REAR DIFFERENTIAL CARRIER ASSEMBLY (w/ Differential Lock) REASSEMBLY


  1. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A0157VD

      Install the 2 thrust washers to the 2 side gears.

    2. Install the 4 thrust washers to the 4 pinion gears.

    3. A0156VW

      Install the 2 side gears into the differential case.

    4. Install the holder into the differential case.

    5. Install the 4 pinion gears.

    6. Align the holes of the differential case and pinion shaft, and install the 3 pinion shafts.

    7. Align the matchmarks and install the differential cover to the differential case.

    8. Temporarily install the 5 bolts and 3 pinion shaft pins.

    9. Using a T10 "TORX" socket, tighten the 5 bolts and 3 pinion shaft pins.

      Torque:
      58 N*m  { 590 kgf*cm, 43 ft.*lbf }
    10. A015BLX

      Using a dial indicator, while holding the side gear, measure the backlash.

      Standard backlash
      0.02 to 0.15 (0.000787 to 0.00591 in.)

      If the backlash is not within the specification, replace the side gear thrust washers with washers of a different thickness.

      Tech Tips


      • Make sure the washers on both sides are the same size.

      • Measure at all 4 pinion gear locations.

      • Apply hypoid gear oil to each sliding surface and rotating part.

      Standard Thrust Washer Thickness
      Specified Condition Specified Condition
      1.53 to 1.57 mm (0.0602 to 0.0618 in.) 1.83 to 1.87 mm (0.0721 to 0.0737 in.)
      1.58 to 1.62 mm (0.0622 to 0.0638 in.) 1.88 to 1.92 mm (0.0740 to 0.0756 in.)
      1.63 to 1.67 mm (0.0641 to 0.0657 in.) 1.93 to 1.97 mm (0.0760 to 0.0776 in.)
      1.68 to 1.72 mm (0.0661 to 0.0677 in.) 1.98 to 2.02 mm (0.0780 to 0.0795 in.)
      1.73 to 1.77 mm (0.0681 to 0.0697 in.) 2.03 to 2.07 mm (0.0799 to 0.0815 in.)
      1.78 to 1.82 mm (0.0701 to 0.0717 in.) 2.08 to 2.12 mm (0.0820 to 0.0835 in.)

    11. After measuring the backlash, remove the 5 set bolts and 3 pinion shaft pins.

  2. ASSEMBLE DIFFERENTIAL CASE


    1. Clean the threads of the bolts, pinion shaft pins, case and cover with non-residue solvent.

    2. A015687E01

      Coat the threads of the bolts and pinion shafts with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Align the matchmarks of the case and cover.

    4. Using a T10 "TORX" socket, install the 5 bolts and 3 pinion shaft pins.

      Torque:
      58 N*m  { 590 kgf*cm, 43 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A0159XQE02

      Differential Cover Side:

      Using SST and a press, press the side bearing onto the differential cover.

      SST
      09550-60010
    2. A015AQ1E03

      Ring Gear Side:

      Using SST and a press, press the side bearing onto the differential case.

      SST
      09550-60010

  4. INSTALL DIFFERENTIAL RING GEAR


    1. Clean the threads of the bolts and differential case with non-residue solvent.

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

    3. A015D7SE02

      Heat the ring gear to about 100°C (212°F) in boiling water.

    4. Carefully take the ring gear out of the boiling water.

    5. After the moisture on the ring gear has completely evaporated, quickly align the matchmarks on the ring gear and differential case and set the ring gear onto the differential case. Then temporarily install the 12 bolts so that the bolt holes in the ring gear and differential case are aligned.

    6. A015DYYE02

      After the ring gear cools down sufficiently, remove the 12 bolts. Then apply thread lock adhesive to the 12 bolts and install them.

      Thread lock
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }

  5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. Place the bearing outer races on their respective bearings.

      Tech Tips

      Do not interchange the left and right outer races.

    2. Install the assembled plate washers to the side bearing.

    3. Install the differential case to the differential carrier.

      Tech Tips

      If it is difficult to install the differential case to the carrier, replace the plate washer with a thinner one.

      However, select a plate washer that allows no clearance between it and the carrier.

    4. Align the matchmarks on the bearing caps and differential carrier.

    5. Install and uniformly tighten the 4 bolts a little at a time.

    6. A0158EM

      Using a dial indicator, check the ring gear runout.

      Maximum runout
      0.05 mm (0.00197 in.)

      If the runout is more than the maximum, replace the ring gear.

    7. Remove the differential case.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A015D62E03

      Using SST and a press, press in the front bearing outer race.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07150 )

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A015E3FE03

      Using SST and a press, press in the rear bearing outer race.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the washer to the drive pinion.

      Tech Tips

      After installing the washer, check the tooth contact pattern. If necessary, replace the washer with one of a different thickness.

    2. A0155NJE02

      Using SST and a press, press the rear bearing into the drive pinion.

      SST
      09506-35010

  9. INSPECT DRIVE PINION PRELOAD


    1. Install the drive pinion and front bearing.

      Tech Tips

      Assemble the spacer and oil seal after adjusting the gear contact pattern.

    2. Install the oil slinger.

    3. A015BH0E02

      Using SST, install the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )
    4. A015CZTE02

      Using SST to hold the flange, adjust the drive pinion preload by tightening the nut.

      SST
      09330-00021   ( 09330-00030 )

      Note


      • Coat the nut and threads of the drive pinion with gear oil.

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

    5. A0157BQ

      Using a torque wrench, measure the preload.

      Standard Preload (at Starting)
      Bearing Specified Condition
      New 1.0 to 1.7 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)
      Reused 0.9 to 1.4 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)

      Note

      Measure the total preload after turning the bearing clockwise and counterclockwise several times to make the bearing smooth.

  10. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A015A82

      Place the bearing outer races on their respective bearings.

      Tech Tips

      Do not interchange the left and right outer races.

    2. Install the assembled plate washer to the side bearing.

    3. Install the differential case to the carrier.

    4. A0156FR

      Using a plastic-faced hammer, tap on the ring gear to make sure the differential case is aligned with the carrier, and fit the bearings and plate washers into the carrier.

      Tech Tips

      If it is difficult to install the differential case to the carrier, replace the plate washer with a thinner one.

      However, select a plate washer that allows no clearance between it and the carrier.

  11. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A015BTO

      Using a dial indicator, measure the backlash while holding the side bearing of the ring gear side.

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

    2. Select a case cover side plate washer using the backlash as a reference.

      Standard Side Plate Washer Thickness
      Mark No. Specified Condition Mark No. Specified Condition
      01 2.66 to 2.68 mm (0.1048 to 0.1056 in.) 13 3.02 to 3.04 mm (0.1190 to 0.1198 in.)
      02 2.69 to 2.71 mm (0.1060 to 0.1068 in.) 14 3.05 to 3.07 mm (0.1202 to 0.1210 in.)
      03 2.72 to 2.74 mm (0.1072 to 0.1080 in.) 15 3.08 to 3.10 mm (0.1212 to 0.1220 in.)
      04 2.75 to 2.77 mm (0.1084 to 0.1091 in.) 16 3.11 to 3.13 mm (0.1225 to 0.1233 in.)
      05 2.78 to 2.80 mm (0.1095 to 0.1103 in.) 17 3.14 to 3.16 mm (0.1237 to 0.1245 in.)
      06 2.81 to 2.83 mm (0.1107 to 0.1115 in.) 18 3.17 to 3.19 mm (0.1249 to 0.1257 in.)
      07 2.84 to 2.86 mm (0.1119 to 0.1127 in.) 19 3.20 to 3.22 mm (0.1261 to 0.1269 in.)
      08 2.87 to 2.89 mm (0.1131 to 0.1139 in.) 20 3.23 to 3.25 mm (0.1273 to 0.1281 in.)
      09 2.90 to 2.92 mm (0.1143 to 0.1150 in.) 21 3.26 to 3.28 mm (0.1284 to 0.1292 in.)
      10 2.93 to 2.95 mm (0.1154 to 0.1162 in.) 22 3.29 to 3.31 mm (0.1296 to 0.1304 in.)
      11 2.96 to 2.98 mm (0.1166 to 0.1174 in.) 23 3.32 to 3.34 mm (0.1308 to 0.1316 in.)
      12 2.99 to 3.01 mm (0.1178 to 0.1186 in.) - -
    3. A015E1W

      Select a ring gear teeth side plate washer so that there is no clearance between the outer race and case.

    4. A0159LI

      Remove the 2 plate washers and differential carrier.

    5. Install the selected plate washer into the lower part of the carrier.

    6. Place the selected plate washer onto the differential case together with the outer races, and install the differential case with the outer races to the carrier.

    7. Using a plastic-faced hammer, tap on the ring gear to make sure the differential case is aligned with the carrier, and fit the bearings and plate washers into the carrier.

    8. A015BTO

      Using a dial indicator, measure 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 washers on both sides by an equal amount.

      Tech Tips

      There should be no clearance between the plate washers and case.

    9. Ensure that there is ring gear backlash.

  12. ADJUST SIDE BEARING PRELOAD


    1. Remove the ring gear side plate washer.

    2. A015DD8

      Using a micrometer, measure the thickness.

    3. Using the backlash as a reference, select a washer that is 0.06 to 0.09 mm (0.00236 to 0.00354 in.) thicker than the removed washer.

      Tech Tips

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

    4. Install the selected plate washer.

    5. A0159OME02

      Using SST and plastic-faced hammer, tap the plate washer so that it fits to the bearing.

      SST
      09504-22011
    6. A0158LKE02

      Align the matchmarks on the caps and carrier.

    7. Install the 4 bearing cap bolts to the specified torque.

      Torque:
      113 N*m  { 1150 kgf*cm, 83 ft.*lbf }

    8. 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.)

  13. INSPECT TOTAL PRELOAD


    1. A0157BQ

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

      Standard total preload (at starting)
      Standard drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 3 to 4 in.*lbf)

  14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A0156QJ

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

    2. Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.

      A0157X1E03

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

      Standard Washer Thickness
      Specified Condition Specified Condition
      1.04 to 1.06 mm (0.0409 to 0.0417 in.) 1.315 to 1.335 mm (0.0518 to 0.0526 in.)
      1.065 to 1.085 mm (0.0420 to 0.0427 in.) 1.34 to 1.36 mm (0.0528 to 0.0535 in.)
      1.09 to 1.11 mm (0.0419 to 0.0437 in.) 1.365 to 1.385 mm (0.0537 to 0.0545 in.)
      1.115 to 1.135 mm (0.0439 to 0.0447 in.) 1.39 to 1.41 mm (0.0547 to 0.0555 in.)
      1.14 to 1.16 mm (0.0449 to 0.0457 in.) 1.415 to 1.435 mm (0.0558 to 0.0565 in.)
      1.165 to 1.185 mm (0.0459 to 0.0467 in.) 1.44 to 1.46 mm (0.0567 to 0.0575 in.)
      1.19 to 1.21 mm (0.0469 to 0.0476 in.) 1.465 to 1.485 mm (0.0577 to 0.0585 in.)
      1.215 to 1.235 mm (0.0478 to 0.0486 in.) 1.49 to 1.51 mm (0.0587 to 0.0595 in.)
      1.24 to 1.26 mm (0.0488 to 0.0496 in.) 1.515 to 1.535 mm (0.0597 to 0.0605 in.)
      1.265 to 1.285 mm (0.0498 to 0.0506 in.) 1.54 to 1.56 mm (0.0607 to 0.0615 in.)
      1.29 to 1.31 mm (0.0508 to 0.0516 in.) -

  15. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT


    1. A015CZTE02

      Using SST to hold the flange, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

  16. REMOVE REAR DRIVE PINION REAR COMPANION FLANGE SUB-ASSEMBLY


    1. A0156MLE02

      Using SST, remove the companion flange.

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

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A0155UFE03

      Using SST, remove the bearing (inner race).

      SST
      09556-22010

      If the front bearing is damaged or worn, replace the bearing.

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. Install a new spacer to the drive pinion.

  20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A0155T3E02

      Using SST and a hammer, tap in the bearing (outer race).

      SST
      09316-60011   ( 09316-00011, 09316-00021 )

    2. Install the bearing (inner race).

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A0156ONE01

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

      SST
      09214-76011
      Standard oil seal depth
      0.05 to 0.95 mm (0.00197 to 0.0374)

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

  23. INSTALL REAR DRIVE PINION REAR COMPANION FLANGE SUB-ASSEMBLY


    1. A015BH0E02

      Using SST, install the companion flange.

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

  24. INSPECT DRIVE PINION PRELOAD


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

    2. A015BVGE04

      Using SST to hold the companion flange, install the nut by tightening it until the standard preload is reached.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      441 N*m  { 4497 kgf*cm, 325 ft.*lbf, or less }
    3. A0157BQ

      Using a torque wrench, measure the preload.

      Standard Preload (at Starting)
      Bearing Specified Condition
      New 1.0 to 1.7 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)
      Reused 0.9 to 1.4 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)

  25. INSPECT TOTAL PRELOAD


    1. A0157BQ

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

      Standard total preload (at starting)
      Standard drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 3 to 4 in.*lbf)

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A015BB5

      Using a dial indicator, measure the ring gear backlash.

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      Tech Tips

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

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

  27. INSPECT RUNOUT OF REAR DRIVE PINION REAR COMPANION FLANGE SUB-ASSEMBLY


    1. A015987E12

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

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

      If the runout is more than the maximum, replace the companion flange.

  28. STAKE DRIVE PINION COMPANION FLANGE REAR NUT


    1. A015A0A

      Using a chisel and hammer, stake the nut.

  29. INSTALL DIFFERENTIAL LOCK SHIFT ACTUATOR


    1. Remove any old FIPG material.

    2. Clean the contact surfaces of any residual FIPG material using non-residue solvent.

    3. A01576IE01

      Apply seal packing to the actuator.

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

      Tech Tips

      Install the actuator within 10 minutes after applying seal packing.

    4. A0156UL

      Install the shift fork and actuator to the differential and align the shift fork hole with the shift lock.

    5. Clean the threads of the set bolt and fork shaft with non-residue solvent.

    6. A015BFDE02

      Coat the threads of the set bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    7. Install the shift fork shaft set bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    8. Engage the sleeve with the dog clutch of the differential case.

    9. A015ARN

      Install the 4 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  30. INSTALL REAR DIFFERENTIAL LOCK COVER


    1. Remove any old FIPG material.

    2. Clean the contact surfaces of any residual FIPG material using non-residue solvent.

    3. A01554PE02

      Apply seal packing to the cover

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

      Tech Tips

      Install the cover within 10 minutes after applying seal packing.

    4. A0157VI

      Install the cover with the 3 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  31. INSTALL NO. 1 TRANSFER INDICATOR SWITCH


    1. Using a SST, install a new gasket and the indicator switch.

      SST
      09922-10010
      A0159F0E01
      Torque:
      without SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      with SST
      28 N*m  { 283 kgf*cm, 20 ft.*lbf }

      Note


      • Rotate SST in the direction shown in the illustration.

      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).

    2. Connect the connector.