FRONT DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CARRIER STRAIGHT PIN


    1. A01X0O7E04

      Using a plastic-faced hammer, tap in the straight pins until the protrusion height shown in the illustration is within the specification.

      Standard height (a)
      9.5 to 10.0 mm (0.374 to 0.393 in.)

  2. INSTALL FRONT DIFFERENTIAL TUBE STRAIGHT PIN


    1. A01X2UOE04

      Using a plastic-faced hammer, tap in the straight pins until the protrusion height shown in the illustration is within the specification.

      Standard height (a)
      9.5 to 10.0 mm (0.374 to 0.393 in.)

  3. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


    1. A01X0GVE01

      Using SST and a press, press in the bearing.

      SST
      09223-00010
    2. A01X1CY

      Using a snap ring expander, install a new snap ring.

  4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01X6OF

      Install the side gear shaft into the differential tube.

    2. Using snap ring pliers, install a new snap ring.

  5. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01X1H4E04

      Using SST and a plastic-faced hammer, tap in a new oil seal.

      SST
      09608-32010
      Standard oil seal depth
      4.8 to 5.8 mm (0.189 to 0.228 in.)

    2. Coat the lip of the oil seal with MP grease.

  6. INSTALL FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01X6QL

      Install the 2 side gear thrust washers onto the 2 side gears.

    2. Install the 2 side gears (with thrust washers), 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly.

      Tech Tips


      • Align the holes of the differential case assembly and pinion shaft.

      • Apply hypoid gear oil to each sliding surface and rotating part.

    3. Measure the side gear backlash.


      1. A01X5OI

        Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly.

        Standard backlash
        0.10 to 0.25 mm (0.00394 to 0.00984 in.)

        If the backlash is not within the specification, replace the 2 side gear thrust washers. Use the table below to select 2 thrust washers of the same thickness which will ensure that the backlash is within the specification.

        Standard Washer Thickness
        Part No. Specified Condition Part No. Specified Condition
        41361-34100 1.43 to 1.47 mm (0.0563 to 0.0578 in.) 41361-34150 1.68 to 1.72 mm (0.0662 to 0.0677 in.)
        41361-34110 1.48 to 1.52 mm (0.0583 to 0.0598 in.) 41361-34160 1.73 to 1.77 mm (0.0682 to 0.0696 in.)
        41361-34120 1.53 to 1.57 mm (0.0603 to 0.0618 in.) 41361-34170 1.78 to 1.82 mm (0.0701 to 0.0716 in.)
        41361-34130 1.58 to 1.62 mm (0.0622 to 0.0637 in.) 41361-34180 1.83 to 1.87 mm (0.0721 to 0.0736 in.)
        41361-34140 1.63 to 1.67 mm (0.0642 to 0.0657 in.) - -
    4. A01X4NX

      Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

    5. Stake the differential case.

  7. INSTALL DIFFERENTIAL RING GEAR


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

    2. Heat the ring gear to about 100°C (212°F) in boiling water.

    3. Carefully take the ring gear out of the boiling water.

    4. After the moisture on the ring gear has completely evaporated, quickly align the matchmarks on the ring gear and differential case and set the ring gear onto the differential case. Then temporarily install the 12 bolts so that the bolt holes in the ring gear and differential case are aligned.

    5. After the ring gear cools down sufficiently, remove the 12 bolts. Then apply adhesive to the 12 bolts and install them.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

  8. INSTALL FRONT DIFFERENTIAL CASE BEARING


    1. A01X97OE02

      Using SST and a press, press in the 2 bearings (inner race).

      SST
      09316-20011
      09316-60011   ( 09316-00041 )

  9. INSTALL FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

    When replacing the 2 differential case bearings, fit the thinnest washer to each bearing. When reusing the bearings, fit a washer of the same thickness as the one removed to each bearing.


    1. A01X9ZNE02
      Text in Illustration
      *1 Plate Washer

      Install a new plate washer to the shaft bearing retainer.

    2. Using SST and a press, press the bearing (outer race) into the differential cross shaft bearing retainer.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )
    3. A01X5S9E02
      Text in Illustration
      *1 Plate Washer

      Install a new plate washer to the differential carrier.

    4. Using SST and a press, press the bearing (outer race) into the differential carrier assembly.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )

  10. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A01X4SEE02

      Using SST, install the bearing (outer race).

      SST
      09950-60020   ( 09951-00810, 09951-00890 )

  11. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01XAPBE03
      Text in Illustration
      *1 Plate Washer

      Using SST, install the washer and bearing (outer race).

      SST
      09950-60020   ( 09951-00890, 09951-01030 )

      Tech Tips

      First use an washer that is the same thickness as the removed washer. If it is necessary to change the washer when adjusting the tooth contact, change to an washer of a different thickness.

  12. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01X2LME05

      Using SST and a press, press in the bearing (inner race).

      SST
      09506-35010

  13. INSTALL FRONT DIFFERENTIAL UNION


    1. A01XAYR

      Install the front differential union to the differential carrier.

  14. INSTALL FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01X0BN

      Install the 2 bolts and oil deflector.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  15. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

  16. INSTALL FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

  17. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. A01XA60E01

      Install the differential cross shaft bearing retainer and differential support with the 14 bolts.

      Torque:
      for bolt A
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
      for bolt B
      155 N*m  { 1581 kgf*cm, 114 ft.*lbf }

  18. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A01X11BE03

      Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

      SST
      09316-60011   ( 09316-00041 )

  19. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  20. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01X5NCE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

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

    2. Coat the threads of the nut with hypoid gear oil.

    3. A01X7AWE02

      Using SST to hold the companion flange in place, then slowly tighten the nut within the drive pinion preload adjustment range so that it reaches the specified drive pinion preload (at Starting).

      SST
      09330-00021   ( 09330-00030 )
      Limit Torque Value
      451 N*m (4599 kgf*cm, 333 ft.*lbf) or less

      Note

      As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.

    4. A01X7WP

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

      Standard Preload (at Starting)
      Bearing Specified Condition
      New 2.69 to 3.19 N*m (28 to 32 kgf*cm, 24 to 28 in.*lbf)
      Reused 1.86 to 2.17 N*m (19 to 22 kgf*cm, 17 to 19 in.*lbf)

      If necessary, disassemble and inspect the differential assembly.

  21. ADJUST BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION


    1. A01X04UE03

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

      SST
      09564-33010
      Standard backlash
      0.17 to 0.27 mm (0.00670 to 0.0106 in.)

      If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount.

      Tech Tips


      • There should be no clearance between the plate washer and differential case.

      • Make sure that there is ring gear backlash.

      Standard Washer Thickness
      Part No. Specified Condition Part No. Specified Condition
      90564-50238 1.49 to 1.51 mm (0.0587 to 0.0594 in.) 90564-50260 1.93 to 1.95 mm (0.0760 to 0.0767 in.)
      90564-50239 1.51 to 1.53 mm (0.0595 to 0.0602 in.) 90564-50261 1.95 to 1.97 mm (0.0768 to 0.0775 in.)
      90564-50240 1.53 to 1.55 mm (0.0603 to 0.0610 in.) 90564-50262 1.97 to 1.99 mm (0.0776 to 0.0783 in.)
      90564-50241 1.55 to 1.57 mm (0.0611 to 0.0618 in.) 90564-50263 1.99 to 2.01 mm (0.0784 to 0.0791 in.)
      90564-50242 1.57 to 1.59 mm (0.0619 to 0.0625 in.) 90564-50264 2.01 to 2.03 mm (0.0792 to 0.0799 in.)
      90564-50243 1.59 to 1.61 mm (0.0626 to 0.0633 in.) 90564-50265 2.03 to 2.05 mm (0.0800 to 0.0807 in.)
      90564-50244 1.61 to 1.63 mm (0.0634 to 0.0641 in.) 90564-50266 2.05 to 2.07 mm (0.0808 to 0.0814 in.)
      90564-50245 1.63 to 1.65 mm (0.0642 to 0.0649 in.) 90564-50267 2.07 to 2.09 mm (0.0815 to 0.0822 in.)
      90564-50246 1.65 to 1.67 mm (0.0650 to 0.0657 in.) 90564-50268 2.09 to 2.11 mm (0.0823 to 0.0830 in.)
      90564-50247 1.67 to 1.69 mm (0.0658 to 0.0665 in.) 90564-50269 2.11 to 2.13 mm (0.0831 to 0.0838 in.)
      90564-50248 1.69 to 1.71 mm (0.0666 to 0.0673 in.) 90564-50270 2.13 to 2.15 mm (0.0839 to 0.0846 in.)
      90564-50249 1.71 to 1.73 mm (0.0674 to 0.0681 in.) 90564-50271 2.15 to 2.17 mm (0.0847 to 0.0854 in.)
      90564-50250 1.73 to 1.75 mm (0.0682 to 0.0688 in.) 90564-50272 2.17 to 2.19 mm (0.0855 to 0.0862 in.)
      90564-50251 1.75 to 1.77 mm (0.0689 to 0.0696 in.) 90564-50273 2.19 to 2.21 mm (0.0863 to 0.0870 in.)
      90564-50252 1.77 to 1.79 mm (0.0697 to 0.0704 in.) 90564-50274 2.21 to 2.23 mm (0.0871 to 0.0877 in.)
      90564-50253 1.79 to 1.81 mm (0.0705 to 0.0712 in.) 90564-50275 2.23 to 2.25 mm (0.0878 to 0.0885 in.)
      90564-50254 1.81 to 1.83 mm (0.0713 to 0.0720 in.) 90564-50276 2.25 to 2.27 mm (0.0886 to 0.0893 in.)
      90564-50255 1.83 to 1.85 mm (0.0721 to 0.0728 in.) 90564-50277 2.27 to 2.29 mm (0.0894 to 0.0901 in.)
      90564-50256 1.85 to 1.87 mm (0.0729 to 0.0736 in.) 90564-50278 2.29 to 2.31 mm (0.0902 to 0.0909 in.)
      90564-50257 1.87 to 1.89 mm (0.0737 to 0.0744 in.) 90564-50279 2.31 to 2.33 mm (0.0910 to 0.0917 in.)
      90564-50258 1.89 to 1.91 mm (0.0745 to 0.0751 in.) 90564-50280 2.33 to 2.35 mm (0.0918 to 0.0925 in.)
      90564-50259 1.91 to 1.93 mm (0.0752 to 0.0759 in.) - -

  22. INSPECT TOTAL PRELOAD


    1. A01X7WP

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

      Standard Total Preload (at Starting)
      Bearing Specified Condition
      New 4.30 to 5.60 N*m (44 to 57 kgf*cm, 39 to 49 in.*lbf)
      Reused 3.19 to 4.30 N*m (33 to 43 kgf*cm, 29 to 38 in.*lbf)

      If necessary, disassemble and inspect the differential.

  23. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. Remove the bearing retainer and differential case.

    2. A01X6QM

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

    3. Install the differential case to the differential carrier.

    4. A01XA60E01

      Install the differential cross shaft bearing retainer and front differential front support assembly LH with the 14 bolts.

      Torque:
      for bolt A
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
      for bolt B
      155 N*m  { 1581 kgf*cm, 114 ft.*lbf }

    5. Hold the companion flange firmly and rotate it in both directions.

    6. Remove the 14 bolts, differential case, cross shaft bearing retainer and front support.

    7. Inspect the tooth contact pattern.

      A01X5XOE06
      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 the ring gear (*e, *f) - -

      If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction.

      Standard Washer Thickness
      Part No. Specified Condition Part No. Specified Condition
      90564-63065 1.815 to 1.835 mm (0.0715 to 0.0722 in.) 90564-63076 2.065 to 2.085 mm (0.0813 to 0.0820 in.)
      90564-63066 1.840 to 1.860 mm (0.0725 to 0.0732 in.) 90564-63077 2.090 to 2.110 mm (0.0823 to 0.0830 in.)
      90564-63067 1.865 to 1.885 mm (0.0735 to 0.0742 in.) 90564-63078 2.115 to 2.135 mm (0.0833 to 0.0840 in.)
      90564-63068 1.890 to 1.910 mm (0.0744 to 0.0751 in.) 90564-63079 2.140 to 2.160 mm (0.0843 to 0.0850 in.)
      90564-63069 1.915 to 1.935 mm (0.0754 to 0.0761 in.) 90564-63080 2.165 to 2.185 mm (0.0853 to 0.0860 in.)
      90564-63070 1.940 to 1.960 mm (0.0764 to 0.0771 in.) 90564-63081 2.190 to 2.210 mm (0.0863 to 0.0870 in.)
      90564-63071 1.965 to 1.985 mm (0.0774 to 0.0781 in.) 90564-63082 2.215 to 2.235 mm (0.0872 to 0.0879 in.)
      90564-63072 1.990 to 2.010 mm (0.0784 to 0.0791 in.) 90564-63083 2.240 to 2.260 mm (0.0882 to 0.0889 in.)
      90564-63074 2.015 to 2.035 mm (0.0794 to 0.0801 in.) 90564-63084 2.265 to 2.285 mm (0.0892 to 0.0899 in.)
      90564-63075 2.040 to 2.060 mm (0.0804 to 0.0811 in.) - -

  24. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  25. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  26. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

    Click here

  27. REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

    Click here

  28. REMOVE DIFFERENTIAL DRIVE PINION

    Click here

  29. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING

  30. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. Install a new bearing spacer.

  31. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

  32. INSTALL NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

  33. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and shaft bearing retainer.

    2. Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

    3. A01X87ME04
      Text in Illustration
      *a 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
      Seal Diameter (A)
      2.0 to 3.0 mm (0.0788 to 0.118 in.)

      Tech Tips

      Install the cross shaft bearing retainer within 10 minutes of applying seal packing.

    4. A01XA60E01

      Install the front differential cross shaft bearing retainer and front differential front support assembly LH with the 11 bolts (A) and 3 new bolts (B).

      Torque:
      for bolt A
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
      for bolt B
      155 N*m  { 1581 kgf*cm, 114 ft.*lbf }

      Note

      Do not add oil or drive the vehicle immediately after installing the retainer, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.

  34. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A01X6FEE02

      Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

      SST
      09316-60011   ( 09316-00041 )

  35. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  36. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01WZYRE02

      Using SST and a hammer, tap in a new oil seal.

      SST
      09502-12010
      09316-60011   ( 09316-00041 )
      Standard oil seal depth
      5.6 to 6.6 mm (0.221 to 0.259 in.)

    2. Coat the lip of the oil seal with MP grease.

  37. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01X5NCE03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

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

  38. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. Coat the threads of a new nut with hypoid gear oil.

    2. A01X7AWE02

      Using SST to hold the companion flange in place, then slowly tighten the nut within the drive pinion preload adjustment range so that it reaches the specified drive pinion preload (at Starting).

      SST
      09330-00021   ( 09330-00030 )
      Limit Torque Value
      451 N*m (4599 kgf*cm, 333 ft.*lbf) or less
    3. A01X7WP

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

      Standard Preload (at Starting)
      Bearing Specified Condition
      New 3.05 to 3.55 N*m (32 to 36 kgf*cm, 27 to 31 in.*lbf)
      Reused 2.22 to 2.53 N*m (23 to 25 kgf*cm, 20 to 22 in.*lbf)

      If the preload is more than the specification, replace the bearing spacer.

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

      Torque:
      451 N*m  { 4599 kgf*cm, 333 ft.*lbf }
      or less

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

      Tech Tips

      Do not loosen the nut to reduce the preload.

  39. INSPECT TOTAL PRELOAD


    1. A01X7WP

      With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure the total preload.

      Standard Total Preload (at Starting)
      Bearing Specified Condition
      New 4.66 to 5.96 N*m (48 to 60 kgf*cm, 42 to 52 in.*lbf)
      Reused 3.55 to 4.66 N*m (37 to 47 kgf*cm, 32 to 41 in.*lbf)

  40. INSPECT BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION


    1. A01X04UE03

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

      SST
      09564-33010
      Standard backlash
      0.17 to 0.27 mm (0.00670 to 0.0106 in.)

  41. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01WZGPE03
      Text in Illustration
      *a Vertical Runout
      *b Lateral Runout
      *c 55 mm (2.17 in.)

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

      Maximum Runout
      Runout Specified Condition
      Vertical runout 0.10 mm (0.00394 in.)
      Lateral runout 0.10 mm (0.00394 in.)

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

  42. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A01X9PM

      Using a chisel and hammer, stake the nut.

  43. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01X1GUE02

      Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end.

      SST
      09608-32010

    2. Coat the lip of the oil seal with MP grease.

      Standard oil seal depth
      -0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

  44. INSTALL DIFFERENTIAL EXTENSION FLANGE TUBE


    1. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and bearing retainer.

    2. Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

    3. A01X52KE05
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the bearing retainer as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal Diameter (A)
      2.0 to 3.0 mm (0.0788 to 0.118 in.)

      Tech Tips

      Install the differential tube within 10 minutes of applying seal packing.

    4. Install the differential tube to the bearing retainer.

    5. A01X7IE

      Install 4 new bolts.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
      or less

      Note

      Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.