REAR DIFFERENTIAL CARRIER ASSEMBLY(for DANA Made w/o Differential Lock) REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

The following procedures are for BD22 (w/o Differential Lock).

PROCEDURE


  1. ASSEMBLE DIFFERENTIAL CASE


    1. B003QRV

      Install the rear No. 1 differential side gear thrust washer to the side gear.

    2. B003QEM

      Install 2 side gears, 2 pinion gears, 2 rear No. 1 differential side gear thrust washers, 2 pinion gear thrust washers and the pinion shaft in the differential case.

      Tech Tips

      Align the holes of the differential case and pinion shaft.

    3. B003K5L

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

    4. Stake the differential case.

  2. 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 that is approximately 100°C (212°F).

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

    4. B003S3XC01
      *a Matchmark

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

    5. After the ring gear cools down sufficiently, apply adhesive to the 12 bolts and Temporarily install them.

      Thread lock
      Toyota Genuine Adhesive 1360K, Three Bond1360K or equivalent

    6. Diametrically tighten the 12 bolts uniformly in several passes.

      Torque:
      175 N*m  { 1785 kgf*cm, 129 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. B003K78N01

      Using SST and a press, press the 2 rear differential case bearings onto the differential case.

      SST
      09950-60010   ( 09951-00430, 09951-00470, 09951-00480, 09951-00550 )
      09950-70010   ( 09951-00560, 09951-00570, 09951-07150 )

  4. INSTALL DIFFERENTIAL OIL STORAGE RING


    1. B003LS7C01
      *1 Differential Oil Storage Ring

      Using SST and a hammer, tap in the differential oil storage ring.

      SST
      09316-60011   ( 09316-00011, 09316-00071 )

      Note

      Be careful not to damage the differential oil storage ring.

  5. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003QDIC01
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Outer)

      Using SST and a press, press the rear drive pinion front tapered roller bearing (outer) into the differential carrier.

      SST
      09316-60011   ( 09316-00011, 09316-00031 )

  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003R6ZC01
      *1 Rear Drive Pinion Rear Tapered Roller Bearing (Outer)

      Using SST and a press, press the adjust shim and rear drive pinion rear tapered roller bearing (outer) into the differential carrier.

      SST
      09316-60011   ( 09316-00011 )
      09951-01000

      Tech Tips

      First, install an adjust shim that has the same thickness as the removed adjust shim. After checking the tooth contact pattern, replace the adjust shim with one of a different thickness if necessary.

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003LXEN01

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

      SST
      09309-37010
      09630-24014   ( 09620-24051 )

  8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. B003MWRN01

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

      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 gear contact pattern.

    2. B003MAL

      Install the rear differential drive pinion oil slinger.

    3. B003N51C01
      *a Turn
      *b Hold

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

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

      Note

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

    4. Adjust the drive pinion preload by tightening the drive pinion nut.

    5. B003QLDN01

      Using SST to hold the companion flange in place, slowly tighten the nut within the drive pinion preload adjustment range so that it reaches the specified drive pinion preload (at Starting).

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      298 N*m  { 3039 kgf*cm, 6913 kgf*cm, 220 ft.*lbf, 500 ft.*lbf }

      Note


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

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

    6. Using a torque wrench, measure the preload.

      Standard Drive Pinion Preload (Starting Torque)
      1.99 to 3.65 N*m (21 to 37 kgf*cm, 18 to 32 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.

  9. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. B003RZQ

      Place the 2 rear differential case bearings (outer) to their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

  10. ADJUST DIFFERENTIAL RING GEAR BACKLASH


    1. B003RKV

      Install the plate washer to the RH side (teeth side).

      Note

      Make sure that the differential ring gear has backlash.

    2. B003L2Q

      Using a dial indicator, while holding the companion flange, measure the ring gear backlash.

      Standard backlash (reference)
      0.13 to 0.20 mm (0.00512 to 0.00787 in.)
    3. B003KH7

      Refer to the backlash when selecting a plate washer for the RH side (teeth side).

    4. B003MK9

      Select a plate washer for the LH side (back side) so that there is no gap between the rear differential case bearing (outer) and differential case.

    5. Using a plastic-faced hammer, install the plate washer to the LH side (back side).

    6. B003L2Q

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

      Standard backlash
      0.13 to 0.20 mm (0.00512 to 0.00787 in.)

      Tech Tips

      If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount.

      Note


      • There should be no clearance between the plate washer and case.

      • Make sure that there is ring gear backlash.

  11. ADJUST SIDE BEARING PRELOAD


    1. B003LMU

      After adjusting the backlash of the differential ring gear, remove the plate washer from the LH side (back side).

    2. B003LN6

      Using a micrometer, measure the thickness of the plate washer.

    3. Using the backlash as a reference, select a new washer that is 0.05 to 0.20 mm (0.00197 to 0.00787 in.) thicker than the removed plate washer and, using a plastic-faced hammer, tap it in so that it fits against the bearing.

      Tech Tips

      Select a plate washer which can be pressed in 2/3 of the full amount with your finger.

    4. B003L2Q

      Recheck the ring gear backlash.

      Standard backlash
      0.13 to 0.20 mm (0.00512 to 0.00787 in.)

      If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount.

      Tech Tips

      An approximately 0.02 mm (0.000787 in.) change in each plate washer results in a 0.03 mm (0.00118 in.) change in the backlash.

      Standard Washer LH (Back Side)
      Part No. Thickness mm (in.) Part No. Thickness mm (in.)
      90564-S0025 2.832 mm (0.1115 in.) 90564-S0040 2.413 mm (0.0950 in.)
      90564-S0026 2.804 mm (0.1104 in.) 90564-S0041 2.385 mm (0.0939 in.)
      90564-S0027 2.777 mm (0.1093 in.) 90564-S0042 2.357 mm (0.0928 in.)
      90564-S0028 2.749 mm (0.1082 in.) 90564-S0043 2.329 mm (0.0917 in.)
      90564-S0029 2.721 mm (0.1071 in.) 90564-S0044 2.302 mm (0.0906 in.)
      90564-S0030 2.693 mm (0.1060 in.) 90564-S0045 2.274 mm (0.0895 in.)
      90564-S0031 2.665 mm (0.1049 in.) 90564-S0046 2.246 mm (0.0884 in.)
      90564-S0032 2.637 mm (0.1038 in.) 90564-S0047 2.218 mm (0.0873 in.)
      90564-S0033 2.609 mm (0.1027 in.) 90564-S0048 2.190 mm (0.0862 in.)
      90564-S0034 2.581 mm (0.1016 in.) 90564-S0049 2.162 mm (0.0851 in.)
      90564-S0035 2.553 mm (0.1005 in.) 90564-S0050 2.134 mm (0.0840 in.)
      90564-S0036 2.525 mm (0.0994 in.) 90564-S0051 2.860 mm (0.1126 in.)
      90564-S0037 2.497 mm (0.0983 in.) 90564-S0052 2.888 mm (0.1137 in.)
      90564-S0038 2.469 mm (0.0972 in.) 90564-S0053 2.916 mm (0.1148 in.)
      90564-S0039 2.441 mm (0.0961 in.) 90564-S0054 2.944 mm (0.1159 in.)
      Standard Washer RH (Teeth Side)
      Part No. Thickness mm (in.) Part No. Thickness mm (in.)
      90564-S0055 0.76 mm (0.0299 in.) 90564-S0091 1.68 mm (0.0661 in.)
      90564-S0056 0.79 mm (0.0311 in.) 90564-S0092 1.70 mm (0.0669 in.)
      90564-S0057 0.81 mm (0.0319 in.) 90564-S0093 1.73 mm (0.0681 in.)
      90564-S0058 0.84 mm (0.0331 in.) 90564-S0094 1.75 mm (0.0689 in.)
      90564-S0059 0.86 mm (0.0339 in.) 90564-S0095 1.78 mm (0.0701 in.)
      90564-S0060 0.89 mm (0.0350 in.) 90564-S0096 1.80 mm (0.0709 in.)
      90564-S0061 0.91 mm (0.0358 in.) 90564-S0097 1.83 mm (0.0720 in.)
      90564-S0062 0.94 mm (0.0370 in.) 90564-S0098 1.85 mm (0.0728 in.)
      90564-S0063 0.97 mm (0.0382 in.) 90564-S0099 1.88 mm (0.0740 in.)
      90564-S0064 0.99 mm (0.0390 in.) 90564-S0100 1.91 mm (0.0752 in.)
      90564-S0065 1.02 mm (0.0402 in.) 90564-S0101 1.93 mm (0.0760 in.)
      90564-S0066 1.04 mm (0.0409 in.) 90564-S0102 1.96 mm (0.0772 in.)
      90564-S0067 1.07 mm (0.0421 in.) 90564-S0103 1.98 mm (0.0780 in.)
      90564-S0068 1.09 mm (0.0429 in.) 90564-S0104 2.01 mm (0.0791 in.)
      90564-S0069 1.12 mm (0.0441 in.) 90564-S0105 2.03 mm (0.0799 in.)
      90564-S0070 1.14 mm (0.0449 in.) 90564-S0106 2.06 mm (0.0811 in.)
      90564-S0071 1.17 mm (0.0461 in.) 90564-S0107 2.08 mm (0.0819 in.)
      90564-S0072 1.19 mm (0.0469 in.) 90564-S0108 2.11 mm (0.0831 in.)
      90564-S0073 1.22 mm (0.0480 in.) 90564-S0109 2.13 mm (0.0839 in.)
      90564-S0074 1.24 mm (0.0488 in.) 90564-S0110 2.16 mm (0.0850 in.)
      90564-S0075 1.27 mm (0.0500 in.) 90564-S0111 2.18 mm (0.0858 in.)
      90564-S0076 1.30 mm (0.0512 in.) 90564-S0112 2.21 mm (0.0870 in.)
      90564-S0077 1.32 mm (0.0520 in.) 90564-S0113 2.24 mm (0.0882 in.)
      90564-S0078 1.35 mm (0.0531 in.) 90564-S0114 2.26 mm (0.0890 in.)
      90564-S0079 1.37 mm (0.0539 in.) 90564-S0115 2.29 mm (0.0902 in.)
      90564-S0080 1.40 mm (0.0551 in.) 90564-S0116 2.31 mm (0.0909 in.)
      90564-S0081 1.42 mm (0.0559 in.) 90564-S0117 2.34 mm (0.0921 in.)
      90564-S0082 1.45 mm (0.0571 in.) 90564-S0118 2.36 mm (0.0929 in.)
      90564-S0083 1.47 mm (0.0579 in.) 90564-S0119 2.39 mm (0.0941 in.)
      90564-S0084 1.50 mm (0.0591 in.) 90564-S0120 2.41 mm (0.0949 in.)
      90564-S0085 1.52 mm (0.0598 in.) 90564-S0121 2.44 mm (0.0961 in.)
      90564-S0086 1.55 mm (0.0610 in.) 90564-S0122 2.46 mm (0.0969 in.)
      90564-S0087 1.57 mm (0.0618 in.) 90564-S0123 2.49 mm (0.0980 in.)
      90564-S0088 1.60 mm (0.0630 in.) 90564-S0124 2.51 mm (0.0988 in.)
      90564-S0089 1.63 mm (0.0642 in.) 90564-S0125 2.54 mm (0.1000 in.)
      90564-S0090 1.65 mm (0.0650 in.) - -

  12. INSPECT TOTAL PRELOAD


    1. B003N5T

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

      Standard Total Preload
      Reduction Ratio Specified Condition
      3.909 1.95 to 3.94 N*m (20 to 40 kgf*cm, 18 to 34 in.*lbf)
      4.300 1.93 to 3.89 N*m (20 to 39 kgf*cm, 18 to 34 in.*lbf)
      4.555 1.91 to 3.86 N*m (20 to 39 kgf*cm, 17 to 34 in.*lbf)

      If necessary, disassemble and inspect the differential.

  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    B003KL7

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

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

    3. Inspect the tooth contact pattern.


      • B003PD0C02
        *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 - -
      • B003LD1C04
        *1 Adjust Shim
        *2 Rear Drive Pinion Rear Tapered Roller Bearing (Outer)

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

      Standard Adjust Shim Thickness
      Part No. Thickness mm (in.) Part No. Thickness mm (in.)
      90564-S0001 1.025 mm (0.0404 in.) 90564-S0011 1.275 mm (0.0502 in.)
      90564-S0002 1.050 mm (0.0413 in.) 90564-S0012 1.300 mm (0.0512 in.)
      90564-S0003 1.075 mm (0.0423 in.) 90564-S0013 1.325 mm (0.0522 in.)
      90564-S0004 1.100 mm (0.0433 in.) 90564-S0014 1.350 mm (0.0531 in.)
      90564-S0005 1.125 mm (0.0443 in.) 90564-S0015 1.375 mm (0.0541 in.)
      90564-S0006 1.150 mm (0.0453 in.) 90564-S0016 1.400 mm (0.0551 in.)
      90564-S0007 1.175 mm (0.0463 in.) 90564-S0017 1.425 mm (0.0561 in.)
      90564-S0008 1.200 mm (0.0472 in.) 90564-S0018 1.450 mm (0.0571 in.)
      90564-S0009 1.225 mm (0.0482 in.) 90564-S0019 1.475 mm (0.0581 in.)
      90564-S0010 1.250 mm (0.0492 in.) - -

  14. REMOVE REAR DRIVE PINION NUT

    Click here

  15. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR

    Click here

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  17. REMOVE DIFFERENTIAL BEARING CAP

    Click here

  18. REMOVE DIFFERENTIAL CASE ASSEMBLY

    Click here

  19. REMOVE DIFFERENTIAL DRIVE PINION

    Click here

  20. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

    Click here

  21. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    Click here

  22. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    Click here

  23. REMOVE DIFFERENTIAL OIL STORAGE RING

    Click here

  24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    Click here

  25. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003R6ZC01
      *1 Rear Drive Pinion Rear Tapered Roller Bearing (Outer)

      Using SST and a press, press the adjust shim and rear drive pinion rear tapered roller bearing (outer) into the differential carrier.

      SST
      09316-60011   ( 09316-00011 )
      09951-01000

  26. INSTALL DIFFERENTIAL OIL STORAGE RING


    1. B003LS7C01
      *1 Differential Oil Storage Ring

      Using SST and a hammer, tap in a new differential oil storage ring.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Be careful not to damage the differential oil storage ring.

  27. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003QDIC01
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Outer)

      Using SST and a press, press the rear drive pinion front tapered roller bearing (outer) into the differential carrier.

      SST
      09316-60011   ( 09316-00011, 09316-00031 )

  28. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B003K6E

      Install a new rear differential drive pinion bearing spacer.

  29. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003P6F

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

  30. INSTALL DIFFERENTIAL DRIVE PINION


    1. B003MWRN01

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

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

  31. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. B003KGT

      Place the 2 rear differential case bearings (outer) to their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

  32. INSTALL DIFFERENTIAL BEARING CAP


    1. Install the 2 plate washers.

    2. B003S2TC02
      *a Matchmark

      Align the matchmarks on the differential bearing cap and differential carrier.

    3. Install the right and left differential bearing caps with the 4 bolts.

      Torque:
      140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

  33. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. B003MAL

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

  34. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  35. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR


    1. B003N51C01
      *a Turn
      *b Hold

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

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

      Note

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

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

    3. B003JQGC01
      *a Turn
      *b Hold

      Using SST to hold the companion flange in place, install a new nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      298 N*m  { 3039 kgf*cm, 6913 kgf*cm, 220 ft.*lbf, 500 ft.*lbf }

  36. INSPECT TOTAL PRELOAD


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

    2. B003N5T

      Using a torque wrench, measure the total preload.

      Standard Total Preload
      Reduction Ratio Preload
      3.909 2.25 to 4.24 N*m (23 to 43 kgf*cm, 20 to 37 in.*lbf)
      4.300 2.23 to 4.19 N*m (23 to 42 kgf*cm, 20 to 37 in.*lbf)
      4.555 2.21 to 4.16 N*m (23 to 42 kgf*cm, 20 to 36 in.*lbf)

      If necessary, disassemble and inspect the differential.

  37. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. B003L2Q

      Using a dial indicator, check the backlash of the differential ring gear.

      Standard backlash
      0.13 to 0.20 mm (0.00512 to 0.00787 in.)

      If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.

      Tech Tips

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

  38. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B003J87C01
      *a 36 mm (1.42 in.)

      Using a dial indicator, measure the runout of the companion flange vertically and laterally.

      Maximum Runout
      Runout Maximum
      Vertical runout 0.10 mm (0.00394 in.)
      Lateral runout 0.10 mm (0.00394 in.)

  39. STAKE DRIVE PINION NUT

    Click here