REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY


  1. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Install the 2 rear No. 1 differential side gear thrust washers to the 2 differential side gears.

      Note


      • Make sure that there is no foreign matter on or cracks and chips in the rear No. 1 differential side gear thrust washers, differential side gears and differential pinion gears, before installation.

      • When replacing a differential side gear or differential pinion gears, replace both sides as one set.

      • Apply sufficient hypoid gear oil to any sliding or rotating parts.

    2. Install the 2 differential side gears, 2 differential pinion gears, 2 rear differential pinion thrust washers and rear differential pinion shaft in the differential case.

      Tech Tips

      Align the holes of the differential case and rear differential pinion shaft.

    3. A01EKV7

      Measure the differential side gear backlash while holding a differential pinion gear toward the differential case.

      Backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      If the backlash is not within the specification, install the 2 rear No. 1 differential side gear thrust washers with different thicknesses.

      Tech Tips

      Refer to the table below and select 2 rear No. 1 differential side gear thrust washers which ensure that the backlash is within the specification.

      Rear No. 1 Differential Side Gear Thrust Washer
      Thickness mm (in.) Thickness mm (in.)
      1.48 to 1.52 (0.0583 to 0.0598) 1.63 to 1.67 (0.0642 to 0.0657)
      1.53 to 1.57 (0.0602 to 0.0618) 1.68 to 1.72 (0.0661 to 0.0677)
      1.58 to 1.62 (0.0622 to 0.0638) 1.73 to 1.77 (0.0681 to 0.0697)
    4. A01EJKO

      Using a pin punch (3 mm) and a hammer, install the rear differential pinion shaft pin through the differential case and hole of the rear differential pinion shaft.

    5. Using a chisel and a hammer, stake the outside of the differential case pin hole.

  2. INSTALL DIFFERENTIAL RING GEAR


    1. A01EMJIE03
      Text in Illustration
      *1 Boiling Water

      Clean the contact surfaces of the differential case and differential ring gear.

    2. Heat the differential ring gear in boiling water.

    3. Carefully remove the differential ring gear from the boiling water.

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

    5. A01EIQ9E06
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the rear differential case and differential ring gear, and install the differential ring gear.

    6. Temporarily install 10 new bolts.

    7. After the differential ring gear cools down sufficiently, tighten the 10 bolts uniformly at a time.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

      Note


      • The new bolts are coated with heat resistant oil. Do not wash it off.

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

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

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01EJEGE02

      Using SST and a press, install the rear differential case bearing (RH side inner race) to the rear differential case sub-assembly.

      SST
      09223-46011

      If the rear differential case bearing (RH side inner race) is damaged, replace it with a new one.

  4. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01EJRAE02

      Using SST and a press, install the rear differential case bearing (LH side inner race) to the rear differential case sub-assembly.

      SST
      09223-46011

      If the rear differential case bearing (LH side inner race) is damaged, replace it with a new one.

  5. INSTALL STRAIGHT PIN


    1. Using a plastic hammer, install the 4 straight pins to the differential carrier.

      A01EJRQE01
      (A)
      8 to 9 mm (0.315 to 0.354 in.)

    2. Thoroughly remove oil and water from the surface of the rear differential case sub-assembly that will face the differential ring gear.

  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01EKKBE02

      Using SST, bolts, nuts and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier.

      SST
      09950-60010   ( 09951-00540, 09951-00620 )
      09950-60020   ( 09951-00680 )

      Tech Tips

      Use M12 x P1.25 bolts with shaft lengths of 186 mm (7.32 in.) (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for installation.

  7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01EKVGE02

      Using SST, bolts, nuts and washers, install the rear drive pinion front tapered roller bearing (outer race) to the rear differential carrier.

      SST
      09950-60010   ( 09951-00490, 09951-00540, 09951-00620 )
      09950-60020   ( 09951-00680 )

      Tech Tips

      Use M12 x P1.25 bolts with shaft lengths of 186 mm (7.32 in.) (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for installation.

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the rear differential drive pinion plate washer to the differential drive pinion.

      Note

      Install each rear differential drive pinion washer to the position it was removed from.

    2. A01EKJ2E01

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

      SST
      09316-60011   ( 09316-00071 )

  9. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01EMKVE02
      Text in Illustration
      *1 Outer Race
      *2 Washer

      Using SST and a press, install the rear differential side gear shaft plate washer and rear differential case bearing (RH side outer race) to the rear differential carrier.

      SST
      09950-60010   ( 09951-00580, 09952-06010 )
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07100 )

      Note


      • Install each rear differential side gear shaft plate washer to the position it was removed from.

      • When replacing a rear differential case bearing, replace the inner and outer races as a set.

      • Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

  10. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01EJY5E02
      Text in Illustration
      *1 Washer
      *2 Outer Race

      Using SST and a press, install the rear differential side gear shaft plate washer and rear differential case bearing (LH side outer race) to the differential side bearing retainer.

      SST
      09950-60010   ( 09951-00580, 09952-06010 )
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07100 )

      Note


      • Install each rear differential side gear shaft plate washer to the position it was removed from.

      • When replacing a rear differential case bearing, replace the inner and outer races as a set.

      • Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

  11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. Install the differential drive pinion with rear drive pinion rear tapered roller bearing (inner race) to the rear differential carrier.

    2. Install the rear drive pinion front tapered roller bearing (inner race) and a new rear drive pinion nut to the differential drive pinion.

      Note


      • New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

      • If reusing a bearing, coat it with hypoid gear oil API GL-5.

    3. A01EMEGE04

      Using SST, gradually tighten the rear drive pinion nut until the specified preload is reached. Do not exceed the torque limit shown below.

      SST
      09564-16020
      Torque:
      without SST
      245 N*m  { 2498 kgf*cm, 181 ft.*lbf, or less }
      with SST
      223 N*m  { 2274 kgf*cm, 164 ft.*lbf, or less }

      Note

      Tighten the rear drive pinion nut gradually. Never tighten it excessively.

      Tech Tips

      Use a torque wrench with a fulcrum length of 500 mm (1.64 ft.).

    4. A01EJ5UE01

      Using SST and a torque wrench, measure the differential drive pinion preload (starting torque) of the differential drive pinion.

      SST
      09556-16011
      Standard drive pinion preload (New bearing)
      0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
      Standard drive pinion preload (Reused bearing)
      0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)

      Note


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

      • Record the preload measurement for use with the total preload measurement.

  12. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.

      Note

      Do not scratch the installation surface.

    2. A01EJ0F

      Install the rear differential case sub-assembly to the rear differential carrier.

    3. Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

  13. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. Insert a dial indicator and magnetic base through the rear differential filler plug hole and set it perpendicular to a ring gear tooth surface's tip.

    2. Using SST, hold the drive pinion in place.

      SST
      09556-16011
    3. A01EIT3E02

      Using SST, rotate the rear differential case forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.10 to 0.22 mm (0.00394 to 0.00866 in.)

      Note

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

    4. If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

      Tech Tips


      • When the backlash is smaller than the specified value, select a thick rear differential side gear shaft plate washer for the RH side and thin rear differential side gear shaft plate washer for the LH side.

      • When the backlash is larger than the specified value, select a thin rear differential side gear shaft plate washer for the RH side and thick rear differential side gear shaft plate washer for the LH side.

      Rear Differential Side Gear Shaft Plate Washer
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      25 1.59 to 1.61 (0.0626 to 0.0634) 43 2.13 to 2.15 (0.0839 to 0.0846)
      26 1.62 to 1.64 (0.0638 to 0.0646) 44 2.16 to 2.18 (0.0850 to 0.0858)
      27 1.65 to 1.67 (0.0650 to 0.0657) 45 2.19 to 2.21 (0.0862 to 0.0870)
      28 1.68 to 1.70 (0.0661 to 0.0669) 46 2.22 to 2.24 (0.0874 to 0.0882)
      29 1.71 to 1.73 (0.0673 to 0.0681) 47 2.25 to 2.27 (0.0886 to 0.0894)
      30 1.74 to 1.76 (0.0685 to 0.0693) 48 2.28 to 2.30 (0.0898 to 0.0906)
      31 1.77 to 1.79 (0.0697 to 0.0705) 49 2.31 to 2.33 (0.0909 to 0.0917)
      32 1.80 to 1.82 (0.0709 to 0.0717) 50 2.34 to 2.36 (0.0921 to 0.0929)
      33 1.83 to 1.85 (0.0720 to 0.0728) 51 2.37 to 2.39 (0.0933 to 0.0941)
      34 1.86 to 1.88 (0.0732 to 0.0740) 52 2.40 to 2.42 (0.0945 to 0.0953)
      35 1.89 to 1.91 (0.0744 to 0.0752) 53 2.43 to 2.45 (0.0957 to 0.0965)
      36 1.92 to 1.94 (0.0756 to 0.0764) 54 2.46 to 2.48 (0.0969 to 0.0976)
      37 1.95 to 1.97 (0.0768 to 0.0776) 55 2.49 to 2.51 (0.0980 to 0.0988)
      38 1.98 to 2.00 (0.0780 to 0.0787) 56 2.52 to 2.54 (0.0992 to 0.1000)
      39 2.01 to 2.03 (0.0791 to 0.0799) 57 2.55 to 2.57 (0.1004 to 0.1012)
      40 2.04 to 2.06 (0.0803 to 0.0811) 58 2.58 to 2.60 (0.1016 to 0.1024)
      41 2.07 to 2.09 (0.0815 to 0.0823) 59 2.61 to 2.63 (0.1028 to 0.1035)
      42 2.10 to 2.12 (0.0827 to 0.0835) 60 2.64 to 2.66 (0.1039 to 0.1047)

  14. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. Remove the 10 bolts and the differential side bearing retainer.

    2. Remove the differential case sub-assembly from the rear differential carrier.

    3. Coat 3 or 4 teeth at 4 different positions on the differential ring gear with Prussian blue.

    4. Install the differential case sub-assembly to the rear differential carrier.

    5. Install the differential side bearing retainer with the 10 bolts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

    6. Turn the differential drive pinion several times.

    7. Remove the 10 bolts and the differential side bearing retainer.

    8. Inspect the tooth contact pattern.

      Note

      Check the tooth contact pattern at 2 or more positions on the circumference of the differential ring gear.

      A01EKNJE03

    9. Perform the following procedure for face or flank contact:


      1. If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

      2. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

        Tech Tips

        If the tooth contact pattern is not correct, reselect rear differential side gear shaft plate washers and reinspect the tooth contact pattern.

      3. Repeat the differential ring gear and differential drive pinion backlash inspection.

        Tech Tips

        If the differential ring gear and differential drive pinion backlash are not as specified, replace the differential ring gear and differential drive pinion with new ones.

    10. Perform the following procedure for heel or toe contact:


      1. A01EIWYE02
        Text in Illustration
        *1 Plate Washer

        Select a rear differential drive pinion plate washer again and install the rear drive pinion rear tapered roller bearing (inner race).

        Rear Differential Drive Pinion Plate Washer
        Mark Thickness mm (in.) Mark Thickness mm (in.)
        41 1.695 to 1.705 (0.0667 to 0.0671) 71 1.955 to 1.965 (0.0770 to 0.0774)
        42 1.705 to 1.715 (0.0671 to 0.0675) 72 1.965 to 1.975 (0.0774 to 0.0778)
        43 1.715 to 1.725 (0.0675 to 0.0679) 73 1.975 to 1.985 (0.0778 to 0.0781)
        44 1.725 to 1.735 (0.0679 to 0.0683) 74 1.985 to 1.995 (0.0781 to 0.0785)
        45 1.735 to 1.745 (0.0683 to 0.0687) 75 1.995 to 2.005 (0.0785 to 0.0789)
        46 1.745 to 1.755 (0.0687 to 0.0691) 76 2.005 to 2.015 (0.0789 to 0.0793)
        47 1.755 to 1.765 (0.0691 to 0.0695) 77 2.015 to 2.025 (0.0793 to 0.0797)
        48 1.765 to 1.775 (0.0695 to 0.0699) 78 2.025 to 2.035 (0.0797 to 0.0801)
        49 1.775 to 1.785 (0.0699 to 0.0703) 79 2.035 to 2.045 (0.0801 to 0.0805)
        50 1.785 to 1.795 (0.0703 to 0.0707) 80 2.045 to 2.055 (0.0805 to 0.0809)
        51 1.795 to 1.805 (0.0707 to 0.0711) 81 2.055 to 2.065 (0.0809 to 0.0813)
        52 1.805 to 1.815 (0.0711 to 0.0715) 82 2.065 to 2.075 (0.0813 to 0.0817)
        53 1.815 to 1.825 (0.0715 to 0.0719) 83 2.075 to 2.085 (0.0817 to 0.0821)
        54 1.825 to 1.835 (0.0719 to 0.0722) 84 2.085 to 2.095 (0.0821 to 0.0825)
        55 1.835 to 1.845 (0.0722 to 0.0726) 85 2.095 to 2.105 (0.0825 to 0.0829)
        56 1.845 to 1.855 (0.0726 to 0.0730) 86 2.105 to 2.115 (0.0829 to 0.0833)
        57 1.855 to 1.865 (0.0730 to 0.0734) 87 2.115 to 2.125 (0.0833 to 0.0837)
        58 1.865 to 1.875 (0.0734 to 0.0738) 88 2.125 to 2.135 (0.0837 to 0.0841)
        59 1.875 to 1.885 (0.0738 to 0.0742) 89 2.135 to 2.145 (0.0841 to 0.0844)
        60 1.885 to 1.895 (0.0742 to 0.0746) 90 2.145 to 2.155 (0.0844 to 0.0848)
        61 1.895 to 1.905 (0.0746 to 0.0750) 91 2.155 to 2.165 (0.0848 to 0.0852)
        62 1.905 to 1.915 (0.0750 to 0.0754) 92 2.165 to 2.175 (0.0852 to 0.0856)
        63 1.915 to 1.925 (0.0754 to 0.0758) 93 2.175 to 2.185 (0.0856 to 0.0860)
        64 1.925 to 1.935 (0.0758 to 0.0762) 94 2.185 to 2.195 (0.0860 to 0.0864)
        65 1.935 to 1.945 (0.0762 to 0.0766) 95 2.195 to 2.205 (0.0864 to 0.0868)
        70 1.945 to 1.955 (0.0766 to 0.0770) - -

  15. MEASURE TOTAL PRELOAD


    1. A01EMODE01

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

      SST
      09556-16011
      Standard total preload (New bearing)
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
      Standard total preload (Reused bearing)
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:


      1. Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

      2. Repeat the total preload measurement.

      3. Repeat the differential ring gear backlash inspection.

      4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

  16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the rear differential case sub-assembly from the rear differential carrier.

  17. REMOVE DIFFERENTIAL DRIVE PINION


    1. Remove the differential drive pinion from the rear differential carrier.

  18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01ELFI

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

      Note

      Face the smaller inside diameter towards the front of the vehicle.

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01EK6W

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

  20. INSTALL DIFFERENTIAL DRIVE PINION


    1. A01EJXS

      Install the differential drive pinion and rear drive pinion front tapered roller bearing (inner race) to the differential carrier.

  21. INSTALL REAR DRIVE PINION NUT


    1. Apply hypoid gear oil LSD to the threads of a new rear drive pinion nut.

    2. A01EMEGE04

      Install the new rear drive pinion nut to the differential drive pinion. Using SST, tighten the new rear drive pinion nut while confirming the preload.

      SST
      09564-16020
      Torque:
      without SST
      245 N*m  { 2498 kgf*cm, 181 ft.*lbf, or less }
      with SST
      223 N*m  { 2274 kgf*cm, 164 ft.*lbf, or less }

      Tech Tips

      Use a torque wrench with a fulcrum length of 500 mm (1.64 ft.).

  22. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01EJ5UE02

      Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque).

      SST
      09556-16011
      Standard drive pinion preload (New bearing)
      0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
      Standard drive pinion preload (Reused bearing)
      0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)

      Note

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

    2. A01EKTFE03

      If the preload is insufficient, use SST to tighten the rear drive pinion nut 5 to 10° at a time. Measure the preload and repeat the adjustment as necessary until the preload matches the specified torque.

    3. If the tightening torque of the rear drive pinion nut exceeds 245 N*m (2498 kgf*cm, 181 ft.*lbf) but the preload is still insufficient, loosen the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.

    4. If there is no defect, replace the rear differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

  23. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01EJ0F

      Install the rear differential case sub-assembly to the rear differential carrier.

  24. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. A01EJAK

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

  25. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011
    3. A01EIT3E02

      Using SST, rotate the rear differential case sub-assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.10 to 0.22 mm (0.00394 to 0.00866 in.)
      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

      Note

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

  26. MEASURE TOTAL PRELOAD


    1. A01EMODE03

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

      SST
      09556-16011
      Standard total preload (New bearing)
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
      Standard total preload (Reused bearing)
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:


      1. Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

      2. Repeat the total preload measurement.

      3. Repeat the differential ring gear backlash inspection.

      4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

  27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. Remove the 10 bolts and differential side bearing retainer.

    2. A01ELDWE01

      Install the 2 bolts and rear differential breather plug oil deflector to the differential side bearing retainer.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }
    3. A01EM7ME01

      Using SST and a hammer, tap in the rear differential carrier cover breather plug to the differential side bearing retainer.

      SST
      09612-10093   ( 09612-10061 )

    4. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.

      Note

      Do not damage the installation surface.

    5. A01ELPTE01

      Apply seal packing to the areas indicated in the illustration of the differential side bearing retainer.

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

      Note


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

      • 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.

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

      • Perform the installation within 3 minutes after applying seal packing.

      • Start applying seal packing within range (A).

    6. A01EJAK

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Note

      After installing the differential side bearing retainer, do not immediately add oil or drive the vehicle for at least 1 hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.

  28. INSPECT TOTAL PRELOAD


    1. A01EJUUE01

      Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09556-16011
      Standard total preload (New bearing)
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
      Standard total preload (Reused bearing)
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

      Note

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before inspection.

  29. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.

    2. Using SST, hold the drive pinion in place.

      SST
      09556-16011
    3. A01EIT3E02

      Using SST, rotate the rear differential case sub-assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.10 to 0.22 mm (0.00394 to 0.00866 in.)

      Note

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

  30. INSTALL REAR DRIVE PINION NUT


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

  31. INSTALL DIFFERENTIAL PRESSURE CONTROL HOSE ELBOW


    1. A01EKK1E02
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the 2 differential pressure control hose elbows and rear differential carrier assembly.

  32. INSTALL DIFFERENTIAL PRESSURE CONTROL HOSE


    1. A01EMEUE02
      Text in Illustration
      *1 Clip

      Using the 2 differential pressure control hose clips, install the differential pressure control hose to the 2 differential pressure control hose elbows in the order shown in the illustration.

      Note


      • Be sure to install the clips in the direction shown in the illustration.

      • Confirm that the differential pressure control hose and the differential pressure control hose clips do not interfere with other parts.

      • Confirm that the differential pressure control hose is not cracked.

  33. INSTALL DIAPHRAGM OIL SEAL


    1. A01EKDQE02
      Text in Illustration
      *1 Oil Seal

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

      SST
      09506-35010
      09554-22010
      Diaphragm oil seal driven in depth
      0.7 to 1.3 mm (0.0276 to 0.0512 in.)

      Note


      • Tap the diaphragm oil seal uniformly so that it is driven in straight.

      • Do not excessively tap the diaphragm oil seal.

    2. Apply a light coat of MP grease to the lip of the new diaphragm oil seal.

  34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01EJ2LE01
      Text in Illustration
      *1 Oil Seal
      *a Oil Seal Drive in Depth

      Using SST and a hammer, install 2 new rear differential side gear shaft oil seals into the rear differential carrier and differential side bearing retainer.

      SST
      09517-30010
      09631-32020
      Oil seal drive in depth
      6.8 to 7.8 mm (0.268 to 0.307 in.)

      Note


      • Tap the rear differential side gear shaft oil seal uniformly so that it is driven in straight.

      • Do not excessively tap the rear differential side gear shaft oil seal.

    2. Apply a light coat of MP grease to the lip of the 2 new rear differential side gear shaft oil seals.

  35. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01EK68E02
      Text in Illustration
      *1 Block

      Using SST and a press, install the rear differential dust deflector.

      SST
      09518-36020
      09950-70010   ( 09951-07150 )

      Note


      • Be sure to press in the rear differential dust deflector until it contacts the bearing end surface.

      • Do not damage the end surface of the electro magnetic control coupling sub-assembly.

  36. INSTALL CONNECTOR CLAMP BRACKET


    1. A01EJ9Q

      Install the connector clamp bracket with the bolt.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }

      Note

      Do not damage the electro magnetic control coupling wire harness.

    2. Install the connector with the claw.

  37. 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.

  38. 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.

      Note


      • Install the transmission coupling conical spring washer so that the marked surface faces the front of the vehicle (coupling side).

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

  39. 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 scratch the installation area.

    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.

    3. A01EKT0E01

      Apply seal packing to the areas indicated in the illustration of the electro magnetic control coupling sub-assembly.

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

      Note


      • 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.

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

      • Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing.

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

      Tech Tips


      • (B) : 1.0 mm (0.0394 in.)

      • (C) : 2.0 mm (0.0787 in.)

      • (D) : 3.0 mm (0.118 in.)

      • (E) : 5.0 mm (0.197 in.)

    4. Apply hypoid gear oil to the splines of the rear drive pinion.

    5. A01EM9O

      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 electro magnetic control coupling sub-assembly.

  40. INSTALL REAR DIFFERENTIAL FILLER PLUG


    1. A01ELIW

      Install a new gasket with the rear differential filler plug (inspection plug).

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

  41. INSPECT ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A01EKUHE01

      Install a dial indicator and magnetic base so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.

    2. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

      SST
      09564-32011
      Maximum runout
      0.065 mm (0.00255 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

    3. Install a dial indicator and magnetic base so that it is perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

    4. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

      SST
      09564-32011
      Maximum runout
      0.073 mm (0.00287 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

  42. INSTALL STUD BOLT


    1. Temporarily install 4 new stud bolts to the electro magnetic control coupling sub-assembly.

    2. A01EJ8UE10
      Text in Illustration
      *1 Hold
      *2 Turn
      *3 Upper Nut
      *4 Lower Nut

      Install 2 service nuts to the stud bolt.

      Recommended service nut
      Thread diameter
      8 mm (0.3150 in.)
      Thread pitch
      1.25 mm (0.0492 in.)

    3. Lock the upper nut using the lower nut.

    4. A01EMD9E02

      Turn the upper nut and tighten the other 3 stud bolts to the electro magnetic control coupling sub-assembly in the same way.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      (A)
      29.1 to 32.3 mm (1.15 to 1.27 in.)

      Tech Tips

      If the threads of the electro magnetic control coupling sub-assembly are damaged while installing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

  43. REMOVE DIFFERENTIAL CARRIER ASSEMBLY


    1. Remove the differential carrier assembly from the overhaul attachment.