REAR DIFFERENTIAL CARRIER ASSEMBLY(w/o Differential Lock) REASSEMBLY

PROCEDURE


  1. ASSEMBLE DIFFERENTIAL CASE

    A01XHOM

    1. Install the rear differential side gear thrust washer to the rear differential side gear.

    2. Install the rear differential pinion thrust washer and rear differential pinion to the rear differential spider.

    3. Fix the differential case RH in place.

    4. A01XERY

      Install the rear differential side gear and rear differential spider to the differential case RH.

    5. A01XGHV

      Using a dial indicator, measure the differential case RH side backlash while pushing the pinion toward the case.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

    6. Remove the rear differential spider from the differential case RH.

    7. A01XH3H

      Install the rear differential side gear and rear differential spider to the differential case LH.

    8. Using a dial indicator, measure the differential case LH side backlash while pushing the pinion toward the case.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      If the backlash is not within the specification, install 2 side gear thrust washers of a different thickness.

      Standard Thrust Washer
      Thickness Thickness
      0.87 to 0.93 mm (0.0343 to 0.0366 in.) 1.17 to 1.23 mm (0.0461 to 0.0484 in.)
      0.97 to 1.03 mm (0.0382 to 0.0406 in.) 1.27 to 1.33 mm (0.0500 to 0.0524 in.)
      1.07 to 1.13 mm (0.0421 to 0.0445 in.) -
    9. B001D7YE09
      Text in Illustration
      *a Matchmark

      Align the matchmarks and assemble the differential case from the RH and LH cases.

    10. Using a plastic-faced hammer, install the differential case.

    11. Install the 8 bolts.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  2. INSTALL DIFFERENTIAL RING GEAR


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

    2. Heat the ring gear in water that is approximately 100°C (212°F).

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

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

    5. B001CTLE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the ring gear with that of the differential case.

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

      Adhesive
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
      Torque:
      97 N*m  { 985 kgf*cm, 71 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE BEARING

    B001GCEE01

    1. Using SST and a press, press the bearing onto the differential case.

      SST
      09308-14010
      09950-60010   ( 09951-00490 )

  4. INSPECT DIFFERENTIAL RING GEAR RUNOUT

    B001H53

    1. Install the differential case to the carrier and install the 2 plate washers so that there is no play in the bearing.

    2. Install the 2 bearing caps with the 4 bolts.

      Torque:
      103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

    3. Using a dial indicator, measure the runout of the ring gear.

      Maximum runout
      0.07 mm (0.00276 in.)

    4. Remove the 2 bearing caps, 2 plate washers and differential case.

  5. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    B001FNKE01

    1. Using SST and a press, press in the roller bearing (outer) to the carrier.

      SST
      09308-14010
      09309-14040

  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B001G7CE01

      Install the plate washer to the carrier.

      Tech Tips

      First, install a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

    2. Using SST and a press, press the roller bearing (outer) into the carrier.

      SST
      09950-70010   ( 09951-07200 )
      09255-10012

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    B001EIME16

    1. Using SST and a press, press the roller bearing (inner) onto the drive pinion.

      SST
      09309-14040

  8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

    B001DA4

    1. Install the drive pinion, rear drive pinion tapered roller bearing and rear differential drive pinion oil slinger.

      Tech Tips

      Install the spacer and oil seal after adjusting the gear contact pattern.

    2. B001GKM

      Using SST, install the companion flange.

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

      Note

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

    3. B001IJPE01

      Using a 30 mm socket wrench, adjust the drive pinion preload by tightening the companion flange nut.

    4. 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
      Limit Torque Value
      457 N*m (4660 kgf*cm, 337ft.*lbf) or less

      Note


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


      • Apply hypoid gear oil LSD to drive pinion thread and seat face.

    5. B001FHM

      Using a torque wrench, measure the preload.

      Standard Preload (at Starting)
      Item Specified Condition
      New bearing 0.68 to 2.03 N*m (6.94 to 20.7 kgf*cm, 6.02 to 17.9 in.*lbf)
      Used bearing 0.73 to 1.83 N*m (7.45 to 18.6 kgf*cm, 6.46 to 16.1 in.*lbf)

      Note

      For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

  9. INSTALL DIFFERENTIAL CASE ASSEMBLY

    A01XMR3

    1. Place the 2 bearing outer races on their respective bearings.

      Tech Tips

      Do not interchange the right and left races.

  10. ADJUST RING GEAR BACKLASH


    1. A01XJ5S

      Install the plate washer on the side without the ring gear teeth.

      Note

      Make sure that the ring gear has backlash.

    2. B001EMV

      Using a dial indicator, while holding the companion flange, measure the ring gear backlash.

      Standard backlash (reference)
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)
    3. A01XJ5S

      Select a plate washer for the side without the ring gear teeth using the backlash as a reference.

    4. A01XHY1

      Select a plate washer for the side with the ring gear teeth so that there is no clearance between the outer race and case.

    5. Using a plastic-faced hammer, install the plate washer for the side with the ring gear teeth.

    6. B001EMV

      Using a dial indicator, while holding the companion flange, measure the ring gear backlash.

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00787 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 case.

      • Make sure that there is ring gear backlash.

  11. ADJUST SIDE BEARING PRELOAD

    B001FED

    1. Remove the ring gear teeth side plate washer and, using a micrometer, measure the thickness.

    2. Using the backlash as a reference, select a new washer that is 0.05 to 0.20 mm (0.00197 to 0.00787 in.) thicker than the removed washer and, using a plastic-faced hammer, tap it in so that it fits against the bearing.

      Tech Tips

      Select a washer which can be pressed in 2/3 of the full amount with your finger.

    3. B001EMV

      Recheck the ring gear backlash.

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00788 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

      An approximately 0.02 mm (0.000787 in.) change in each plate washer results in a 0.03 mm (0.00118 in.) change in the backlash.

      Standard Washer
      Mark Thickness Mark Thickness
      70 2.05 to 2.07 mm (0.0808 to 0.0816 in.) 62 2.41 to 2.43 mm (0.0950 to 0.0957 in.)
      71 2.07 to 2.09 mm (0.0816 to 0.0823 in.) 63 2.43 to 2.45 mm (0.0957 to 0.0965 in.)
      72 2.09 to 2.11 mm (0.0823 to 0.0831 in.) 64 2.45 to 2.47 mm (0.0965 to 0.0973 in.)
      73 2.11 to 2.13 mm (0.0831 to 0.0839 in.) 65 2.47 to 2.49 mm (0.0972 to 0.0980 in.)
      74 2.13 to 2.15 mm (0.0839 to 0.0847 in.) 66 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
      75 2.15 to 2.17 mm (0.0847 to 0.0855 in.) 67 2.51 to 2.53 mm (0.0988 to 0.0996 in.)
      76 2.17 to 2.19 mm (0.0855 to 0.0863 in.) 68 2.53 to 2.55 mm (0.0996 to 0.1000 in.)
      77 2.19 to 2.21 mm (0.0863 to 0.0871 in.) 69 2.55 to 2.57 mm (0.1000 to 0.1012 in.)
      78 2.21 to 2.23 mm (0.0871 to 0.0879 in.) 01 2.57 to 2.59 mm (0.1012 to 0.1020 in.)
      79 2.23 to 2.25 mm (0.0879 to 0.0887 in.) 32 2.59 to 2.61 mm (0.1020 to 0.1028 in.)
      80 2.25 to 2.27 mm (0.0887 to 0.0894 in.) 33 2.61 to 2.63 mm (0.1028 to 0.1035 in.)
      81 2.27 to 2.29 mm (0.0894 to 0.0902 in.) 03 2.63 to 2.65 mm (0.1035 to 0.1043 in.)
      82 2.27 to 2.31 mm (0.0902 to 0.0891 in.) 34 2.65 to 2.67 mm (0.1043 to 0.1051 in.)
      83 2.31 to 2.33 mm (0.0910 to 0.0918 in.) 35 2.67 to 2.69 mm (0.1051 to 0.1059 in.)
      84 2.33 to 2.35 mm (0.0918 to 0.0926 in.) 05 2.69 to 2.71 mm (0.1059 to 0.1067 in.)
      85 2.35 to 2.37 mm (0.0926 to 0.0934 in.) 36 2.71 to 2.73 mm (0.1067 to 0.1075 in.)
      86 2.37 to 2.39 mm (0.0934 to 0.0942 in.) 37 2.73 to 2.75 mm (0.1075 to 0.1082 in.)
      87 2.39 to 2.41 mm (0.0942 to 0.0950 in.) 07 2.75 to 2.77 mm (0.1082 to 0.1091 in.)

  12. INSTALL BEARING CAP


    1. B001D53E05
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the cap and carrier.

    2. Install the 2 bearing caps with the 4 bolts.

      Torque:
      103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

      Tech Tips

      After rotating the ring gear 5 times or more, recheck the backlash.

  13. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. B001H53

      Using a dial indicator, measure the runout of the ring gear.

      Maximum runout
      0.07 mm (0.00276 in.)

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

  14. INSPECT TOTAL PRELOAD

    B001FHM

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

      Standard total preload (at starting)
      Drive pinion preload plus 0.20 to 0.40 N*m (2.0 to 4.1 kgf*cm, 1.8 to 3.5 in.*lbf)

      If necessary, disassemble and inspect the differential.

  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    A01XGLR

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

    2. Hold the companion flange firmly in place and rotate the ring gear in both directions.

    3. Inspect the tooth contact pattern.


      • B001E79E01
      • B001HRYE01
        Text in Illustration
        *1 Plate Washer
        *2 Rear Drive Pinion Rear Tapered Roller Bearing (Outer)

        If the teeth are not engaged properly, use the following chart to select a proper washer.

        Standard Plate Washer
        Mark Thickness Mark Thickness
        29 1.84 to 1.86 mm (0.0725 to 0.0732 in.) 53 2.08 to 2.10 mm (0.0819 to 0.0826 in.)
        31 1.86 to 1.88 mm (0.0733 to 0.0740 in.) 55 2.10 to 2.12 mm (0.0827 to 0.0834 in.)
        33 1.88 to 1.90 mm (0.0741 to 0.0748 in.) 57 2.12 to 2.14 mm (0.0835 to 0.0842 in.)
        35 1.90 to 1.92 mm (0.0749 to 0.0755 in.) 59 2.14 to 2.16 mm (0.0843 to 0.0850 in.)
        37 1.92 to 1.94 mm (0.0756 to 0.0763 in.) 61 2.16 to 2.18 mm (0.0851 to 0.0858 in.)
        39 1.94 to 1.96 mm (0.0764 to 0.0771 in.) 63 2.18 to 2.20 mm (0.0859 to 0.0866 in.)
        41 1.96 to 1.98 mm (0.0772 to 0.0779 in.) 65 2.20 to 2.22 mm (0.0867 to 0.0874 in.)
        43 1.98 to 2.00 mm (0.0780 to 0.0787 in.) 67 2.22 to 2.24 mm (0.0875 to 0.0881 in.)
        45 2.00 to 2.02 mm (0.0788 to 0.0795 in.) 69 2.24 to 2.26 mm (0.0882 to 0.0889 in.)
        47 2.02 to 2.04 mm (0.0796 to 0.0803 in.) 71 2.26 to 2.28 mm (0.0890 to 0.0897 in.)
        49 2.04 to 2.06 mm (0.0804 to 0.0811 in.) 73 2.28 to 2.30 mm (0.0898 to 0.0905 in.)
        51 2.06 to 2.08 mm (0.0812 to 0.0818 in.) 75 2.30 to 2.32 mm (0.0906 to 0.0913 in.)

  16. REMOVE REAR DRIVE PINION NUT

    B001GX2E22

    1. Using SST to hold the companion flange in place, remove the nut.

      SST
      09330-00021

  17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

    Click here

  20. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

    B001F2S

    1. Install a new bearing spacer to the drive pinion.

  22. INSTALL DIFFERENTIAL OIL STORAGE RING


    1. B001FERE01

      Using SST, tap in a new oil storage ring.

      SST
      09308-14010

  23. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

  24. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)

  25. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  26. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    B001EBCE01

    1. Apply MP grease to a new oil seal.

    2. Using SST and a hammer, tap in the oil seal.

      SST
      09554-30011
      Standard oil seal depth
      -0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

  27. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    B001GKME17

    1. Using SST, install the companion flange to the drive pinion.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )
      Text in Illustration
      *a Turn
      *b Hold

      Note

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

    2. B001COQE22

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

    3. 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
      Limit Torque Value
      457 N*m (4660 kgf*cm, 337ft.*lbf) or less

  28. INSPECT DRIVE PINION PRELOAD

    B001DWY

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

      Standard Preload (at Starting)
      Item Specified Condition
      New bearing 0.83 to 2.18 N*m (8.64 to 22.2 kgf*cm, 7.35 to 19.3 in.*lbf)
      Used bearing 0.88 to 1.98 N*m (8.97 to 20.2 kgf*cm, 7.79 to 17.5 in.*lbf)

      • If the result not as specified, replace the bearing spacer.


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

      Limit Torque Value
      457 N*m (4660 kgf*cm, 337ft.*lbf) or less

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

      Tech Tips

      Do not loosen the pinion nut to reduce the preload.

  29. INSPECT TOTAL PRELOAD


    1. B001FHM

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

      Standard total preload (at starting)
      Drive pinion preload plus 0.20 to 0.40 N*m (2.0 to 4.1 kgf*cm, 1.8 to 3.5 in.*lbf)

      If necessary, disassemble and inspect the differential.

  30. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    B001EMV

    1. Using a dial indicator, check the backlash of the ring gear.

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

      • If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.

        Tech Tips

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

  31. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    B001I47E47
    Text in Illustration
    *a Vertical Runout
    *b Lateral Runout

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

      Distance from center to runout measurement point
      30 mm (1.18 in.)
      Maximum Runout
      Item 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.

  32. STAKE DRIVE PINION NUT

    B001IIB

    1. Using a chisel and hammer, stake the nut.