REAR DIFFERENTIAL CARRIER ASSEMBLY(w/ Differential Lock) REASSEMBLY

PROCEDURE


  1. INSTALL DIFFERENTIAL CASE ASSEMBLY

    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
      0.88 to 0.92 mm (0.0346 to 0.0362 in.) 1.18 to 1.22 mm (0.0465 to 0.0480 in.)
      0.98 to 1.02 mm (0.0386 to 0.0402 in.) 1.28 to 1.32 mm (0.0504 to 0.0520 in.)
      1.08 to 1.12 mm (0.0425 to 0.0441 in.) -
    9. B001G5HE13
      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:
      47.1 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 to approximately 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 install the ring gear to the differential case.

    5. B001CTLE16
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the ring gear and 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:
      96.6 N*m  { 985 kgf*cm, 71 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. B001GCEE01

      Using SST and a press, install the bearing to the differential case.

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

  4. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. A01XEEF

      Install the differential case to the carrier, and then install the 2 adjusting nuts so that there is no play in the bearing.

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

      Torque:
      102.9 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 adjusting nuts and differential case.

  5. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B001FNKE01

      Using SST and a press, install the tapered roller bearing to the carrier.

      SST
      09308-14010
      09309-14040

  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)


    1. B001EUME01

      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, install the tapered roller bearing to the carrier.

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

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)


    1. B001EIME15

      Using SST and a press, install the tapered roller bearing to the drive pinion.

      SST
      09506-30012

  8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. B001DA4

      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. B001FB7E09
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the drive pinion 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 to its threads and tip.

    3. Coat the threads of the nut with hypoid gear oil LSD.

    4. B001IJPE01

      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, being careful not to overtighten it.

      • 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 (7 to 20 kgf*cm, 7 to 17 in.*lbf)
      Used bearing 0.73 to 1.83 N*m (8 to 18 kgf*cm, 7 to 16 in.*lbf)

      Note

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

  9. INSTALL DIFFERENTIAL CASE ASSEMBLY

    A01XEDA

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

      Tech Tips

      Do not interchange the right and left races.

  10. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT

    A01XEOR

    1. Install the 2 adjusting nuts to the carrier, making sure the nuts are threaded properly.

  11. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. B001GF9E06
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the cap and carrier.

    2. Install the right and left bearing caps with the 4 bolts.

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

      Tech Tips

      If the bearing cap does not fit tightly onto the carrier, the adjusting nuts are not threaded properly.

      Reinstall the adjusting nuts if necessary.

    3. B001GAAE06
      Text in Illustration
      *a for LH Side

      Tighten the 4 bearing cap bolts to the specified torque, and then loosen them to the point where the adjusting nuts can be turned by SST.

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

    4. Using SST, tighten the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.008 in.).

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    5. B001DVEE04
      Text in Illustration
      *a for RH Side

      While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side.

      Tech Tips

      After the bearings have settled, loosen the adjusting nut on the drive pinion side.

    6. Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

      SST
      09504-00011
    7. B001EFWE01

      Using a dial indicator, adjust the ring gear backlash until it is within the specification.

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

      Tech Tips


      • The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.

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

    8. B001GF9E07
      Text in Illustration
      *a Matchmark

      Tighten the bearing cap bolts.

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

  12. 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)
      Item Specified Condition
      New bearing 0.88 to 2.43 N*m (9 to 24 kgf*cm, 8 to 21 in.*lbf)
      Used bearing 0.93 to 2.23 N*m (10 to 22 kgf*cm, 9 to 19 in.*lbf)

      If necessary, disassemble and inspect the differential.

      Note

      Record the differential ring gear preload.

  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    A01XM3F
    Text in Illustration
    *A Drive Side *B Coast Side
    *a Proper Contact *b Toe Contact
    *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear.
    *e Heel Contact *f Flank Contact
    *g Select an adjusting washer that will shift the drive pinion away from the ring gear. *h Heel Contact
    *i Flank Contact *j Toe Contact
    *k Face Contact - -

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

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

    3. Inspect the tooth contact pattern.


      • B001CFVE01
      • Text in Illustration
        *A Drive Side *B Coast Side
        *a Proper Contact *b Toe Contact
        *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear.
        *e Heel Contact *f Flank Contact
        *g Select an adjusting washer that will shift the drive pinion away from the ring gear. *h Heel Contact
        *i Flank Contact *j Toe Contact
        *k Face Contact - -
    4. 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 an appropriate washer for correction.

      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 2.14 to 2.16 mm (0.0843 to 0.0850 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.)

  14. REMOVE REAR DRIVE PINION NUT

    B001GX2E20

    1. Using SST to hold the drive pinion companion flange, remove the nut.

      SST
      09330-00021

  15. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B001FVBE20
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the drive pinion companion flange.

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

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B001HPU

      Install a new bearing spacer to the drive pinion.

  19. INSTALL DIFFERENTIAL OIL STORAGE RING


    1. B001FERE01

      Using SST, tap in a new oil storage ring.

      SST
      09308-14010

  20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. Apply MP grease to the oil seal lip.

    2. B001EBCE01

      Using SST and a hammer, install a new carrier oil seal.

      SST
      09214-76011
      Standard oil seal drive in depth
      -0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

  23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR


    1. B001FB7E10
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )
    2. B001IJPE01

      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

  24. INSPECT DRIVE PINION PRELOAD


    1. B001DWY

      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 (9 to 22 kgf*cm, 8 to 19 in.*lbf)
      Reused bearing 0.88 to 1.98 N*m (9 to 20 kgf*cm, 8 to 17 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.

  25. INSPECT TOTAL PRELOAD


    1. B001DWY

      Using a torque wrench, measure the preload.

      Standard total preload (at starting)
      Item Specified Condition
      New bearing 1.03 to 2.58 N*m (11 to 26 kgf*cm, 10 to 22 in.*lbf)
      Reused bearing 1.08 to 2.38 N*m (12 to 24 kgf*cm, 10 to 21 in.*lbf)

      If necessary, disassemble and inspect the differential.

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    A01XLCJ

    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 within the specification, 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.

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

    B001I47E45
    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.

  28. INSTALL REAR DRIVE PINION NUT

    B001IIB

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

  29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

    A01XK3U

    1. Install 2 new adjusting nut locks to the bearing caps with the 2 bolts.

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. After tightening the bolts, bend the nut locks.

  30. INSTALL REAR DIFFERENTIAL LOCK SHIFT FORK


    1. Apply MP grease to shaft.

    2. B001IBHE05
      Text in Illustration
      *a Hole
      *b Groove

      Install the fork shaft so that the hole of the shift fork shaft aligns with that of the shift fork.

    3. Remove any FIPG material and be careful not to drop the oil shaft retainer.

    4. B001IB5E10
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the carrier as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      FIPG Width
      Approx. 1 to 2 mm (0.0394 to 0.0787 in.)

      Tech Tips

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

    5. Clean the threads of the bolts and retainer bolt holes with toluene or trichloroethylene.

    6. B001EYZE04
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads at the tip of each mount bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    7. Install the shaft retainer with the 2 bolts.

      Torque:
      23.2 N*m  { 237 kgf*cm, 17 ft.*lbf }
    8. A01XCUR

      Using a 5 mm pin punch and hammer, install the slotted spring pin to the shift fork.

    9. Using a 6 mm hexagon wrench, install the screw plug.

      Torque:
      21.6 N*m  { 220 kgf*cm, 16 ft.*lbf }
    10. B001GCXE08
      Text in Illustration
      *a Lock

      Push the differential lock sleeve in deeply and hold it in position.

    11. B001HA2E08

      Install the ball, spring and spring seat.

    12. Clean the threads of the 2 plugs and plug holes with toluene or trichloroethylene.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Text in Illustration
      *a Adhesive

    13. Using a 6 mm hexagon wrench, install the screw plug.

      Torque:
      23.2 N*m  { 237 kgf*cm, 17 ft.*lbf }

  31. INSTALL DIFFERENTIAL LOCK INDICATOR SWITCH

    A01XJI3

    1. Install the indicator switch together with a new gasket.

      Torque:
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }

  32. INSPECT REAR DIFFERENTIAL LOCK SLEEVE

    A01XFYK

    1. Measure the distance between the sleeve and tip of the differential case when the differential is free, and when it is locked.

      Standard distance
      Locked: 17.45 to 18.85 mm (0.687 to 0.742 in.)
      Free: 32.40 to 33.90 mm (1.276 to 1.334 in.)

  33. INSTALL DIFFERENTIAL LOCK SHIFT ACTUATOR

    B001HKTE06
    Text in Illustration
    *1 Shift Fork
    *2 Actuator Installation Hole
    *a Outside

    1. Check that the outermost rack tooth of the shift fork is approximately above the center line of the actuator installation hole.

    2. B001CF2E01
      Text in Illustration
      *a Matchmark
      *b Groove

      Make sure that the matchmarks on the pinion of the actuator are in the range of 0 to 5 degrees clockwise from the center line of the actuator.

      Note


      • If the matchmarks are not within this range, rotate the pinion.

      • Do not apply positive battery voltage directly to the terminals.

      • If the matchmarks move to the limit of rotation, stop applying electric current.

    3. Install a new O-ring to the actuator.

    4. Apply a light coat of gear oil to the O-ring.

    5. Apply MP grease to the gear.

    6. B001EICE03
      Text in Illustration
      *a Knock Pin

      Mack sure that the outermost rack tooth of the shift fork aligns with the matchmarks on the pinion of the actuator.

    7. Install the actuator so that the knock pin on the carrier side fits into the long hole on the actuator side.

      Tech Tips

      Do not damage the O-ring of the actuator.

    8. Rotate the actuator counterclockwise so that the knock pin slides to the end of the hole as shown in the illustration.

    9. Install the bolts.

      Torque:
      26.5 N*m  { 270 kgf*cm, 20 ft.*lbf }