REAR DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT


  1. REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. Remove the center exhaust pipe assembly Click here.

  2. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. Depress the brake pedal and hold it.

    2. A01EIP4E01
      Text in Illustration
      *1 Piece of Cloth

      Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.

      Note


      • Put a piece of cloth or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.

      • Do not remove the bolts.

    3. A01EMABE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the rear propeller shaft and electromagnetic control coupling assembly.

    4. A01EJS9E01

      Remove the 4 nuts and 4 washers.

    5. A01ELS3

      Using a brass bar and a hammer, separate the propeller with center bearing shaft assembly.

    6. A01EM4R

      Remove the 4 bolts, 2 No. 1 center support bearing washers and 2 No. 2 center support bearing washers.

      Note

      When removing the bolts and washers, do not apply excessive force to the universal joint.

    7. Pull out the propeller with center bearing shaft assembly from the transfer.

      Note


      • When removing the propeller shaft, do not apply excessive force to the universal joint.

      • During and after the removal of the propeller shaft, keep the universal joint angle straight (within 15 degrees).

      • Be careful not to damage the oil seal.

    8. A01EK8YE01

      Insert SST into the transfer to prevent oil leaks.

      SST
      09325-20010

      Note

      Be careful not to damage the oil seal.

  3. DRAIN DIFFERENTIAL OIL


    1. A01EM4S

      Using a 10 mm hexagon wrench, remove the rear differential carrier cover plug and gasket.

    2. A01EKOJ

      Using a 10 mm hexagon wrench, remove the rear differential drain plug and gasket to drain the differential oil.

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

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
    4. A01EM4S

      Using a 10 mm hexagon wrench, temporarily install the rear differential carrier cover plug.

      Tech Tips

      Add differential oil before installing a new gasket and fully tightening the rear differential carrier cover plug.

  4. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A01EM2F

      Disconnect the electro magnetic control coupling sub-assembly connector and vacuum hose.

      Note

      Do not damage the electro magnetic control coupling wire harness.

    2. A01EJUT

      Remove the 4 bolts.

    3. Using a brass bar and a hammer, tap the electro magnetic control coupling sub-assembly to remove the electro magnetic control coupling sub-assembly from the rear differential carrier assembly.

      Note

      Do not drop the electro magnetic control coupling sub-assembly.

  5. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER


    1. A01EK2BE01
      Text in Illustration
      *1 Transmission Coupling Conical Spring Washer

      Remove the transmission coupling conical spring washer from the rear differential carrier assembly.

  6. REMOVE TRANSMISSION COUPLING SPACER


    1. A01EKCHE01
      Text in Illustration
      *1 Transmission Coupling Spacer

      Remove the transmission coupling spacer from the rear differential carrier assembly.

  7. REMOVE DIAPHRAGM OIL SEAL


    1. A01EM05E02

      Using SST, remove the diaphragm oil seal from the rear differential carrier assembly.

      SST
      09308-10010

  8. INSTALL DIAPHRAGM OIL SEAL


    1. A01EINJE01

      Using SST and a hammer, install a new diaphragm oil seal into the rear differential carrier assembly.

      SST
      09506-35010
      09554-22010
      Oil seal driven in depth (A)
      0.7 to 1.3 mm (0.0276 to 0.0511 in.)

  9. INSTALL TRANSMISSION COUPLING SPACER


    1. A01EKCHE01
      Text in Illustration
      *1 Transmission Coupling Spacer

      Install the transmission coupling spacer to the rear differential carrier assembly.

      Note

      Keep the transmission coupling spacer free of oil and foreign matter.

  10. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER


    1. A01EK2BE01
      Text in Illustration
      *1 Transmission Coupling Conical Spring Washer

      Install the transmission coupling conical spring washer to the rear differential carrier assembly as shown in the illustration.

      Note

      Keep the transmission coupling conical spring washer free of oil and foreign matter.

  11. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      Note


      • Do not damage the contact surface.

      • Be sure to completely remove all seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      • Do not allow the removed seal packing to enter the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier assembly and the electro magnetic control coupling sub-assembly.

      Note

      Do not damage the contact surface.

    3. A01ELJ4E02
      Text in Illustration
      *a 20 mm (0.787 in.)
      *b 1.0 mm (0.0394 in.)
      *c 1.4 mm (0.0551 in.)
      *d 3.0 mm (0.118 in.)
      *d 2.0 mm (0.0787 in.)

      Apply seal packing to the areas indicated in the illustration of the rear differential carrier assembly.

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

      Note


      • Start applying seal packing within range (A).

      • Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).

      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.

      • Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing. If the electro magnetic control coupling sub-assembly is not installed within 10 minutes after applying seal packing, completely remove and then reapply seal packing.

      • After installing the electro magnetic control coupling sub-assembly, do not immediately add oil or drive the vehicle for at least 1 hour.

    4. A01EJUT

      Install the electro magnetic control coupling sub-assembly with the 4 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note


      • Do not damage the diaphragm oil seal.

      • Do not damage the contact surface of the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

    5. A01EM2F

      Connect the electro magnetic control coupling sub-assembly connector and vacuum hose.

      Note

      Do not damage the electro magnetic control coupling wire harness.

  12. ADD DIFFERENTIAL OIL


    1. A01EM4S

      Remove the rear differential carrier cover plug.

    2. Add differential oil Click here.

  13. INSPECT DIFFERENTIAL OIL


    1. A01EKCWE03

      Check that the oil level is between 0 and 5 mm (0 and 0.196 in.) from the bottom lip of the rear differential carrier cover plug opening.

    2. Inspect for oil leaks if the oil level is low.

  14. INSTALL REAR DIFFERENTIAL CARRIER COVER PLUG


    1. A01EM4S

      Using a 10 mm hexagon wrench, install a new gasket and the rear differential carrier cover plug.

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

  15. INSPECT FOR DIFFERENTIAL OIL LEAK

  16. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. A01EK8YE01

      Remove SST from the transfer.

      SST
      09325-20010

    2. Install the propeller with center bearing shaft assembly.

      Note


      • Be careful not to damage the oil seal.

      • Be careful not to damage the universal joint boot when installing the propeller shaft.

    3. A01EMABE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the rear propeller shaft and electromagnetic control coupling assembly and install the 4 nuts and 4 washers temporarily.

      Note

      Do not allow grease to adhere to be bolts or washers.

    4. A01EM4R

      Temporarily install the propeller with center bearing shaft assembly with the 4 bolts, 2 No. 1 center support bearing washers and 2 No. 2 center support bearing washers.

      Note


      • Reuse the washers.

      • Do not allow grease to adhere to be bolts or washers.

    5. A01EJS9E01

      Fully tighten the 4 nuts.

      Torque:
      37 N*m  { 379 kgf*cm, 27 ft.*lbf }

  17. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    SST
    09370-50010

    1. Remove the piece of cloth or equivalent from the universal joint.

    2. Depress the brake pedal and hold it.

    3. A01EKBT

      Using a hexagon wrench (6 mm), tighten the 6 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    4. A01EK2SE01

      With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft as shown in the illustration.

      Length A
      65.5 to 70.5 mm (2.579 to 2.776 in.)
    5. A01EJ81E02
      Text in Illustration
      *1 No. 1 Center Support Bearing Assembly
      *2 No. 2 Center Support Bearing Assembly

      With the vehicle unloaded, adjust the front and rear dimensions between the edge surface of the center support bearing and the edge surface of the cushion respectively as shown in the illustration, and then tighten the bolts.

      Length A
      11.5 to 13.5 mm (0.453 to 0.532 in.)

    6. Check that the center line of the bracket is at a right angle to the shaft axial direction.

    7. A01EM4R

      Fully tighten the 4 bolts.

      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }

  18. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. Install the center exhaust pipe assembly Click here.

  19. INSPECT AND ADJUST TRANSFER OIL


    1. Inspect and adjust transfer oil Click here.

  20. INSPECT FOR TRANSFER OIL LEAK