REAR DIFFERENTIAL CARRIER ASSEMBLY(for LSD) DISASSEMBLY

PROCEDURE


  1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE


    1. B001Y41E40
      *1 Vertical Runout:
      *2 Lateral Runout:
      *3 35 mm (1.38 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.

  2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01X88S

      Using a dial indicator, measure the ring gear runout.

      Maximum runout
      0.05 mm (0.00197 in.)

      If the runout is more than the maximum, replace the ring gear.

  3. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01X7LZ

      Using a dial indicator, measure the ring gear backlash.

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      Tech Tips

      Measure at 3 or more positions around the circumference of the ring gear.

      If the backlash is not as specified, adjust the side bearing preload or repair as necessary.

  4. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT


    1. B001YKVE14

      Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. B001X9YE02

      Using SST to hold the flange, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

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


    1. B001YL0E02

      Using SST, remove the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )

  6. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. B001YN3E02

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

      SST
      09308-10010

  7. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  8. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B001Z8VE03

      Using SST, remove the front bearing (inner race) from the drive pinion.

      SST
      09556-22010

      If the front bearing is damaged or worn, replace the bearing.

  9. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01X9B2

      Remove the 2 bolts and 2 adjusting nut locks.

  10. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. B001WRQE06
      *1 Matchmark

      Place matchmarks on the bearing caps and differential carrier.

    2. Remove the 4 bolts, 2 bearing caps, 2 adjusting nuts and 2 bearings (outer race).

    3. B001VKLE01

      Remove the differential case from the differential carrier.

      Tech Tips

      Tag the 2 case bearing outer races to show the location for reassembly.

  11. REMOVE DIFFERENTIAL DRIVE PINION


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

  12. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  13. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B001Z0UE01

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

      SST
      09950-00020

      If either the drive pinion or ring gear is damaged, replace them as a set.

  14. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01X7BD

      Using a brass bar and hammer, tap out the bearing (outer race).

  16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01XAFU

      Using a brass bar and hammer, tap out the bearing (outer race).

  17. REMOVE DIFFERENTIAL RING GEAR


    1. B001Y7QE06
      *1 Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Remove the 12 ring gear set bolts.

    3. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

  18. INSPECT RUNOUT OF DIFFERENTIAL CASE

    Tech Tips

    If the ring gear runout is at the maximum or less (refer to the "Inspect Runout of Differential Ring Gear" procedure), this inspection is not necessary.


    1. Install the differential case to the differential carrier.

    2. A01X1OP

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.04 mm (0.00157 in.)

      If the runout is more than the maximum, replace the differential case and side bearings as a set.

    3. Remove the differential case from the differential carrier.

  19. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. B001YCAE02

      Using SST, remove the 2 side bearings (inner race) from the differential case.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00480 )

  20. DISASSEMBLE DIFFERENTIAL CASE


    1. B001XRVE10
      *1 Matchmark

      Place matchmarks on the differential case LH and RH.

    2. Remove the 8 bolts uniformly, a little at a time.

    3. Using a plastic-faced hammer, separate the differential case LH and RH.

    4. Remove the 2 side gears, 6 side gear thrust washers, 4 clutch plates, 2 spring retainers, compression spring, 4 pinion gears, 4 pinion gear thrust washers and spider from the differential case.

      Tech Tips


      • Keep the disassembled parts in order.

      • If the side gear backlash has been adjusted by a TOYOTA dealer, adjusting shims are installed between the side gear thrust washer and the differential case.

      If replacing a side gear, also replace the thrust washer that contacts it.

  21. INSPECT REAR DIFFERENTIAL SIDE GEAR THRUST WASHER

    Tech Tips

    If replacing the thrust washer, also replace the clutch plate that contacts it.


    1. A01X4H1

      Using a micrometer, check that the thickness of the thrust washer is even.

      Thickness (Reference)
      1.97 to 2.06 mm (0.0776 to 0.0811 in.)

      If necessary, replace the thrust washer.

    2. Visually check the thrust washer.

      If bare metal is showing, replace the thrust washer.

  22. INSPECT CLUTCH PLATE


    1. A01X9AG

      Using a micrometer, check that the thickness of the clutch plate is even.

      Thickness (Reference)
      1.97 to 2.03 mm (0.0776 to 0.0799 in.)

      If necessary, replace the clutch plate.

  23. INSPECT COMPRESSION SPRING


    1. A01X90X

      Using vernier caliper, measure the free length of the spring.

      Length (Reference)
      32.8 mm (1.29134 in.)

      If necessary, replace the compression spring.