REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Use an overhaul stand as necessary.

PROCEDURE


  1. INSTALL DIFFERENTIAL RING GEAR


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

    2. Heat the differential ring gear in boiling water.

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

      CAUTION:

      Do not burn yourself.

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

      Note

      Do not overtighten the vise.

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

    6. A002CEZC01
      *a Matchmark

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

    7. Temporarily install 12 new rear differential case bolts to which thread lock has been applied.

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

    8. After the ring gear has cooled sufficiently, tighten the 12 new rear differential case bolts.

      Torque:
      98.6 N*m  { 1005 kgf*cm, 73 ft.*lbf }

      Note


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

      • Install the new rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.

      • Tighten the rear differential case bolts after the differential ring gear has cooled down sufficiently.

      • Do not allow any oil to contact the rear differential case bolt, differential ring gear threads or differential case seating surface.

  2. INSTALL REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

    Tech Tips

    Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A00274YN03

      Using SST and a press, install a new rear differential case bearing (LH side inner race) to the rear differential case sub-assembly.

      SST
      09223-46011

      Note

      Replace the inner and outer races as a set.

  3. INSTALL REAR DIFFERENTIAL CASE BEARING (for RH Side)

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

    Tech Tips

    Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A0029U8N03

      Using SST and a press, install the rear differential case bearing (RH side inner race) to the rear differential case sub-assembly.

      SST
      09223-46011

      Note

      Replace the inner and outer races as a set.

  4. INSTALL STRAIGHT PIN


    1. Using a plastic hammer, install the 4 straight pins to the rear differential carrier.

      A002921N02
      Protrusion (A)
      8 to 9 mm (0.315 to 0.354 in.)

  5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.


    1. A002B3MC01
      *1 Rear Drive Pinion Rear Tapered Roller Bearing (Outer Race)

      Using SST, bolt, nuts and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier.

      SST
      09950-60010   ( 09951-00500, 09951-00530 )
      09950-60020   ( 09951-00680, 09951-00890 )

      Tech Tips

      Use M12 x P1.5 bolts with shaft lengths of 124 mm (4.88 in.) and M12 x P1.5 nuts for installation.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.


    1. A002B7BC01
      *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) to the rear differential carrier.

      SST
      09950-60010   ( 09951-00610 )
      09950-70010   ( 09951-07150 )

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.


    1. Install the rear differential drive pinion plate washer to the differential drive pinion.

      Note

      Install each rear differential drive pinion plate washer to the position it was removed from.

    2. A002B9EN06

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

      SST
      09506-30012

  8. INSTALL REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

    Tech Tips

    Replace the rear differential case bearing (LH side outer race) when removing the rear differential case bearing (LH side inner race) from the rear differential case sub-assembly.


    1. A0029H6C01
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

      Using SST and a press, install the rear differential side gear shaft plate washer and a new rear differential case bearing (LH side outer race) to the differential side bearing retainer.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      Note


      • Install each rear differential side gear shaft plate washer to the position it was removed from.

      • Replace the inner and outer races as a set.

      • Install the rear drive shaft oil seal LH after performing the tooth contact inspection and backlash adjustment.

  9. INSTALL REAR DIFFERENTIAL CASE BEARING (for RH Side)

    Note

    New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

    Tech Tips

    Replace the rear differential case bearing (RH side outer race) when removing the rear differential case bearing (RH side inner race) from the rear differential case sub-assembly.


    1. A0026X3C01
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

      Using SST and a press, install the rear differential side gear shaft plate washer and the rear differential case bearing (RH side outer race) to the rear differential carrier.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      Note


      • Install each rear differential side gear shaft plate washer to the position it was removed from.

      • Replace the inner and outer races as a set.

      • Install the rear drive shaft oil seal RH after performing the tooth contact inspection and backlash adjustment.

  10. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A002752

      Install the differential drive pinion with rear drive pinion rear tapered roller bearing (inner race) to the rear differential carrier.

    2. Apply hypoid gear oil LSD to the threads of a new rear drive pinion nut and its seating surface.

    3. Install the rear drive pinion front tapered roller bearing (inner race) and rear drive pinion nut to the differential drive pinion.

      Note

      New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

    4. A002APRC01
      *a Turn
      *b Hold
      *c Fulcrum length of SST: 50 mm (1.97 in.)
      *d Fulcrum length of torque wrench: 750 mm (2.46 ft.)

      Using SST, gradually tighten the rear drive pinion nut until the specified preload is reached. Do not exceed the torque limit shown below.

      SST
      09556-16011
      09564-16020
      Torque
      without SST [Torque wrench (N*m (kgf*cm, ft.*lbf))]
      321 N*m (3273 kgf*cm, 237 ft.*lbf) or less
      with SST [Reading of torque wrench (N*m (kgf*cm, ft.*lbf))]
      301 N*m (3069 kgf*cm, 222 ft.*lbf) or less

      Note


      • Tighten the rear drive pinion nut gradually. Never tighten it excessively.

      • This torque value is effective when SST is parallel to the torque wrench.

      • The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 750 mm (2.46 ft.).

      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

        Click here

    5. A0027MKN03

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

      SST
      09556-16011
      Standard Drive Pinion Preload (Starting Torque)
      New Bearing
      1.83 to 3.04 N*m (19 to 30 kgf*cm, 17 to 26 in.*lbf)
      Reused Bearing
      1.51 to 2.52 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the bearing forward and backward before inspection.

  11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.

      Note


      • Do not damage the contact surface.

      • Be sure to completely remove all seal packing from the rear differential carrier and differential side bearing retainer.

      • Do not allow the removed seal packing to enter the rear differential carrier.

    2. A002AYP

      Install the rear differential case assembly to the rear differential carrier.

    3. A0029YX

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42.2 N*m  { 430 kgf*cm, 31 ft.*lbf }

  12. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A0029BYN02

      Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

      Tech Tips

      Measure at 3 or more areas on the circumference of the differential ring gear.

    4. If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

      Tech Tips


      • Adjust the thickness of the LH and RH rear differential side gear shaft plate washers by the same amount each time until the backlash is within the standard range. If the thickness on the LH side is increased, decrease the thickness on the RH side, and if the thickness on the LH side is decreased, increase the thickness on the RH side.

      • When the backlash is smaller than the specified value, select a thick rear differential side gear shaft plate washer for the RH side and thin rear differential side gear shaft plate washer for the LH side.

      • When the backlash is larger than the specified value, select a thin rear differential side gear shaft plate washer for the RH side and thick rear differential side gear shaft plate washer for the LH side.

      Rear Differential Side Gear Shaft Plate Washer
      Mark Thickness Mark Thickness
      75 1.74 to 1.76 mm (0.0686 to 0.0692 in.) 96 2.34 to 2.36 mm (0.0922 to 0.0929 in.)
      76 1.77 to 1.79 mm (0.0697 to 0.0704 in.) 97 2.37 to 2.39 mm (0.0934 to 0.0940 in.)
      77 1.80 to 1.82 mm (0.0709 to 0.0716 in.) 98 2.40 to 2.42 mm (0.0945 to 0.0952 in.)
      78 1.83 to 1.85 mm (0.0721 to 0.0728 in.) 99 2.43 to 2.45 mm (0.0957 to 0.0964 in.)
      79 1.86 to 1.88 mm (0.0733 to 0.0740 in.) 00 2.46 to 2.48 mm (0.0969 to 0.0976 in.)
      80 1.89 to 1.91 mm (0.0745 to 0.0751 in.) 01 2.49 to 2.51 mm (0.0981 to 0.0988 in.)
      81 1.92 to 1.94 mm (0.0756 to 0.0763 in.) 02 2.52 to 2.54 mm (0.0993 to 0.0999 in.)
      82 1.95 to 1.97 mm (0.0768 to 0.0775 in.) 03 2.55 to 2.57 mm (0.1004 to 0.1011 in.)
      83 1.98 to 2.00 mm (0.0780 to 0.0787 in.) 04 2.58 to 2.60 mm (0.1016 to 0.1023 in.)
      84 2.01 to 2.03 mm (0.0792 to 0.0799 in.) 05 2.61 to 2.63 mm (0.1028 to 0.1035 in.)
      85 2.04 to 2.06 mm (0.0804 to 0.0811 in.) 06 2.64 to 2.66 mm (0.1040 to 0.1047 in.)
      86 2.07 to 2.09 mm (0.0815 to 0.0822 in.) 07 2.67 to 2.69 mm (0.1052 to 0.1059 in.)
      88 2.10 to 2.12 mm (0.0827 to 0.0834 in.) 08 2.70 to 2.72 mm (0.1063 to 0.1070 in.)
      89 2.13 to 2.15 mm (0.0839 to 0.0846 in.) 09 2.73 to 2.75 mm (0.1075 to 0.1082 in.)
      90 2.16 to 2.18 mm (0.0851 to 0.0858 in.) 10 2.76 to 2.78 mm (0.1087 to 0.1094 in.)
      91 2.19 to 2.21 mm (0.0863 to 0.0870 in.) 11 2.79 to 2.81 mm (0.1099 to 0.1106 in.)
      92 2.22 to 2.24 mm (0.0875 to 0.0881 in.) 12 2.82 to 2.84 mm (0.1111 to 0.1118 in.)
      93 2.25 to 2.27 mm (0.0886 to 0.0893 in.) 13 2.85 to 2.87 mm (0.1123 to 0.1129 in.)
      94 2.28 to 2.30 mm (0.0898 to 0.0905 in.) 14 2.88 to 2.90 mm (0.1134 to 0.1141 in.)
      95 2.31 to 2.33 mm (0.0910 to 0.0917 in.) - -

  13. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. Remove the 10 bolts and the differential side bearing retainer.

    2. Remove the rear differential case assembly from the rear differential carrier.

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

    4. Install the rear differential case assembly to the rear differential carrier.

    5. A0029YX

      Install the differential side bearing retainer with the 10 bolts.

      Torque:
      42.2 N*m  { 430 kgf*cm, 31 ft.*lbf }

    6. Turn the differential drive pinion at least 10 times.

    7. Remove the 10 bolts and the differential side bearing retainer.

    8. Remove the rear differential case assembly from the rear differential carrier.

    9. Inspect the tooth contact pattern.

      A002BXAC02
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select washers that will bring the drive pinion closer to the ring gear
      *e Toe Contact *f Flank Contact
      *g Select washers that will bring the drive pinion away from the ring gear - -

      Tech Tips

      Check the tooth contact pattern at 2 or more positions on the circumference of the differential ring gear.

    10. Perform the following procedure for face or flank contact:


      1. If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

      2. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

        Tech Tips

        If the tooth contact pattern is not correct, reselect rear differential side gear shaft plate washers and reinspect the tooth contact pattern.

      3. Repeat the differential ring gear and differential drive pinion backlash inspection.

        Tech Tips

        If the differential ring gear and differential drive pinion backlash are not as specified, reselect the rear differential drive pinion plate washer and then readjust the differential drive pinion preload, differential ring gear and differential drive pinion backlash and reinspect the tooth contact pattern.

    11. Perform the following procedure for heel or toe contact:


      1. A002BSTC01
        *1 Rear Differential Drive Pinion Plate Washer

        Select a rear differential drive pinion plate washer again and install the rear drive pinion rear tapered roller bearing (inner race).

        Rear Differential Drive Pinion Plate Washer
        Mark Thickness Mark Thickness
        41 1.695 to 1.705 mm (0.0667 to 0.0671 in.) 73 1.975 to 1.985 mm (0.0778 to 0.0781 in.)
        42 1.705 to 1.715 mm (0.0671 to 0.0675 in.) 74 1.985 to 1.995 mm (0.0781 to 0.0785 in.)
        43 1.715 to 1.725 mm (0.0675 to 0.0679 in.) 75 1.995 to 2.005 mm (0.0785 to 0.0789 in.)
        44 1.725 to 1.735 mm (0.0679 to 0.0683 in.) 76 2.005 to 2.015 mm (0.0789 to 0.0793 in.)
        45 1.735 to 1.745 mm (0.0683 to 0.0687 in.) 77 2.015 to 2.025 mm (0.0793 to 0.0797 in.)
        46 1.745 to 1.755 mm (0.0687 to 0.0690 in.) 78 2.025 to 2.035 mm (0.0797 to 0.0801 in.)
        47 1.755 to 1.765 mm (0.0690 to 0.0695 in.) 79 2.035 to 2.045 mm (0.0801 to 0.0805 in.)
        48 1.765 to 1.775 mm (0.0695 to 0.0699 in.) 80 2.045 to 2.055 mm (0.0805 to 0.0809 in.)
        49 1.775 to 1.785 mm (0.0699 to 0.0703 in.) 81 2.055 to 2.065 mm (0.0809 to 0.0813 in.)
        50 1.785 to 1.795 mm (0.0703 to 0.0707 in.) 82 2.065 to 2.075 mm (0.0813 to 0.0816 in.)
        51 1.795 to 1.805 mm (0.0707 to 0.0711 in.) 83 2.075 to 2.085 mm (0.0817 to 0.0821 in.)
        52 1.805 to 1.815 mm (0.0711 to 0.0715 in.) 84 2.085 to 2.095 mm (0.0821 to 0.0825 in.)
        53 1.815 to 1.825 mm (0.0715 to 0.0719 in.) 85 2.095 to 2.105 mm (0.0825 to 0.0829 in.)
        54 1.825 to 1.835 mm (0.0719 to 0.0722 in.) 86 2.105 to 2.115 mm (0.0829 to 0.0833 in.)
        55 1.835 to 1.845 mm (0.0722 to 0.0726 in.) 87 2.115 to 2.125 mm (0.0833 to 0.0837 in.)
        56 1.845 to 1.855 mm (0.0726 to 0.0730 in.) 88 2.125 to 2.135 mm (0.0837 to 0.0841 in.)
        57 1.855 to 1.865 mm (0.0730 to 0.0734 in.) 89 2.135 to 2.145 mm (0.0841 to 0.0844 in.)
        58 1.865 to 1.875 mm (0.0734 to 0.0738 in.) 90 2.145 to 2.155 mm (0.0844 to 0.0848 in.)
        59 1.875 to 1.885 mm (0.0738 to 0.0742 in.) 91 2.155 to 2.165 mm (0.0848 to 0.0852 in.)
        60 1.885 to 1.895 mm (0.0742 to 0.0746 in.) 92 2.165 to 2.175 mm (0.0852 to 0.0856 in.)
        61 1.895 to 1.905 mm (0.0746 to 0.0750 in.) 93 2.175 to 2.185 mm (0.0856 to 0.0860 in.)
        62 1.905 to 1.915 mm (0.0750 to 0.0754 in.) 94 2.185 to 2.195 mm (0.0860 to 0.0864 in.)
        63 1.915 to 1.925 mm (0.0754 to 0.0758 in.) 95 2.195 to 2.205 mm (0.0864 to 0.0868 in.)
        64 1.925 to 1.935 mm (0.0758 to 0.0762 in.) 96 2.205 to 2.215 mm (0.0869 to 0.0872 in.)
        65 1.935 to 1.945 mm (0.0762 to 0.0766 in.) 97 2.215 to 2.225 mm (0.0873 to 0.0875 in.)
        70 1.945 to 1.955 mm (0.0766 to 0.0770 in.) 98 2.225 to 2.235 mm (0.0876 to 0.0879 in.)
        71 1.955 to 1.965 mm (0.0770 to 0.0774 in.) 99 2.235 to 2.245 mm (0.0880 to 0.0883 in.)
        72 1.965 to 1.975 mm (0.0774 to 0.0778 in.) 00 2.245 to 2.255 mm (0.0884 to 0.0887 in.)

    12. Readjust the differential drive pinion preload, differential ring gear and differential drive pinion backlash and reinspect the tooth contact pattern.

  14. INSPECT TOTAL PRELOAD


    1. A0027MKN03

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

      SST
      09556-16011
      Standard Total Preload (Starting Torque)
      New Bearing
      3.12 to 5.86 N*m (32 to 59 kgf*cm, 28 to 51 in.*lbf)
      Reused Bearing
      2.80 to 5.34 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:


      1. Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

      2. Repeat the total preload measurement.

      3. Repeat the differential ring gear and differential drive pinion backlash inspection.

      4. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

  15. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

    A0029YX

    1. Remove the 10 bolts and differential side bearing retainer.

  16. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY


    1. A002AYP

      Remove the rear differential case assembly from the rear differential carrier.

  17. REMOVE DIFFERENTIAL DRIVE PINION

    A002752

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

  18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A002AD6

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

      Tech Tips

      Face the smaller inside diameter towards the front of the vehicle.

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    A002AF3

    1. Install the rear differential drive pinion oil slinger to the differential drive pinion.

  20. INSTALL DIFFERENTIAL DRIVE PINION


    1. A002752

      Install the differential drive pinion to the rear differential carrier.

    2. A0029YX

      Install the differential side bearing retainer with the 10 bolts.

      Torque:
      42.2 N*m  { 430 kgf*cm, 31 ft.*lbf }

  21. TEMPORARILY TIGHTEN REAR DRIVE PINION NUT


    1. Apply hypoid gear oil LSD to the threads of the rear drive pinion nut and its seating surface.

    2. A002BRAC01
      *a Turn
      *b Hold

      Using SST, temporarily install the rear drive pinion nut to the differential drive pinion.

      SST
      09556-16011
      09564-16020
    3. A0027MKN03

      Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque).

      SST
      09556-16011
      Standard Drive Pinion Preload (Starting Torque)
      New Bearing
      1.83 to 3.04 N*m (19 to 30 kgf*cm, 17 to 26 in.*lbf)
      Reused Bearing
      1.51 to 2.52 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the bearing forward and backward before adjustment.

    4. A002APRC01
      *a Turn
      *b Hold
      *c Fulcrum length of SST: 50 mm (1.97 in.)
      *d Fulcrum length of torque wrench: 750 mm (2.46 ft.)

      If the preload is insufficient, use SST to tighten the rear drive pinion nut 5° to 10° at a time. Measure the drive pinion preload and repeat the adjustment as necessary until the preload matches the specified torque.

      SST
      09556-16011
      09564-16020
      Torque
      without SST [Torque wrench (N*m (kgf*cm, ft.*lbf))]
      321 N*m (3273 kgf*cm, 237 ft.*lbf) or less
      with SST [Reading of torque wrench (N*m (kgf*cm, ft.*lbf))]
      301 N*m (3069 kgf*cm, 222 ft.*lbf) or less

      Note


      • Tighten the rear drive pinion nut gradually. Never tighten it excessively.

      • This torque value is effective when SST is parallel to the torque wrench.

      • The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 750 mm (2.46 ft.).

      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

        Click here

    5. If the tightening torque of the rear drive pinion nut exceeds the specified torque but the preload is still insufficient, remove the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.

    6. If no damage is found, replace the rear differential drive pinion bearing spacer, apply hypoid gear oil LSD to rear drive pinion nut threads and repeat the procedure above.

  22. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

    A0029YX

    1. Remove the 10 bolts and differential side bearing retainer.

  23. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A002AQB

      Install the rear differential breather plug oil deflector with the 2 bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  24. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY


    1. A002AYP

      Install the rear differential case assembly to the rear differential carrier.

  25. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. A0029YX

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42.2 N*m  { 430 kgf*cm, 31 ft.*lbf }

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A0029BYN02

      Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

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

      Tech Tips

      Measure at 3 or more areas on the circumference of the differential ring gear.

  27. INSPECT TOTAL PRELOAD


    1. A0027MKN03

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

      SST
      09556-16011
      Standard Total Preload (Starting Torque)
      New Bearing
      3.12 to 5.86 N*m (32 to 59 kgf*cm, 28 to 51 in.*lbf)
      Reused Bearing
      2.80 to 5.34 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:


      1. Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

      2. Repeat the total preload measurement.

      3. Repeat the differential ring gear and differential drive pinion backlash inspection.

      4. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

  28. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. A0029YX

      Remove the 10 bolts and differential side bearing retainer.

    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.

      Note

      Do not damage the contact surface.

    3. A002C7RC01
      *a 2.0 mm (0.0787 in.)
      *b 3.0 mm (0.118 in.)
      *c 20 mm (0.787 in.)
      *d 2 to 3 mm (0.0787 to 0.118 in.)

      Apply seal packing to the areas indicated in the illustration of the rear differential carrier.

      Seal Packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Note


      • Start applying seal packing within range (A).

      • Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).

      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.

      • Install the differential side bearing retainer within 3 minutes after applying seal packing. If the differential side bearing retainer is not installed within 3 minutes after applying seal packing, completely remove and then reapply seal packing.

    4. A0029YX

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42.2 N*m  { 430 kgf*cm, 31 ft.*lbf }

      Note

      After installing the differential side bearing retainer, do not add oil or drive the vehicle for at least 1 hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.

  29. INSPECT TOTAL PRELOAD


    1. A0027MKN03

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

      SST
      09556-16011
      Standard Total Preload (Starting Torque)
      New Bearing
      3.12 to 5.86 N*m (32 to 59 kgf*cm, 28 to 51 in.*lbf)
      Reused Bearing
      2.80 to 5.34 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

  30. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A0029BYN02

      Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

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

      Tech Tips

      Measure at 3 or more areas on the circumference of the differential ring gear.

  31. INSTALL REAR DRIVE PINION NUT

    A002ATK

    1. Using a chisel and a hammer, stake the rear drive pinion nut as shown in the illustration.

  32. INSTALL DIAPHRAGM OIL SEAL


    1. A002BM2C01
      *1 Diaphragm Oil Seal

      Using SST and a press, install a new diaphragm oil seal into the rear differential carrier assembly.

      SST
      09506-35010
      09554-22010
      Standard Distance (A)
      0.7 to 1.3 mm (0.0276 to 0.0511 in.)

      Note


      • Install the diaphragm oil seal uniformly.

      • Press fit the diaphragm oil seal straight.

    2. Apply a light coat of MP grease to the lip of the new diaphragm oil seal.

  33. INSTALL REAR DRIVE SHAFT OIL SEAL LH


    1. A002BU1C01
      *1 Rear Drive Shaft Oil Seal LH

      Using SST and a press, install a new rear drive shaft oil seal LH into the differential side bearing retainer.

      SST
      09223-46011
      09631-32020
      Standard Distance (A)
      8.2 to 8.8 mm (0.323 to 0.346 in.)

      Note


      • Install the rear drive shaft oil seal LH uniformly.

      • Press fit the rear drive shaft oil seal LH straight.

    2. Apply a light coat of MP grease to the lip of the new rear drive shaft oil seal LH.

  34. INSTALL REAR DRIVE SHAFT OIL SEAL RH


    1. A002742C01
      *1 Rear Drive Shaft Oil Seal RH

      Using SST and a press, install a new rear drive shaft oil seal RH into the rear differential carrier.

      SST
      09223-46011
      09631-32020
      Standard Distance (A)
      8.2 to 8.8 mm (0.323 to 0.346 in.)

      Note


      • Install the rear drive shaft oil seal RH uniformly.

      • Press fit the rear drive shaft oil seal RH straight.

    2. Apply a light coat of MP grease to the lip of the new rear drive shaft oil seal RH.

  35. INSTALL TRANSMISSION COUPLING SPACER


    1. A0029ZFC02
      *1 Transmission Coupling Spacer

      Install the transmission coupling spacer to the rear differential carrier assembly.

      Note

      Keep the transmission coupling spacer free of oil and foreign matter.

  36. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER


    1. A0026VHC02
      *1 Transmission Coupling Conical Spring Washer

      Install the transmission coupling conical spring washer to the rear differential carrier assembly as shown in the illustration.

      Note

      Keep the transmission coupling conical spring washer free of oil and foreign matter.

  37. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A002BO2N01

      Using SST and a press, install the rear differential dust deflector.

      SST
      09223-15030
      09950-70010   ( 09951-07150 )
      Standard Distance (A)
      0 to 0.6 mm (0 to 0.0236 in.)

      Note

      Do not damage the end surface of the electro magnetic control coupling sub-assembly.

      Tech Tips

      If the end surface of the electro magnetic control coupling sub-assembly is damaged while installing the rear differential dust deflector, replace the electro magnetic control coupling sub-assembly with a new one.

  38. INSTALL STUD BOLT


    1. A002COXC01
      *a Upper Nut
      *b Lower Nut
      *c Hold
      *d Turn

      Temporarily install 4 new stud bolts to the electro magnetic control coupling sub-assembly.

    2. Install 2 service nuts to the stud bolt.

      Recommended Service Nut
      Thread Diameter
      10 mm (0.394 in.)
      Thread Pitch
      1.0 mm (0.0394 in.)

    3. Lock the upper nut using the lower nut.

    4. A002BL0N01

      Turn the upper nut and tighten the other 3 stud bolts to the electro magnetic control coupling sub-assembly in the same way.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Standard Distance (A)
      22.55 to 25.85 mm (0.888 to 1.017 in.)

      Note

      Prevent foreign matter from entering the electro magnetic control coupling sub-assembly.

      Tech Tips

      If the threads of the electro magnetic control coupling sub-assembly are damaged while installing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

  39. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      Note


      • Do not damage the contact surface.

      • Be sure to completely remove all seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      • Do not allow the removed seal packing to enter the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier assembly and the electro magnetic control coupling sub-assembly.

      Note

      Do not damage the contact surface.

    3. A0028V0C01
      *a 20 mm (0.787 in.)
      *b 1.0 mm (0.0394 in.)
      *c 1.4 mm (0.0551 in.)
      *d 3.0 mm (0.118 in.)
      *e 2.0 mm (0.0787 in.)

      Apply seal packing to the areas indicated in the illustration of the rear differential carrier assembly.

      Seal Packing
      Toyota Genuine Seal Packing 1280G, Three Bond 1280G or equivalent

      Note


      • Start applying seal packing within range (A).

      • Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).

      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.

      • Install the electro magnetic control coupling sub-assembly within 3 minutes after applying seal packing. If the electro magnetic control coupling sub-assembly is not installed within 3 minutes after applying seal packing, completely remove and then reapply seal packing.

      • After installing the electro magnetic control coupling sub-assembly, do not immediately add oil or drive the vehicle for at least 1 hour.

    4. A0027GZ

      Install the electro magnetic control coupling sub-assembly with the 4 bolts.

      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note


      • Do not damage the diaphragm oil seal.

      • Do not damage the contact surface of the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

  40. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A002CM4

      Using a socket wrench, service nut and a hammer, install the rear differential carrier cover breather plug to the rear differential carrier.

      Note

      Tap the rear differential carrier cover breather plug in until the flange meets the edge of the rear differential carrier sub-assembly.

      Tech Tips


      • Use a service nut with an inner diameter of 13 mm (0.512 in.) and a socket wrench appropriate for the service nut.

      • Tap in the rear differential carrier cover breather plug until it sits flush with the rear differential carrier assembly.

  41. INSPECT RUNOUT OF ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A0028IVC01
      *a Vertical Runout
      *b Lateral Runout

      Install a dial indicator and magnetic base perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.

    2. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

      SST
      09564-32011
      Maximum Runout
      0.06 mm (0.00236 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

    3. Install a dial indicator and magnetic base perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

    4. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

      SST
      09564-32011
      Maximum Runout
      0.07 mm (0.00276 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

  42. INSTALL REAR DIFFERENTIAL FILLER PLUG


    1. A002AH3

      Install a new gasket and the rear differential filler plug.

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

  43. INSTALL CONNECTOR BRACKET


    1. A0027X9

      Install a new clamp to the connector bracket as shown in the illustration.

    2. A0029L2

      Install the 2 connector brackets with the 3 bolts.

      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

  44. INSTALL ELECTRO MAGNETIC CONTROL COUPLING WIRE HARNESS


    1. A002814C01
      *a Identification Mark
      *b Clamp
      *c Width of Clamp

      Install a new clamp to the electro magnetic control coupling wire harness as shown in the illustration.

      Standard Distance (A)
      84 to 90 mm (3.31 to 3.54 in.)

      Note

      Be sure to align the clamp with the identification mark.

    2. A002AJJN02

      Engage the claw to install the electro magnetic control coupling wire harness connector.

    3. Install the electro magnetic control coupling wire harness to the clamp (A).

    4. Install the clamp (B) to the connector bracket.

      Note

      Do not damage the electro magnetic control coupling wire harness.