PROCEDURE
ASSEMBLE DIFFERENTIAL CASE
Install the rear No. 1 differential side gear thrust washer to the side gear.
Tech Tips
Using the table below, select 2 thrust washers which will ensure that the backlash is within the specifications.
| Standard Washer Thickness | ||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
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.
Measure the side gear backlash.
Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
| Backlash |
|---|
| 0.05 to 0.20 mm (0.00197 to 0.00787 in.) |
If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.
Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.
Stake the differential case.
INSTALL DIFFERENTIAL RING GEAR
Clean the contact surfaces of the differential case and differential ring gear.
Heat the differential ring gear in boiling water that is approximately 100°C (212°F).
Carefully remove the differential ring gear from the boiling water.
| *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.
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 |
Diametrically tighten the 12 bolts uniformly in several passes.
INSTALL REAR DIFFERENTIAL CASE BEARING
Using SST and a press, press the 2 rear differential case bearings onto the differential case.
INSPECT DIFFERENTIAL RING GEAR RUNOUT
Install the differential case on the differential carrier, and install the 2 plate washers so that there is no play in the bearing.
Install the 2 differential bearing caps with the 4 bolts.
| *a | 98 mm (3.86 in.) |
Using a dial indicator, measure the runout of the differential ring gear.
| Maximum runout |
|---|
| 0.07 mm (0.00276 in.) |
Remove the 2 differential bearing caps, 2 plate washers and differential case assembly.
INSTALL DIFFERENTIAL OIL STORAGE RING
| *1 | Differential Oil Storage Ring |
Using SST and a hammer, tap in the differential oil storage ring.
Note
Be careful not to damage the differential oil storage ring.
INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
| *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.
INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
| *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.
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.
INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
Using SST and a press, press the rear drive pinion rear tapered roller bearing (inner) onto the differential drive pinion.
ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
Install the differential drive pinion, rear drive pinion front tapered roller bearing (inner).
Tech Tips
Install the rear differential drive pinion bearing spacer and rear differential carrier oil seal after adjusting the gear contact pattern.
Install the rear differential drive pinion oil slinger.
| *a | Turn |
| *b | Hold |
Using SST, install the rear drive pinion companion flange sub-assembly with dust deflector.
Note
Before using SST (center bolt), apply hypoid gear oil to its threads and tip.
Adjust the drive pinion preload by tightening the drive pinion nut.
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).
| Limit torque value |
|---|
| 457 N*m (4660 kgf*cm, 337 ft.*lbf) or less |
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.
Using a torque wrench, measure the preload.
| Standard Drive Pinion Preload (Starting Torque) | ||||||||
|---|---|---|---|---|---|---|---|---|
|
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.
INSTALL DIFFERENTIAL CASE ASSEMBLY
Place the 2 rear differential case bearings (outer) to their respective bearings.
Tech Tips
Make sure the right and left races are not interchanged.
ADJUST DIFFERENTIAL RING GEAR BACKLASH
Install the plate washer to the RH side (teeth side).
Note
Make sure that the differential ring gear has backlash.
Using a dial indicator, while holding the companion flange, measure the ring gear backlash.
| Standard backlash (reference) |
|---|
| 0.10 to 0.20 mm (0.00394 to 0.00787 in.) |
Refer to the backlash when selecting a plate washer for the RH side (teeth side).
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.
Using a plastic-faced hammer, install the plate washer to the LH side (back side).
Using a dial indicator, adjust the ring gear backlash until it is within the specification.
| Standard backlash |
|---|
| 0.10 to 0.20 mm (0.00394 to 0.00787 in.) |
Tech Tips
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.
ADJUST SIDE BEARING PRELOAD
After adjusting the backlash of the differential ring gear, remove the plate washer from the LH side (back side).
Using a micrometer, measure the thickness of the plate washer.
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.
Recheck the ring gear backlash.
| Standard backlash |
|---|
| 0.10 to 0.20 mm (0.00394 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) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| Standard Washer RH (Teeth Side) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
INSPECT TOTAL PRELOAD
Using a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.
| Standard Total Preload | |||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
If necessary, disassemble and inspect the differential.
INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.
Hold the companion flange firmly in place and rotate the differential ring gear in both directions.
Inspect the tooth contact pattern.
| *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 | - | - |
| *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 | ||||||||||||||||||||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
REMOVE REAR DRIVE PINION NUT
REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR
REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
REMOVE DIFFERENTIAL BEARING CAP
REMOVE DIFFERENTIAL CASE ASSEMBLY
REMOVE DIFFERENTIAL DRIVE PINION
REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
REMOVE DIFFERENTIAL OIL STORAGE RING
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
| *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.
INSTALL DIFFERENTIAL OIL STORAGE RING
| *1 | Differential Oil Storage Ring |
Using SST and a hammer, tap in a new differential oil storage ring.
Note
Be careful not to damage the differential oil storage ring.
INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
| *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.
INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
Install a new rear differential drive pinion bearing spacer.
INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
Install the rear drive pinion front tapered roller bearing (inner).
INSTALL DIFFERENTIAL DRIVE PINION
Using SST and a press, install the differential drive pinion.
INSTALL DIFFERENTIAL CASE ASSEMBLY
Place the 2 rear differential case bearings (outer) to their respective bearings.
Tech Tips
Make sure the right and left races are not interchanged.
INSTALL DIFFERENTIAL BEARING CAP
Install the 2 plate washers.
| *a | Matchmark |
Align the matchmarks on the differential bearing cap and differential carrier.
Install the right and left differential bearing caps with the 4 bolts.
INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
Install the rear differential drive pinion oil slinger to the differential drive pinion.
INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR
| *a | Turn |
| *b | Hold |
Using SST, install the rear drive pinion companion flange sub-assembly with dust deflector.
Note
Before using SST (center bolt), apply hypoid gear oil to its threads and tip.
Apply hypoid gear oil LSD to the drive pinion thread and nut seat face.
| *a | Turn |
| *b | Hold |
Using SST to hold the companion flange in place, install a new nut.
| Limit torque value |
|---|
| 457 N*m (4660 kgf*cm, 337 ft.*lbf) or less |
INSPECT TOTAL PRELOAD
Using a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.
Using a torque wrench, measure the total preload.
| Standard Total Preload | |||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
If necessary, disassemble and inspect the differential.
INSPECT DIFFERENTIAL RING GEAR BACKLASH
Using a dial indicator, check the backlash of the differential ring gear.
| Standard backlash |
|---|
| 0.10 to 0.20 mm (0.00394 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.
INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
| *a | 30 mm (1.18 in.) |
Using a dial indicator, measure the runout of the companion flange vertically and laterally.
| Maximum Runout | ||||||
|---|---|---|---|---|---|---|
|
STAKE DRIVE PINION NUT