REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL DIFFERENTIAL RING GEAR


    1. Clean the contact surfaces of the rear differential case sub-assembly and differential ring gear.

    2. Clean the ring gear set bolt hole.

    3. A011OWWC03
      *a 100°C (212°F)

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

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

      CAUTION:

      Use thick gloves to protect your hands as the differential ring gear is hot.

    5. Secure the rear differential case sub-assembly between aluminum plates in a vise.

      Note

      Do not overtighten the vise.

    6. A011PD6C02
      *a Matchmark
      *b Thread Lock

      After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the rear differential case sub-assembly.

    7. Align the matchmarks on the differential ring gear and rear differential case sub-assembly.

    8. After the differential ring gear has cooled sufficiently, install 10 new bolts to which thread lock has been applied.

      Adhesive
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent.

      Note


      • New ring gear set bolts should be used every time the differential ring gear is installed.

      • Do not allow oil to adhere to the ring gear set bolts during installation.

    9. Temporarily install the 10 bolts.

    10. A011O7B

      After the differential ring gear cools down, tighten the 10 bolts.

      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note

      Tighten diametrically opposite ring gear set bolts in pairs.

    11. A011MW0C01
      *a Paint Mark
      *b 60° to 90°

      Tighten the 10 set bolts an additional 60° to 90°.

      Note

      Tighten diametrically opposite ring gear set bolts in pairs.

  2. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. Using SST and a press, install the rear differential case bearing inner races LH and RH to the rear differential case sub-assembly.

      SST
      09950-60010   ( 09951-00560, 09951-00570 )
      09950-70010   ( 09951-07100 )
      A011M3VC02
      *a for LH Side *b for RH Side

      Note


      • Do not apply hypoid gear oil to a new bearing.

      • Do not deform the bearing cage. Set SST to the center of the rear differential case sub-assembly.

      • If the bearing is replaced, replace it and its outer race as a set.

  3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A011NYPN07

      Using SST and a press, install the rear drive pinion rear tapered roller bearing inner race to the differential drive pinion.

      SST
      09316-60011   ( 09316-00031 )
      09612-24014   ( 09613-22011 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Disassemble SST (09613-22011) and use only the pipe section.

    2. A011O60C03
      *1 Rear Drive Pinion Rear Tapered Roller Bearing Outer Race
      *2 Rear Differential Drive Pinion Plate Washer

      Using SST and a press, install a new rear differential drive pinion plate washer and rear drive pinion rear tapered roller bearing outer race.

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

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Select a rear differential drive pinion plate washer of the same thickness as the removed one.

  4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A011P73C03
      *1 Rear Drive Pinion Front Tapered Roller Bearing Outer Race

      Using SST and a press, install the rear drive pinion front tapered roller bearing outer race.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

      Note

      Do not apply hypoid gear oil to a new bearing.

    2. A011QKL

      Install the rear drive pinion front tapered roller bearing inner race to the rear differential carrier.

      Note

      Do not apply hypoid gear oil to a new bearing.

  5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when replacing the rear differential dust deflector.


    1. A011MSDN07

      Using SST and a press, insert a new rear differential dust deflector to the rear drive pinion companion flange.

      SST
      09316-60011   ( 09316-00011 )

      Note


      • Slowly press in the rear differential dust deflector. Do not press it excessively.

      • If any burrs remain after pressing in the rear differential dust deflector, remove them.

  6. INSTALL DIFFERENTIAL DRIVE PINION


    1. A011PPGN06

      Using SST and a press, install the differential drive pinion.

      SST
      09316-60011   ( 09316-00011, 09316-00041 )
      09608-04031

      Tech Tips

      Install the rear differential drive pinion bearing spacer and rear differential carrier oil seal after adjusting the tooth contact pattern.

  7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A011P4M

      Install the rear differential drive pinion oil slinger.

  8. INSTALL REAR DRIVE PINION COMPANION FLANGE


    1. A011Q3SC02
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note


      • Install the rear drive pinion companion flange so that there is a slight looseness in the differential drive pinion because the rear differential drive pinion bearing spacer is not yet installed.

      • Apply molybdenum grease to the threads of SST center bolt (09953-03010) before use.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 40 mm.

    2. Coat the threads of the rear drive pinion nut with hypoid gear oil LSD.

    3. A011Q6MC03
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and temporary tighten the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

      CAUTION:

      Hold the overhaul attachment during the operation.

      Note

      Apply hypoid gear oil LSD to the rear drive pinion nut and the threads of the differential drive pinion.

      Tech Tips

      Tighten the nut approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. Turn the bearing clockwise and counterclockwise several times to stabilize it.

    2. A011P74C01

      Using SST and a torque wrench, measure the preload.

      SST
      09229-55010
      Differential drive pinion preload (at starting)
      1.15 to 1.55 N*m (11.7 to 15.8 kgf*cm, 10.2 to 13.7 in.*lbf)

      • If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.

        Torque
        490 N*m (4997 kgf*cm, 361 ft.*lbf) or less

      Note

      As there is no rear differential drive pinion bearing spacer, tighten the rear drive pinion nut a little at a time. Do not overtighten it.

  10. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A011LXR

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing or differential ring gear.

  11. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A011N6UC01
      *a Groove

      Using SST and a hammer, install the differential side bearing outer race RH to the differential ring gear tooth side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Tap in the rear differential case bearing outer race RH until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    2. A011NKZC02
      *1 Disc

      Install SST to the rear differential carrier with the 2 bolts (A).

      SST
      09571-50010

    3. Tighten SST bolt (B) until SST disc lightly touches the rear differential case bearing outer race RH.

    4. A011Q4JN11

      Using SST and a hammer, install the rear differential case bearing outer race LH to the differential ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Note

      Do not apply hypoid gear oil to a new bearing.

      Tech Tips

      Tap in the rear differential case bearing outer race LH until it touches the rear differential case bearing inner race roller.

  12. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. A011N80N16

      Using SST, install the thinnest rear differential side gear shaft snap ring to the back surface of the differential ring gear.

      SST
      09905-00031

      Tech Tips


      • If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are new, select a thinner rear differential side gear shaft snap ring and install it.

      • If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are reused, install a rear differential side gear shaft snap ring with the same thickness as the removed one.

    2. A011PP4E04

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    3. Tighten SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      SST
      09571-50010

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

      Tech Tips

      Tighten SST bolt to apply the preload to the rear differential case bearing.

    4. Turn the differential ring gear clockwise and counterclockwise several times.

    5. A011NGK

      Using a dial indicator, measure the backlash of the differential ring gear at 3 positions.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      Note

      The difference between the maximum and minimum values must be within 0.05 mm (0.00197 in.).

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft snap ring.

      • If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the differential ring gear tooth side with a rear differential side gear shaft snap ring of a different thickness as described in the following procedure.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft snap ring.

    6. Loosen SST bolt and separate SST disc from the rear differential case bearing outer race RH.

      Note

      Do not remove SST.

    7. A011PHBN01

      Using SST and a hammer, create a clearance between the rear differential side gear shaft snap ring on the differential ring gear back surface side and the rear differential case bearing outer race LH.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )
    8. A011N80N17

      Using SST, remove the rear differential side gear shaft snap ring from the differential ring gear back surface side.

      SST
      09905-00031
    9. A011N80N17

      Using SST, install a rear differential side gear shaft snap ring with a different thickness.

      SST
      09905-00031

      Tech Tips

      When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash also changes by 0.02 mm (0.000787 in.).

      Rear Differential Side Gear Shaft Snap Ring thickness
      Part No. No. Thickness Part No. No. Thickness
      90521-99062 66 3.66 mm (0.14409 in.) 90521-99084 06 4.06 mm (0.15984 in.)
      90521-99063 68 3.68 mm (0.14488 in.) 90521-99085 08 4.08 mm (0.16063 in.)
      90521-99064 70 3.70 mm (0.14567 in.) 90521-99086 10 4.10 mm (0.16142 in.)
      90521-99065 72 3.72 mm (0.14646 in.) 90521-99087 12 4.12 mm (0.16220 in.)
      90521-99066 74 3.74 mm (0.14724 in.) 90521-99088 14 4.14 mm (0.16299 in.)
      90521-99067 76 3.76 mm (0.14803 in.) 90521-99089 16 4.16 mm (0.16378 in.)
      90521-99068 78 3.78 mm (0.14882 in.) 90521-99090 18 4.18 mm (0.16457 in.)
      90521-99070 80 3.80 mm (0.14961 in.) 90521-99091 20 4.20 mm (0.16535 in.)
      90521-99071 82 3.82 mm (0.15039 in.) 90521-99092 22 4.22 mm (0.16614 in.)
      90521-99072 84 3.84 mm (0.15118 in.) 90521-99095 24 4.24 mm (0.16693 in.)
      90521-99073 86 3.86 mm (0.15197 in.) 90521-99096 26 4.26 mm (0.16772 in.)
      90521-99074 88 3.88 mm (0.15276 in.) 90521-99097 28 4.28 mm (0.16850 in.)
      90521-99075 90 3.90 mm (0.15354 in.) 90521-99100 30 4.30 mm (0.16929 in.)
      90521-99076 92 3.92 mm (0.15433 in.) 90521-99101 32 4.32 mm (0.17008 in.)
      90521-99077 94 3.94 mm (0.15512 in.) 90521-99102 34 4.34 mm (0.17087 in.)
      90521-99078 96 3.96 mm (0.15591 in.) 90521-99103 36 4.36 mm (0.17165 in.)
      90521-99079 98 3.98 mm (0.15669 in.) 90521-99104 38 4.38 mm (0.17244 in.)
      90521-99081 00 4.00 mm (0.15748 in.) 90521-99105 40 4.40 mm (0.17323 in.)
      90521-99082 02 4.02 mm (0.15827 in.) 90521-99107 42 4.42 mm (0.17402 in.)
      90521-99083 04 4.04 mm (0.15905 in.) - - -
    10. A011Q0G

      Using a plastic-faced hammer, lightly tap the differential ring gear tooth side of the rear differential carrier.

    11. A011PP4C08
      *a Turn

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    12. Tighten SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      SST
      09571-50010

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    13. A011NGK

      Using a dial indicator, measure the backlash of the differential ring gear at 3 positions.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the back surface of the differential ring gear with one of a different thickness.

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft snap ring.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft snap ring.

  13. ADJUST REAR DIFFERENTIAL CASE BEARING PRELOAD


    1. A011PP4C08
      *a Turn

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    2. Tighten SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      SST
      09571-50010

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    3. A011PFKN09

      Using SST, install the thinnest rear differential side gear shaft snap ring to the differential ring gear tooth side.

      SST
      09905-00031
    4. A011Q8V

      Remove the dial indicator and loosen the bolt until SST disc is separated from the rear differential case bearing outer race RH on the differential ring gear tooth side.

    5. A011Q0G

      Using a plastic-faced hammer, lightly tap the differential ring gear tooth side of the rear differential carrier to stabilize the rear differential case bearing.

    6. A011NGK

      Using a dial indicator, measure the backlash of the differential ring gear at 3 positions. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the rear differential side gear shaft snap ring on the differential ring gear tooth side with a thicker one.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      Tech Tips

      If the value is not within the specified range, replace the snap ring with one of a different thickness in the following procedure.

    7. A011OZV

      Remove the 2 bolts and SST.

  14. ADJUST TOTAL PRELOAD


    1. A011P74E04

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

      SST
      09229-55010
      Total preload (at starting)
      Item Specified Condition
      New bearing 1.93 to 3.75 N*m (19.7 to 38.2 kgf*cm, 17.1 to 33.2 in.*lbf)
      Reused bearing 1.73 to 3.10 N*m (17.6 to 31.6 kgf*cm, 15.3 to 27.4 in.*lbf)

      Note


      • If the measured preload is less than the specified value, replace the rear differential side gear shaft snap ring of the differential ring gear tooth surface side with a thicker one.

      • If the measured preload is more than the specified value, replace the rear differential side gear shaft snap ring of the differential ring gear tooth surface side with a thinner one.

      Tech Tips

      When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 1 in.*lbf).

    2. A011NGK

      Set a dial indicator to the end of the differential ring gear face.

    3. While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      Note


      • If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both the right and left rear differential side gear shaft snap rings equally.

      • When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash will also change by approximately 0.02 mm (0.000787 in.).

    4. Recheck the total preload.

  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A011MZ0

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

    2. Rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A011NBXC07
      *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) - -

      Note

      Check the tooth contact pattern at 4 or more positions around circumference of the differential ring gear.

    4. A011Q88C02
      *1 Rear Differential Drive Pinion Plate Washer

      If the teeth are not contacting properly, use the following table to select a proper rear differential drive pinion plate washer for correction.

      Tech Tips


      • If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.

      • If the thickness of the rear differential drive pinion plate washer has been changed, adjust the backlash and measure the total preload.

      Rear Differential Drive Pinion Plate Washer thickness
      Part No. No. Thickness Part No. No. Thickness
      90201-70002 88 1.87 to 1.89 mm (0.0736 to 0.0744 in.) 90201-70024 10 2.09 to 2.11 mm (0.0823 to 0.0830 in.)
      90201-70004 90 1.89 to 1.91 mm (0.0745 to 0.0751 in.) 90201-70026 12 2.11 to 2.13 mm (0.0831 to 0.0838 in.)
      90201-70006 92 1.91 to 1.93 mm (0.0752 to 0.0759 in.) 90201-70028 14 2.13 to 2.15 mm (0.0839 to 0.0846 in.)
      90201-70008 94 1.93 to 1.95 mm (0.0760 to 0.0767 in.) 90201-70030 16 2.15 to 2.17 mm (0.0847 to 0.0854 in.)
      90201-70010 96 1.95 to 1.97 mm (0.0768 to 0.0775 in.) 90201-70032 18 2.17 to 2.19 mm (0.0855 to 0.0862 in.)
      90201-70012 98 1.97 to 1.99 mm (0.0776 to 0.0783 in.) 90201-70034 20 2.19 to 2.21 mm (0.0863 to 0.0870 in.)
      90201-70014 00 1.99 to 2.01 mm (0.0784 to 0.0791 in.) 90201-70036 22 2.21 to 2.23 mm (0.0871 to 0.0877 in.)
      90201-70016 02 2.01 to 2.03 mm (0.0792 to 0.0799 in.) 90201-70038 24 2.23 to 2.25 mm (0.0878 to 0.0885 in.)
      90201-70018 04 2.03 to 2.05 mm (0.0780 to 0.0807 in.) 90201-70040 26 2.25 to 2.27 mm (0.0886 to 0.0893 in.)
      90201-70020 06 2.05 to 2.07 mm (0.0808 to 0.0814 in.) 90201-70042 28 2.27 to 2.29 mm (0.0894 to 0.0901 in.)
      90201-70022 08 2.07 to 2.09 mm (0.0815 to 0.0822 in.) - - -

  16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING (for RH Side)

    Click here

  17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING (for LH Side)

    Click here

  18. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Click here

  19. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)

    Click here

  20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Click here

  21. REMOVE REAR DRIVE PINION NUT


    1. A011NDVC03
      *a Turn
      *b Hold

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

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )

      CAUTION:

      Hold the overhaul attachment during the operation.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 45 mm.

  22. REMOVE REAR DRIVE PINION COMPANION FLANGE

    Click here

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  24. REMOVE DIFFERENTIAL DRIVE PINION

    Click here

  25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A011QKL

      Remove the rear drive pinion front tapered roller bearing inner race from the rear differential carrier.

  26. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A011P6L

      Install a new rear differential drive pinion bearing spacer to the differential drive pinion.

      Note

      Install the rear differential drive pinion bearing spacer with the larger diameter side facing toward the differential drive pinion.

  27. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A011QKL

      Install the rear drive pinion front tapered roller bearing inner race to the rear differential carrier.

  28. INSTALL DIFFERENTIAL DRIVE PINION


    1. A011PPGN07

      Using SST and a press, install the differential drive pinion to the rear differential carrier.

      SST
      09316-60011   ( 09316-00011, 09316-00041 )
      09608-04031

  29. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A011P4M

      Install the rear differential drive pinion oil slinger.

  30. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  31. INSTALL REAR DRIVE PINION COMPANION FLANGE


    1. A011PLFC01
      *a Turn
      *b Hold

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

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note

      Apply molybdenum grease to the threads of SST center bolt (09953-03010) before use.

      Tech Tips

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 45 mm.

    2. Coat the threads of a new rear drive pinion nut with hypoid gear oil LSD.

    3. A011MYGC01
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and temporary tighten the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

      CAUTION:

      Hold the overhaul attachment during the operation.

      Note


      • Do not tighten the nut excessively, otherwise the threads will be stripped.

      • Apply hypoid gear oil LSD to the threads of the drive pinion nut and differential drive pinion.

      Tech Tips

      Tighten the drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and then tighten it further while observing the preload.

  32. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A011LXR

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing and differential ring gear.

  33. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A011QJLC01
      *a Groove

      Using SST and a hammer, install the rear differential case bearing outer race RH to the differential ring gear tooth side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the rear differential case bearing outer race until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    2. A011NKZC05
      *1 Disc

      Install SST to the rear differential carrier with the 2 bolts (A).

      SST
      09571-50010

    3. Tighten SST bolt (B) until SST disc lightly touches the rear differential case bearing outer race RH.

    4. A011OLTE05

      Using SST and a hammer, install the rear differential case bearing outer race LH to the differential ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the rear differential case bearing outer race until it touches the rear differential case bearing inner race roller.

  34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. A011N80E08

      Using SST, install the rear differential side gear shaft snap ring to the rear differential carrier on the differential ring gear back surface side.

      SST
      09905-00031

      Tech Tips

      Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.

    2. A011PP4C05
      *a Turn

      Set a dial indicator on the rear differential carrier.

    3. Tighten SST bolt to alter the shape of the rear differential carrier by approximately 0.1 mm (0.00394 in.).

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

    4. A011PFKN10

      Using SST, install the rear differential side gear shaft snap ring to the differential ring gear tooth side.

      SST
      09905-00031

      Tech Tips

      Use the rear differential side gear shaft snap ring installed when performing tooth contact adjustment.

    5. A011Q0G

      Remove the dial indicator and tap the rear differential carrier on the differential ring gear tooth side using a plastic-faced hammer to stabilize the rear differential case bearing.

    6. A011OZV

      Remove the 2 bolts and SST.

  35. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A011P74E01

      Using SST and a torque wrench, measure the starting torque of the differential drive pinion.

      SST
      09229-55010
      Differential drive pinion preload (at starting)
      1.25 to 1.65 N*m (12.7 to 16.8 kgf*cm, 11.1 to 14.6 ft.*lbf)

      • If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut 5 to 10°.

        Torque
        490 N*m (4997 kgf*cm, 361 ft.*lbf) or less

      • If the preload is less than the specified minimum value even when the tightening torque of the rear drive pinion nut is more than the specified maximum value, loosen the rear drive pinion nut and check that the threads of the drive pinion nut and differential drive pinion are not stripped.

      • If the threads are not stripped, replace the rear differential drive pinion bearing spacer. Apply hypoid gear oil LSD to the threads of the differential drive pinion and repeat the procedure.

      Tech Tips


      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

  36. INSPECT TOTAL PRELOAD


    1. A011P74E01

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

      SST
      09229-55010
      Total preload (at starting)
      Item Specified Condition
      New bearing 2.03 to 3.85 N*m (20.7 to 39.3 kgf*cm, 17.7 to 34.1 in.*lbf)
      Reused bearing 1.83 to 3.20 N*m (18.7 to 32.6 kgf*cm, 16.2 to 28.3 in.*lbf)

  37. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A011P6R

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Standard Backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      If the backlash is not within the specified range, adjust the backlash or perform repairs as necessary.

  38. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A011O6RC02
      *a 10 mm (0.394 in.)

      Using a dial indicator, measure the runout of the differential drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.

      Maximum runout
      0.08 mm (0.00315 in.)

      If the runout is more than the maximum, replace the differential drive pinion and differential ring gear.

  39. STAKE REAR DRIVE PINION NUT


    1. A011QFJE01

      Using SST and a hammer, stake the rear drive pinion nut.

      SST
      09930-00010

  40. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A011QL9C03
      *1 Rear Differential Side Gear Shaft Oil Seal
      *a Oil Seal Installation Depth

      Using SST and a hammer, install 2 new rear differential side gear shaft oil seals.

      SST
      09223-15030
      09950-70010   ( 09951-07150 )
      Oil seal installation depth
      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      Note


      • Make sure to check the identification marks on the rear differential side gear shaft oil seals before installation because the part numbers differ between the left and right sides.

      • To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seals.

      • When installing the rear differential side gear shaft oil seals, tap them in until the outer surface of each seal is flush with the rear differential carrier.

      • Make sure the difference between the maximum and minimum measured values is less than 0.85 mm (0.0335 in.), as a greater difference may lead to oil leaks.

  41. INSTALL REAR DIFFERENTIAL DRAIN PLUG


    1. Using a hexagon wrench, install the differential drain plug together with a new gasket.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  42. REMOVE REAR DIFFERENTIAL CARRIER


    1. A011NNI

      Remove the 4 bolts and rear differential carrier from the overhaul stand.

      Note

      Clean the fitting surface between the rear differential carrier and rear differential carrier cover.

  43. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A011P7J

      Clean the seal packing attached to the rear differential carrier and rear differential carrier cover using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.

      Note

      Do not scratch the sealing surface.

    2. Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  44. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN

    Tech Tips

    It is not necessary to remove a rear differential carrier straight pin unless it is being replaced.


    1. A011OJ2C01
      *a Protrusion

      Using a plastic-faced hammer, install the 2 rear differential carrier straight pins to the rear differential carrier cover.

      Protrusion
      10 to 12 mm (0.394 to 0.472 in.)

  45. INSTALL REAR DIFFERENTIAL CARRIER COVER


    1. A011Q1AC01
      *1 Seal Packing
      *a 2 to 3 mm (0.0788 to 0.118 in.)

      Apply seal packing 1281 to the rear differential carrier as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent

      Note


      • Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and end of application.

      • Install the rear differential carrier cover within 3 minutes of application.

    2. A011OSI

      Install the rear differential carrier cover with the 8 bolts.

      Torque:
      46.6 N*m  { 475 kgf*cm, 34 ft.*lbf }

      Note

      Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.

  46. INSTALL REAR DIFFERENTIAL BREATHER PLUG


    1. A011MYY

      Install the rear differential breather plug to the rear differential carrier cover.

      Torque:
      20.6 N*m  { 210 kgf*cm, 15 ft.*lbf }