DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT


  1. DRAIN REAR DIFFERENTIAL OIL


    1. Stop the vehicle on a level place.

    2. A01GXLT

      for Front Differential:


      1. Using a 10 mm hexagon wrench, remove the filler plug and gasket.

      2. Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.

      3. Using a 10 mm hexagon wrench, install a new gasket and the drain plug.

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }
    3. A01H1RT

      for Rear Differential:


      1. Using a 10 mm hexagon wrench, remove the filler plug and gasket.

      2. Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.

      3. Using a 10 mm hexagon wrench, install a new gasket and the drain plug.

        Torque:
        49 N*m  { 500 kgf*cm, 37 ft.*lbf }

  2. REMOVE DRIVE SHAFT ASSEMBLY

    Click here

  3. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

    Click here

  4. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01H1X5

      Remove the 8 bolts from the differential carrier cover.

    2. A01GXE2

      Using a brass bar and hammer, remove the differential carrier cover from the differential carrier.

      Note


      • Set the brass bar on the ribbed part of the differential carrier cover.

      • Do not damage the installation surface of the differential carrier.

  5. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND


    1. A01GXYRE01

      Set the differential carrier to an overhaul stand as shown in the illustration.

      Tech Tips

      Install the differential carrier with the back surface of the ring gear facing the overhaul stand as shown in the illustration.

  6. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01GZ41E01

      Using SST, remove the 2 oil seals.

      SST
      09308-00010

  7. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01GZOLE04
      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. A01GXISE01

      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 (0.00394 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 (0.00787 in.).

      Tech Tips

      Approximately 0.1 mm (0.00394 in.) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly.

    5. A01GXXH

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

      Tech Tips


      • For reassembly purposes, measure the thickness of the differential side gear shaft snap ring, and record the result.

      • 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. Remove the dial indicator from the differential carrier.

    7. A01GXRRE02
      Text in Illustration
      *1 Disc
      *a Turn

      Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race.

      Tech Tips

      Do not remove SST.

  8. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01H28XE02

      Using SST and a hammer, create a clearance between the case bearing outer race on the back surface of 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. A01GWLB

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

      Tech Tips


      • For reassembly purposes, measure the thickness of the differential side gear shaft snap ring, and record the result.

      • 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.

  9. REMOVE REAR DIFFERENTIAL CASE BEARING OUTER RACE


    1. A01GY8YE03
      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. A01GZOLE05
      Text in Illustration
      *1 Disc

      Remove the 2 bolts and SST from the differential carrier.

  10. REMOVE REAR DIFFERENTIAL CASE BEARING OUTER RACE


    1. A01GYUNE01

      Raise the ring gear 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.

  11. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GXTA

      Remove the rear differential case from the differential carrier as shown in the illustration.

      Note

      Do not damage the case bearing and ring gear.

  12. REMOVE REAR DRIVE PINION NUT


    1. A01GYI5E02

      Using SST and a hammer, unstake the staked part of the drive pinion nut.

      SST
      09930-00010

      Note


      • Do not grind the tip of SST with a grinder, etc.

      • Completely unstake the drive pinion nut to prevent damaging the threads of the drive pinion.

    2. A01H1N6E03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, fix the companion flange in place.

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

    3. While supporting the overhaul attachment, using SST, remove the rear drive pinion nut.

      SST
      09229-55010

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


    1. A01H0VJE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the companion flange from the differential carrier.

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

      Tech Tips

      Before using SST center bolt, apply hypoid gear oil to its threads and tip.

  14. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01H08LE01

      Using SST, remove the oil seal from the differential carrier.

      SST
      09308-00010

  15. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GY0N

      Using a magnet hand, remove the oil slinger from the differential carrier.

  16. REMOVE DIFFERENTIAL DRIVE PINION WITH BEARING INNER RACE


    1. A01H0C2

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

      Note

      Do not drop the drive pinion.

  17. REPLACE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01H1L3

      Replace the drive pinion bearing spacer with a new one and install it to the drive pinion.

      Tech Tips

      The bearing spacer can be installed facing either direction.

  18. INSTALL DIFFERENTIAL DRIVE PINION WITH BEARING INNER RACE


    1. A01GX9TE01

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

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

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GY0N

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

  20. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01GXB2E01

      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
      -0.5 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 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.

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


    1. A01GZOAE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange to the differential carrier.

      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.

      Tech Tips

      Before using SST center bolt, apply hypoid gear oil to its threads and tip.

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

    3. A01GXCNE01
      Text in Illustration
      *a Turn
      *b Hold

      Use SST to hold the companion flange.

      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


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

      • Perform the tightening while supporting the overhaul attachment.

      Tech Tips


      • Tighten the nut with a force of 100 N*m (1020 kgf*cm, 74 ft.*lbf) and keep tightening while checking the starting torque of the drive pinion.

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

  22. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GYW6

      Insert the differential case from the ring gear tooth side.

      Note

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

  23. INSTALL REAR DIFFERENTIAL CASE BEARING OUTER RACE


    1. A01H2BYE01
      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. A01GZOLE08
      Text in Illustration
      *1 Disc

      Install SST to the differential carrier with the 2 bolts.

      SST
      09571-50010

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

    4. A01H28XE02

      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.

  24. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01GWLB

      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. A01GXISE01

      Install a dial indicator on the differential carrier.

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

      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.

      • Approximate 0.1 mm (0.00394 in.) 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.

      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.).

    4. A01GXXH

      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. A01GXRRE03
      Text in Illustration
      *1 Disc
      *a Turn

      Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race.

    6. A01GXKD

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

    7. A01GZOLE02

      Remove the 2 bolts and SST from the differential carrier.

  25. ADJUST DRIVE PINION PRELOAD


    1. A01GWBYE01

      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)

      Tech Tips


      • 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.

      Note


      • 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.

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

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

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

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

    4. 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.

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

  26. INSPECT TOTAL PRELOAD


    1. A01GWBYE01

      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
      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)

  27. STAKE REAR DRIVE PINION NUT


    1. A01GXO9E01

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

      SST
      09930-00010

  28. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01GWCYE01

      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 (-0.0197 to 0.0196 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.

  29. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY FROM OVERHAUL STAND


    1. A01GXYRE01

      Remove the differential carrier from the overhaul stand.

  30. INSTALL REAR DIFFERENTIAL CARRIER COVER


    1. A01H1CKE09
      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 (0.0787 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.

      • A01H1X5

        Install the differential carrier cover within 3 minutes of application.

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

      Torque:
      47 N*m  { 479 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.

  31. CLEAN REAR DIFFERENTIAL CARRIER ASSEMBLY

    Click here

  32. INSTALL DRIVE SHAFT ASSEMBLY

    Click here

  33. ADD REAR DIFFERENTIAL OIL


    1. for Front Differential:


      1. A01H1DIE01

        Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the differential filler plug hole.

        Note


        • Too much or too little oil will lead to differential problems.

        • After changing the oil, drive the vehicle and then check the oil level again.

        Oil type
        Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 or equivalent.
        Capacity
        0.7 to 0.8 liters (0.74 to 0.84 US qts., 0.62 to 0.70 Imp. qts.)
      2. A01H27B

        Using a 10 mm hexagon wrench, install a new gasket and the filler plug.

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    2. for Rear Differential:


      1. A01GYOJE01

        Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.196 in.) from the bottom lip of the differential filler plug hole.

        Note


        • Too much or too little oil will lead to differential problems.

        • After changing the oil, drive the vehicle and then check the oil level again.

        Oil type
        Toyota Genuine Differential Gear Oil LX 75W-85 GL-5 or equivalent
        Capacity
        1.3 to 1.4 liters (1.38 to 1.47 US qts., 1.15 to 1.23 Imp. qts.)
      2. A01H1J4

        Using a 10 mm hexagon wrench, install a new gasket and the filler plug.

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