

Text in Illustration
*1	Seal Packing

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

INSPECT DRIVE PINION PRELOAD

Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Starting)

Item	Specified Condition
New bearing	0.98 to 1.57 Nm (10 to 16 kgfcm, 8.7 to 14 in.*lbf)
Used bearing	0.49 to 0.78 Nm (5 to 8 kgfcm, 4.3 to 6.9 in.*lbf)

If the result not as specified, replace the bearing spacer.

If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

Torque:: 370 N*m { 3770 kgf*cm, 273 ft.*lbf, or less }

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.

Tech Tips

Do not loosen the pinion nut to reduce the preload.

INSPECT TOTAL PRELOAD

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

Standard Total Preload (at Starting)

Item	Specified Condition
New bearing	1.2 to 2.45 Nm (12 to 25 kgfcm, 10.6 to 21.7 in.*lbf)
Used bearing	0.71 to 1.66 Nm (7.2 to 17 kgfcm, 6.3 to 14.7 in.*lbf)

If necessary, disassemble and inspect the differential.

INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. Using SST and a dial indicator, measure the ring gear backlash.
  
  SST
  
  09564-32011
  
  Standard backlash
  
  0.11 to 0.21 mm (0.0043 to 0.00827 in.)
  - If the backlash is not within the specification, adjust the side bearing preload.

Standard backlash
0.11 to 0.21 mm (0.0043 to 0.00827 in.)

INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

Text in Illustration
*a	Vertical runout
*b	Lateral runout

Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Distance from center to runout measurement point
30 mm (1.18 in.)

Maximum Runout

Item	Specified Condition
Vertical runout	0.15 mm (0.00591 in.)
Lateral runout	0.15 mm (0.00591 in.)

If the runout is more than the maximum, replace the companion flange.

STAKE FRONT DRIVE PINION COMPANION FLANGE NUT
1. Using a chisel and hammer, stake the drive pinion nut.
INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Coat the lip of a new oil seal with MP grease.
2. Using SST and a plastic-faced hammer, tap in the oil seal until its surface is flush with the differential carrier end.
  
  SST
  
  09608-32010
  
  Standard oil seal depth
  
  -0.45 to 0.45 mm (-0.0177 to 0.0177 in.)
INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
1. Using a brass bar and hammer, tap in the side bearing retainer deflector.
  
  Note
  
  Install the side bearing retainer deflector so that it is facing in the correct direction.
INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY
1. Remove any old FIPG material from the contact surfaces of the differential and clutch case.
  
  Note
  
  Do not drop oil on the contact surfaces of the differential and clutch case.
2. Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.
3. Text in Illustration
  
  *1 Seal Packing
  
  Apply seal packing to the differential as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Tech Tips
  
  Install the differential tube within 10 minutes of applying seal packing.
4. Install the differential tube to the differential.
5. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
6. Apply adhesive to 2 or 3 threads at the tip of each bolt.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
7. Using an E14 "TORX" socket wrench, install the 4 bolts.
  
  Torque:
  
  110 N*m { 1120 kgf*cm, 81 ft.*lbf }