FRONT DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH


    1. B003OKEN02

      Using SST and a press, press in the front differential side gear shaft bearing RH.

      SST
      09223-00010

    2. Using a snap ring expander, install the snap ring.

      Tech Tips

      Install the snap ring securely.

  2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. B003NQB

      Install the differential side gear shaft sub-assembly RH to the front differential tube assembly.

    2. Using a snap ring pliers, install a new snap ring.

      Tech Tips

      Install the snap ring securely.

  3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH

    Click here

  4. INSTALL DIFFERENTIAL CLUTCH HUB


    1. B003MD4

      Install the differential clutch hub to the differential side gear shaft sub-assembly RH.

    2. Using snap ring expander, install the side gear shaft hole snap ring.

      Tech Tips

      Install the snap ring securely.

      Note

      Make sure to install the differential clutch hub in the correct direction.

  5. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING


    1. B003KDEC01
      *a Front Differential Side Gear Needle Roller Bearing Depth

      Using SST and a press, press in 2 new front differential side gear needle roller bearings.

      SST
      09950-60010   ( 09951-00380 )
      Front differential side gear needle roller bearing depth
      1.4 to 2.0 mm (0.0552 to 0.0787 in.)

  6. ASSEMBLE DIFFERENTIAL CASE


    1. B003QRV

      Install 2 thrust washers to the 2 differential side gears.

      Tech Tips

      Using the table below, select 2 differential side gear thrust washers which will ensure that the backlash is within the specifications.

      Standard Thrust Washer Thickness
      Thickness mm (in.) Thickness mm (in.)
      1.48 to 1.52 (0.0583 to 0.0598) 1.73 to 1.77 (0.0682 to 0.0696)
      1.53 to 1.57 (0.0603 to 0.0618) 1.78 to 1.82 (0.0701 to 0.0716)
      1.58 to 1.62 (0.0622 to 0.0637) 1.83 to 1.87 (0.0721 to 0.0736)
      1.63 to 1.67 (0.0642 to 0.0657) 1.88 to 1.92 (0.0741 to 0.0755)
      1.68 to 1.72 (0.0662 to 0.0677) -
    2. B003QEM

      Install the 2 differential side gears, 2 differential pinion gears, 2 differential side gear thrust washers, 2 differential pinion gear thrust washers and differential pinion shaft to the differential case.

      Tech Tips

      Align the holes of the differential case and differential pinion shaft.

    3. B003QSO

      Measure the side gear backlash.


      1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.

        Side gear backlash
        0.15 mm (0.00591 in.) or less

        • If the backlash is not as specified, install 2 differential side gear thrust washers with different thicknesses.

    4. B003K5L

      Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the differential pinion shaft.

    5. Stake the differential case.

  7. INSTALL DIFFERENTIAL RING GEAR


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

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

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

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

    5. B003KQOC01
      *a Matchmark

      Align the matchmarks on the differential ring gear and differential case.

    6. After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.

      Thread lock
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
      Torque:
      96.5 N*m  { 984 kgf*cm, 71 ft.*lbf }

  8. INSTALL FRONT DIFFERENTIAL CASE BEARING


    1. B003QRWN02

      Using SST and a press, press the 2 front differential case bearings (inner) onto the differential case.

      SST
      09950-60010   ( 09951-00520, 09951-00610 )
      09950-70010   ( 09951-07150 )

  9. INSTALL FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

    When replacing the 2 front differential case bearings, install the thinnest washer to each front differential case bearing. When reusing the front differential case bearings, install a new plate washer of the same thickness as the one that was removed to each front differential case bearing.


    1. B003RR0N02

      Using SST and a press, press in the front differential case bearing (outer) to the differential side bearing retainer.

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07150 )
    2. B003KXQN02

      Using SST and a press, press in the front differential case bearing (outer) to the differential carrier.

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07150 )

  10. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003KC8C01
      *1 Front Drive Pinion Front Tapered Roller Bearing (Outer)
      *a Turn
      *b Hold

      Using SST, install the front drive pinion front tapered roller bearing (outer).

      SST
      09950-60020   ( 09951-00720, 09951-00890 )

  11. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Using a brass bar and hammer, tap in a new oil storage ring.

    2. B003KYDC01
      *1 Front Drive Pinion Rear Tapered Roller Bearing (Outer)
      *a Turn
      *b Hold

      Using SST, install the front drive pinion rear tapered roller bearing (outer).

      SST
      09950-60020   ( 09951-00720, 09951-00890 )

  12. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


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

      Tech Tips

      First, install a drive pinion plate washer that has the same thickness as the removed drive pinion plate washer. After checking the tooth contact pattern, replace the drive pinion plate washer with one of a different thickness if necessary.

    2. B003P7GN06

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

      SST
      09506-30012

  13. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. B003PBT

      Install the differential drive pinion, front drive pinion rear tapered roller bearing (inner) and front differential drive pinion oil slinger.

      Tech Tips

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

    2. B003QROC05
      *a Turn
      *b Hold

      Using SST, install the front drive pinion companion flange sub-assembly with dust deflector.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )

      Note

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

    3. Adjust the differential drive pinion preload by tightening the front drive pinion companion flange nut.

    4. B003NYXC04
      *a Turn
      *b Hold

      Using SST to hold the front drive pinion companion flange sub-assembly with dust deflector in place, tighten the front drive pinion companion flange nut.

      SST
      09330-00021   ( 09330-00030 )
      Limit torque value
      370 N*m (3773 kgf*cm, 273 ft.*lbf) or less

      Note


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

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

    5. B003NRP

      Using a torque wrench, measure the preload.

      Standard Preload (Starting Torque)
      Item Specified Condition
      New bearing 0.98 to 1.92 N*m (10 to 19 kgf*cm, 9 to 16 in.*lbf)
      Reused bearing 0.97 to 1.81 N*m (10 to 18 kgf*cm, 9 to 16 in.*lbf)

      Note


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

      • Record the differential drive pinion preload for the total preload measurement.

  14. INSTALL DIFFERENTIAL CASE ASSEMBLY

  15. ADJUST DIFFERENTIAL RING GEAR BACKLASH


    1. Install the side bearing retainer with the 10 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }
    2. B003LCPN05

      Using SST and a dial indicator, measure the ring gear backlash.

      SST
      09564-33010
      Standard backlash
      0.11 to 0.21 mm (0.00433 to 0.00826 in.)

      • If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.

        Tech Tips

        There should be no clearance between the plate washer and case. Make sure that the ring gear has backlash.

        Standard Washer LH Thickness (Side Opposite Ring Gear)
        Part No. Thickness mm (in.) Part No. Thickness mm (in.)
        90564-50184 1.57 to 1.59 (0.0619 to 0.0625) 90564-50194 1.87 to 1.89 (0.0737 to 0.0744)
        90564-50124 1.59 to 1.61 (0.0626 to 0.0633) 90564-50134 1.89 to 1.91 (0.0744 to 0.0751)
        90564-50185 1.61 to 1.63 (0.0634 to 0.0641) 90564-50195 1.91 to 1.93 (0.0752 to 0.0759)
        90564-50186 1.63 to 1.65 (0.0642 to 0.0649) 90564-50196 1.93 to 1.95 (0.0760 to 0.0767)
        90564-50126 1.65 to 1.67 (0.0650 to 0.0657) 90564-50136 1.95 to 1.97 (0.0768 to 0.0775)
        90564-50187 1.67 to 1.69 (0.0658 to 0.0665) 90564-50197 1.97 to 1.99 (0.0776 to 0.0783)
        90564-50188 1.69 to 1.71 (0.0666 to 0.0673) 90564-50198 1.99 to 2.01 (0.0784 to 0.0791)
        90564-50128 1.71 to 1.73 (0.0674 to 0.0681) 90564-50138 2.01 to 2.03 (0.0792 to 0.0799)
        90564-50189 1.73 to 1.75 (0.0682 to 0.0688) 90564-50199 2.03 to 2.05 (0.0800 to 0.0807)
        90564-50190 1.75 to 1.77 (0.0689 to 0.0696) 90564-50200 2.05 to 2.07 (0.0808 to 0.0814)
        90564-50130 1.77 to 1.79 (0.0697 to 0.0704) 90564-50140 2.07 to 2.09 (0.0815 to 0.0822)
        90564-50191 1.79 to 1.81 (0.0705 to 0.0712) 90564-50201 2.09 to 2.11 (0.0823 to 0.0830)
        90564-50192 1.81 to 1.83 (0.0713 to 0.0720) 90564-50202 2.11 to 2.13 (0.0831 to 0.0838)
        90564-50132 1.83 to 1.85 (0.0721 to 0.0728) 90564-50142 2.13 to 2.15 (0.0839 to 0.0846)
        90564-50193 1.85 to 1.87 (0.0729 to 0.0736) 90564-50203 2.15 to 2.17 (0.0847 to 0.0854)
        Standard Washer RH Thickness (ring gear side)
        Part No. Thickness mm (in.) Part No. Thickness mm (in.)
        90564-50204 1.57 to 1.59 (0.0619 to 0.0625) 90564-50214 1.87 to 1.89 (0.0737 to 0.0744)
        90564-50154 1.59 to 1.61 (0.0626 to 0.0633) 90564-50164 1.89 to 1.91 (0.0744 to 0.0751)
        90564-50205 1.61 to 1.63 (0.0634 to 0.0641) 90564-50215 1.91 to 1.93 (0.0752 to 0.0759)
        90564-50206 1.63 to 1.65 (0.0642 to 0.0649) 90564-50216 1.93 to 1.95 (0.0760 to 0.0767)
        90564-50156 1.65 to 1.67 (0.0650 to 0.0657) 90564-50166 1.95 to 1.97 (0.0768 to 0.0775)
        90564-50207 1.67 to 1.69 (0.0658 to 0.0665) 90564-50217 1.97 to 1.99 (0.0776 to 0.0783)
        90564-50208 1.69 to 1.71 (0.0666 to 0.0673) 90564-50218 1.99 to 2.01 (0.0784 to 0.0791)
        90564-50158 1.71 to 1.73 (0.0674 to 0.0681) 90564-50168 2.01 to 2.03 (0.0792 to 0.0799)
        90564-50209 1.73 to 1.75 (0.0682 to 0.0688) 90564-50219 2.03 to 2.05 (0.0800 to 0.0807)
        90564-50210 1.75 to 1.77 (0.0689 to 0.0696) 90564-50220 2.05 to 2.07 (0.0808 to 0.0814)
        90564-50160 1.77 to 1.79 (0.0697 to 0.0704) 90564-50170 2.07 to 2.09 (0.0815 to 0.0822)
        90564-50211 1.79 to 1.81 (0.0705 to 0.0712) 90564-50221 2.09 to 2.11 (0.0823 to 0.0830)
        90564-50212 1.81 to 1.83 (0.0713 to 0.0720) 90564-50222 2.11 to 2.13 (0.0831 to 0.0838)
        90564-50162 1.83 to 1.85 (0.0721 to 0.0728) 90564-50172 2.13 to 2.15 (0.0839 to 0.0846)
        90564-50213 1.85 to 1.87 (0.0729 to 0.0736) 90564-50223 2.15 to 2.17 (0.0847 to 0.0854)

  16. INSPECT TOTAL PRELOAD


    1. B003NRP

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

      Standard Total Preload (Starting Torque)
      Item Specified Condition
      New bearing 1.2 to 2.8 N*m (13 to 28 kgf*cm, 11 to 24 in.*lbf)
      Reused bearing 1.19 to 2.69 N*m (13 to 27 kgf*cm, 11 to 23 in.*lbf)

      Note

      Record the differential ring gear preload.

  17. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. Remove the differential case bearing retainer and differential case.

    2. B003O2N

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

    3. Install the differential case and differential case bearing retainer.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

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

    5. Remove the differential case bearing retainer and differential case.

    6. Inspect the tooth contact pattern.

      B003ROCC01
      *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 - -
    7. B003P0DC05
      *1 Drive Pinion Washer

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

      Standard Washer Thickness
      Part No. Thickness mm (in.) Part No. Thickness mm (in.)
      90564-35109 1.69 to 1.71 (0.0666 to 0.0673) 90564-35120 2.02 to 2.04 (0.0796 to 0.0803)
      90564-35110 1.72 to 1.74 (0.0678 to 0.0685) 90564-35121 2.05 to 2.07 (0.0807 to 0.0814)
      90564-35111 1.75 to 1.77 (0.0689 to 0.0696) 90564-35123 2.08 to 2.10 (0.0819 to 0.0826)
      90564-35112 1.78 to 1.80 (0.0701 to 0.0708) 90564-35124 2.11 to 2.13 (0.0831 to 0.0838)
      90564-35113 1.81 to 1.83 (0.0713 to 0.0720) 90564-35125 2.14 to 2.16 (0.0843 to 0.0850)
      90564-35114 1.84 to 1.86 (0.0725 to 0.0732) 90564-35126 2.17 to 2.19 (0.0855 to 0.0862)
      90564-35115 1.87 to 1.89 (0.0737 to 0.0744) 90564-35127 2.20 to 2.22 (0.0867 to 0.0874)
      90564-35116 1.90 to 1.92 (0.0748 to 0.0755) 90564-35128 2.23 to 2.25 (0.0878 to 0.0885)
      90564-35117 1.93 to 1.95 (0.0760 to 0.0767) 90564-36129 2.26 to 2.28 (0.0890 to 0.0897)
      90564-35118 1.96 to 1.98 (0.0772 to 0.0779) 90564-35130 2.29 to 2.31 (0.0902 to 0.0909)
      90564-35119 1.99 to 2.01 (0.0784 to 0.0791) 90564-35131 2.32 to 2.34 (0.0914 to 0.0921)

  18. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

    Click here

  19. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR

    Click here

  20. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

    Click here

  22. REMOVE DIFFERENTIAL DRIVE PINION

  23. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B003KY2

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

  24. INSTALL DIFFERENTIAL DRIVE PINION

  25. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003JUM

      Install the front drive pinion rear tapered roller bearing (inner) to the differential drive pinion.

  26. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  27. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

    Click here

  28. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR

    Click here

  29. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. Remove any old seal packing material from the differential side bearing retainer.

      Note

      Do not drop oil on the contact surfaces of the differential carrier and differential side bearing retainer.

    2. Clean residual seal packing material on the contact surface using gasoline or alcohol.

    3. B003Q6LC04
      *a Seal Packing

      Apply seal packing to the differential side bearing retainer as shown in the illustration.

      Seal packing
      Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

      Tech Tips

      Install the differential side bearing retainer within 3 minutes after applying seal packing.

    4. Install the differential side bearing retainer with the 10 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  30. INSPECT TOTAL PRELOAD


    1. B003NRP

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

      Standard Preload (Starting Torque)
      Item Specified Condition
      New bearing 1.3 to 2.9 N*m (14 to 29 kgf*cm, 12 to 25 in.*lbf)
      Reused bearing 1.29 to 2.79 N*m (14 to 28 kgf*cm, 12 to 24 in.*lbf)

      • If necessary, disassemble and inspect the differential.

  31. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. B003LCPN06

      Using SST and a dial indicator, measure the ring gear backlash.

      SST
      09564-32011
      Standard backlash
      0.11 to 0.21 mm (0.00433 to 0.00826 in.)

      • If the backlash is not within the specification, adjust the side bearing preload.

  32. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  33. STAKE FRONT DRIVE PINION COMPANION FLANGE NUT

    Click here

  34. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH

    Click here

  35. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR


    1. B003JZD

      Using a brass bar and hammer, tap in the front differential side bearing retainer deflector.

      Note

      Make sure to install the front differential side bearing retainer deflector in the correct direction.

  36. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY


    1. Install a new side gear intermediate shaft hole snap ring to the differential side gear inter shaft sub-assembly.

    2. B003PEP

      Using a plastic-faced hammer, tap the differential side gear inter shaft sub-assembly into the differential case.

    3. Check that there is 2 to 3 mm (0.0788 to 0.118 in.) of axial play.

    4. Check that the differential side gear inter shaft sub-assembly cannot be completely pulled out by hand.

  37. INSTALL DIFFERENTIAL CLUTCH SLEEVE


    1. Install the differential clutch sleeve.

  38. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY


    1. Remove any old seal packing material on the contact surfaces of the differential and clutch case.

      Note

      Do not drop oil on the contact surfaces of the differential and clutch case.

    2. Clean residual seal packing material on the contact surface using gasoline or alcohol.

    3. B003K5WC04
      *a Seal Packing

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

      Seal packing
      Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

      Tech Tips

      Install the differential tube within 3 minutes after applying seal packing.

    4. Install the front differential tube to the differential.

    5. B003KXP

      Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

    6. Using an E14 ''TORX'' socket wrench, install the 4 bolts.

      Torque:
      110 N*m  { 1122 kgf*cm, 81 ft.*lbf }

  39. INSTALL DIFFERENTIAL MOTOR ACTUATOR ASSEMBLY


    1. B003JVZC02
      *a Seal Packing

      Remove any seal packing material from the contact surface of the differential and clutch case. Also, do not drop oil on the contact surfaces.

    2. Clean residual seal packing material from the contact surfaces using gasoline or alcohol.

    3. Apply seal packing to the front differential tube as shown.

      Seal packing
      Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

      Tech Tips

      Install the actuator within 3 minutes after applying seal packing.

    4. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

    5. B003N7C

      Install the differential motor actuator assembly to the front differential tube.

    6. Install the 4 bolts.

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

  40. INSTALL OIL TEMPERATURE SENSOR


    1. B003QN2

      Install the oil temperature sensor to the front differential carrier assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }