FRONT DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT


  1. DRAIN DIFFERENTIAL OIL


    1. Stop the vehicle on a level place.

    2. A015CRJ

      for Front Differential:


      1. Remove the engine under cover.

      2. Using a 10 mm hexagon wrench, remove the filler plug and gasket.

      3. Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.

      4. Using a 10 mm hexagon wrench, install a new gasket and the drain plug.

        Torque:
        39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    3. for Rear Differential:


      1. Remove the filler plug and gasket.

      2. Remove the drain plug and gasket, and drain the oil.

      3. Install a new gasket and the drain plug.

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

  2. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY


    1. Remove the differential carrier Click here.

  3. REMOVE DIFFERENTIAL EXTENSION FLANGE TUBE


    1. A015AC3

      Remove the 4 bolts.

    2. Using a plastic-faced hammer, remove the differential tube.

  4. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A015560E02

      Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. A015C24E02

      Using SST to hold the companion flange, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

  5. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY


    1. A0155P9E04

      Using SST, remove the companion flange from the differential carrier.

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

  6. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A0157D1E02

      Using SST, remove the oil seal.

      SST
      09308-10010

  7. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  8. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. A01564FE01

      Remove the bolts labeled B and front differential front support assembly LH.

    2. Remove the bolts labeled A.

    3. Using a plastic-faced hammer, tap out the bearing retainer.

  9. REMOVE FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the differential case from the differential carrier.

  10. REMOVE DIFFERENTIAL DRIVE PINION


    1. A0159S4E02

      Set the differential carrier to an overhaul stand as shown in the illustration.

    2. Using a press, press out the drive pinion.

      Note

      Do not drop the drive pinion.

  11. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. Remove the bearing (inner race) from the differential carrier.

  12. REPLACE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. Replace the bearing spacer with a new one.

  13. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

  14. INSTALL FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

  15. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and shaft bearing retainer.

    2. Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

    3. A0159ZLE01

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal Diameter (A)
      2.0 to 3.0 mm (0.0788 to 0.118 in.)

      Tech Tips

      Install the shaft bearing retainer within 10 minutes of applying seal packing.

    4. A01564FE01

      Install the front differential cross shaft bearing retainer and front differential front support assembly LH with the 11 bolts (A) and 3 new bolts (B).

      Torque:
      for bolt A
      65 N*m  { 633 kgf*cm, 48 ft.*lbf }
      for bolt B
      155 N*m  { 1581 kgf*cm, 114 ft.*lbf }

      Note

      Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.

  16. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A015D49E02

      Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

      SST
      09316-60011   ( 09316-00041 )

  17. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  18. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A0156S0E02

      Using SST and a hammer, tap in a new oil seal.

      SST
      09502-12010
      09316-60011   ( 09316-00041 )
      Standard oil seal depth
      5.6 to 6.6 mm (0.221 to 0.260 in.)

    2. Coat the lip of the oil seal with MP grease.

  19. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A0155P9E04

      Using SST, install the companion flange.

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

  20. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A0159FCE02

      Using SST, hold the companion flange.

      SST
      09330-00021   ( 09330-00030 )

    2. Coat the threads of a new nut with hypoid gear oil.

    3. Install the nut by tightening it until the standard preload is reached.

      Torque:
      451 N*m  { 4599 kgf*cm, 332 ft.*lbf, or less }
    4. A01560M

      Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

      Standard Preload (at Starting)
      Bearing Specified Condition
      New 3.0 to 3.5 N*m (31 to 35 kgf*cm, 27 to 50 in.*lbf)
      Reused 2.1 to 2.5 N*m (22 to 24 kgf*cm, 19 to 21 in.*lbf)

      If the preload is more than the specification, replace the bearing spacer.

      If the preload is less than the specification, tighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

      Torque:
      451 N*m  { 4599 kgf*cm, 332 ft.*lbf, or less }

      If the maximum torque is exceeded while tightening the nut, replace the bearing spacer and repeat the preload procedure.

      Tech Tips

      Do not loosen the nut to reduce the preload.

  21. INSPECT TOTAL PRELOAD


    1. A01560M

      With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure the total preload.

      Standard Total Preload (at Starting)
      Bearing Specified Condition
      New Standard drive pinion preload plus 1.6 to 2.4 N*m (17 to 24 kgf*cm, 15 to 21 in.*lbf)
      Reused Standard drive pinion preload plus 1.3 to 2.1 N*m (14 to 21 kgf*cm, 12 to 18 in.*lbf)

  22. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A015933

      Using a chisel and hammer, stake the nut.

  23. INSTALL DIFFERENTIAL EXTENSION FLANGE TUBE


    1. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and bearing retainer.

    2. Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

    3. A0155ZSE01

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal Diameter (A)
      2.0 to 3.0 mm (0.0788 to 0.118 in.)

      Tech Tips

      Install the differential tube within 10 minutes of applying seal packing.

    4. Install the differential tube to the bearing retainer.

    5. A015AC3

      Install 4 new bolts.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf, or less }

      Note

      Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.

  24. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY


    1. Install the front differential carrier Click here.

  25. ADD DIFFERENTIAL OIL


    1. A015750E27

      Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the differential filler plug hole.

      Note


      • Too much or too little oil will lead to differential problems.

      • After changing the oil, drive the vehicle and then check the oil level again.

      Front differential oil type and viscosity
      Toyota Genuine Differential gear oil LT 75W-85 GL-5 or equivalent
      Rear Differential Oil Type and Viscosity
      Item Oil Type and Viscosity
      w/o LSD Toyota Genuine Differential gear oil LT 75W-85 GL-5 or equivalent
      w/ LSD Toyota Genuine Differential gear oil LX 75W-85 GL-5 or equivalent
      Front differential capacity
      1.85 to 1.95 liters (1.96 to 2.06 US qts., 1.63 to 1.71 Imp. qts.)
      Rear Differential Capacity
      Item Specified Condition
      Standard 4.15 to 4.25 liters (4.39 to 4.49 US qts., 3.66 to 3.74 Imp. qts.)
      w/ LSD 4.10 to 4.20 liters (4.34 to 4.43 US qts., 3.60 to 3.69 Imp. qts.)
      w/ Differential lock

    2. for Front Differential:


      1. Using a 10 mm hexagon wrench, install a new gasket and the filler plug.

        Torque:
        39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      2. Install the engine under cover.

    3. for Rear Differential:


      1. Install a new gasket and the filler plug.

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