REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01WVAD

      Install the 2 thrust washers to the side gears.

    2. Install the side gears to the differential case.

    3. Install the 4 pinion gears and 4 thrust washers to the spider.

    4. Install the spider assembly to the differential case.

      Tech Tips

      Install the spider to the differential case tightly.

    5. A01WWC4

      Using a dial indicator, measure the side gear backlash while holding the side gear and spider.

      Standard backlash
      0.02 to 0.15 mm (0.000787 to 0.00591 in.)

      Tech Tips


      • Measure at all 4 pinion gear locations.

      • Measure the backlash at the differential case LH and RH.

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

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

      Standard Thrust Washer Thickness
      Part No. Specified Condition Part No. Specified Condition
      41361-60560 1.53 to 1.57 mm (0.0603 to 0.0618 in.) 41361-60620 1.83 to 1.87 mm (0.0720 to 0.0736 in.)
      41361-60570 1.58 to 1.62 mm (0.0622 to 0.0637 in.) 41361-60630 1.88 to 1.92 mm (0.0740 to 0.0755 in.)
      41361-60580 1.63 to 1.67 mm (0.0642 to 0.0657 in.) 41361-60640 1.93 to 1.97 mm (0.0760 to 0.0775 in.)
      41361-60590 1.68 to 1.72 mm (0.0662 to 0.0677 in.) 41361-60650 1.98 to 2.02 mm (0.0780 to 0.0795 in.)
      41361-60600 1.73 to 1.77 mm (0.0682 to 0.0696 in.) 41361-60660 2.03 to 2.07 mm (0.0800 to 0.0814 in.)
      41361-60610 1.78 to 1.82 mm (0.0701 to 0.0716 in.) 41361-60670 2.08 to 2.12 mm (0.0819 to 0.0834 in.)

  2. ASSEMBLE DIFFERENTIAL CASE


    1. Install the spider assembly to the differential case.

      Tech Tips

      Install the spider to the differential case tightly.

    2. A01WQCRE12
      Text in Illustration
      *a Matchmark

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

    3. Install the 8 bolts and tighten them uniformly, a little at a time.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01WRYRE02

      Using SST and a press, press the RH side bearing (inner race) into the differential case.

      SST
      09710-30050
      09950-70010   ( 09951-07150 )
    2. A01WTMDE04

      Using SST and a press, press the LH side bearing (inner race) into the differential case.

      SST
      09710-30050
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07150 )

  4. INSTALL DIFFERENTIAL RING GEAR


    1. Clean the threads of the bolts and differential case with non-residue solvent.

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

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

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

    5. 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.

    6. A01WS5AE03
      Text in Illustration
      *a Matchmark

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

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

  5. CHECK DIFFERENTIAL RING GEAR RUNOUT


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

      Tech Tips

      Do not interchange the left and right outer races.

    2. Install the assembled plate washers onto the side bearing.

    3. Install the differential case onto the differential carrier.

      Tech Tips

      If it is difficult to install the differential case onto the carrier, replace the plate washer with a thinner one. However, select a plate washer that allows no clearance between it and the carrier.

    4. Align the matchmarks on the bearing caps and differential carrier.

    5. Install and uniformly tighten the 4 bolts a little at a time.

    6. A01WU5G

      Using a dial indicator, check the ring runout.

      Maximum runout
      0.05 mm (0.00197)

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

    7. Remove the differential case.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01WRMOE04

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

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07150 )

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01WUFBE04

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

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

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the washer on the drive pinion.

      Tech Tips

      After installing the washer, check the tooth contact pattern. If necessary, replace the washer with one of a different thickness.

    2. A01WVQSE08
      Text in Illustration
      *1 Plate Washer

      Using SST and a press, press the rear bearing (inner race) into the drive pinion.

      SST
      09506-35010

  9. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01WS28

      Install the drive pinion, front bearing (inner race) and oil slinger.

      Tech Tips

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

    2. A01WSA9E03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )
    3. A01WRX4E02

      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
      441 N*m (4497 kgf*cm, 325 ft.*lbf) or less

      Note


      • Apply hypoid gear oil to the nut.

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

    4. A01WW6E

      Using a torque wrench, measure the preload.

      Standard Preload (at Starting)
      Reduction Ratio Bearing Specified Condition
      3.307 New 1.32 to 2.22 N*m (14 to 22 kgf*cm, 12 to 19 in.*lbf)
      Reused 0.52 to 0.87 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf)
      3.909 New 0.73 to 1.38 N*m (8 to 14 kgf*cm, 7 to 12 in.*lbf)
      Reused 0.54 to 1.06 N*m (6 to 10 kgf*cm, 5 to 9 in.*lbf)

      Tech Tips

      Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth.

  10. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. Place the bearing (outer races) on their respective bearings.

      Tech Tips

      Do not interchange the left and right outer races.

    2. Install the differential case onto the carrier.

      Tech Tips

      Make sure that there is backlash between the ring gear and drive pinion.

  11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01WRJE

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

  12. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH


    1. A01WQLOE05
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the bearing caps and carrier. Screw in the 4 bearing cap bolts 2 or 3 turns and press down the bearing caps by hand.

      Tech Tips

      If the bearing caps do not fit tightly on the carrier, the adjusting nuts are not engaged properly.

      Reinstall the adjusting nuts if necessary.

    2. A01WUEB

      Tighten the 4 bolts.

      Torque:
      90 N*m  { 918 kgf*cm, 66 ft.*lbf }
    3. A01WTS2E04

      Loosen the 4 bolts to the point where the adjusting nuts can be turned by SST.

      SST
      09504-00011

    4. Using SST, tighten the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.00787 in.).

      SST
      09504-00011
    5. A01WRVME03

      While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side. After the bearings are settled, loosen the adjusting nut on the drive pinion side.

    6. A01WRGAE02

      Place a dial indicator on the top of the adjusting nut on the ring gear side.

    7. Adjust the side bearing to zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move.

    8. A01WRVME03

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

      SST
      09504-00011
    9. A01WS71E05

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

      Standard backlash
      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 by an equal amount. For example, loosen the nut on the left side 1 notch and tighten the nut on the right side 1 notch.

    10. A01WUEB

      Tighten the 4 bearing cap bolts.

      Torque:
      90 N*m  { 918 kgf*cm, 66 ft.*lbf }

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

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

  13. INSPECT TOTAL PRELOAD


    1. A01WW6E

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

      Standard Drive Pinion Preload (at Starting)
      Reduction Ratio Side Bearing Supplier Specified Condition
      3.307 New 1.77 to 2.95 N*m (19 to 30 kgf*cm, 16 to 26 in.*lbf)
      Reused 0.97 to 1.60 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)
      3.909 New 1.11 to 2.01 N*m (12 to 20 kgf*cm, 10 to 17 in.*lbf)
      Reused 0.92 to 1.69 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)

  14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01WV5L

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

    2. Turn the companion flange in both directions and inspect the ring gear for proper tooth contact.

      A01WSX9E02
      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 contacting properly, use the following table and select a proper plate washer for correction.

      Standard Plate Washer Thickness
      Part No. Specified Condition Part No. Specified Condition
      90564-40004 1.04 to 1.06 mm (0.0410 to 0.0417 in.) 90564-40016 1.315 to 1.335 mm (0.0518 to 0.0525 in.)
      90564-40006 1.065 to 1.085 mm (0.0420 to 0.0427 in.) 90564-40017 1.34 to 1.36 mm (0.0528 to 0.0535 in.)
      90564-40007 1.09 to 1.11 mm (0.0430 to 0.0437 in.) 90564-40018 1.365 to 1.385 mm (0.0538 to 0.0545 in.)
      90564-40008 1.115 to 1.135 mm (0.0439 to 0.0446 in.) 90564-40019 1.39 to 1.41 mm (0.0548 to 0.0555 in.)
      90564-40009 1.14 to 1.16 mm (0.0449 to 0.0456 in.) 90564-40020 1.415 to 1.435 mm (0.0557 to 0.0564 in.)
      90564-40010 1.165 to 1.185 mm (0.0459 to 0.0466 in.) 90564-40021 1.44 to 1.46 mm (0.0567 to 0.0574 in.)
      90564-40011 1.19 to 1.21 mm (0.0469 to 0.0476 in.) 90564-40022 1.465 to 1.485 mm (0.0577 to 0.0584 in.)
      90564-40012 1.215 to 1.235 mm (0.0479 to 0.0486 in.) 90564-40023 1.49 to 1.51 mm (0.0587 to 0.0594 in.)
      90564-40013 1.24 to 1.26 mm (0.0489 to 0.0496 in.) 90564-40024 1.515 to 1.535 mm (0.0597 to 0.0604 in.)
      90564-40014 1.265 to 1.285 mm (0.0498 to 0.0505 in.) 90564-40025 1.54 to 1.56 mm (0.0607 to 0.0614 in.)
      90564-40015 1.29 to 1.31 mm (0.0508 to 0.0515 in.) - -

  15. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT


    1. A01WTWYE03

      Using SST to hold the flange, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

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

    Click here

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    Click here

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. Install a new spacer onto the drive pinion.

  20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01WUDIE02

      Using SST and a hammer, tap in the bearing (outer race).

      SST
      09316-60011   ( 09316-00011, 09316-00021 )

    2. Install the bearing (inner race).

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

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


    1. A01WSA9E03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

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

  24. INSPECT DRIVE PINION PRELOAD


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

    2. A01WUVUE01

      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
      441 N*m (4497 kgf*cm, 325 ft.*lbf) or less
    3. A01WW6E

      Using a torque wrench, measure the preload.

      Standard Preload (at Starting)
      Reduction Ratio Bearing Specified Condition
      3.307 New 1.67 to 2.57 N*m (18 to 26 kgf*cm, 15 to 22 in.*lbf)
      Reused 0.87 to 1.22 N*m (9 to 12 kgf*cm, 8 to 10 in.*lbf)
      3.909 New 1.08 to 1.73 N*m (12 to 17 kgf*cm, 10 to 15 in.*lbf)
      Reused 0.89 to 1.41 N*m (10 to 14 kgf*cm, 8 to 12 in.*lbf)

  25. INSPECT TOTAL PRELOAD


    1. A01WW6E

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

      Standard Drive Pinion Preload (at Starting)
      Reduction Ratio Bearing Specified Condition
      3.307 New 2.12 to 3.30 N*m (22 to 33 kgf*cm, 19 to 29 in.*lbf)
      Reused 1.32 to 1.95 N*m (14 to 19 kgf*cm, 12 to 17 in.*lbf)
      3.909 New 1.46 to 2.36 N*m (15 to 24 kgf*cm, 13 to 20 in.*lbf)
      Reused 1.27 to 2.04 N*m (13 to 20 kgf*cm, 12 to 18 in.*lbf)

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01WU6W

      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.

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


    1. A01WU7IE35
      Text in Illustration
      *a Vertical Runout
      *b Vertical Runout
      *c 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.

  28. STAKE DRIVE PINION COMPANION FLANGE REAR NUT


    1. A01WTL5

      Using a chisel and hammer, stake the nut.

  29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01WU36

      Install 2 new nut locks on the bearing caps.

    2. Install the 2 bolts, and bend the nut locks.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    3. Bend the nut locks.