DIFFERENTIAL CARRIER ASSEMBLY (w/ Differential Lock) REASSEMBLY


  1. ASSEMBLE DIFFERENTIAL CASE


    1. A01J3G0

      Install the side gear thrust washer to the side gear.

    2. Install the 4 rear differential pinion gear thrust washers to the 4 rear drive pinion gears.

    3. Install the 4 rear differential pinion gear thrust washers and 4 rear drive pinion gears to the spider.

    4. Secure the differential case RH.

    5. A01J64I

      Install the rear differential side gear and rear differential spider to the differential case RH.

    6. A01J3E7

      Using a dial indicator, measure the differential case RH backlash while holding the pinion toward the case.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

    7. Remove the rear differential spider from the differential case RH.

    8. A01J3JD

      Install the rear differential side gear and rear differential spider to the differential case LH.

    9. Using a dial indicator, measure the differential case LH backlash while holding the pinion toward the case.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      Tech Tips

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

      Standard Washer Thickness
      Thickness mm (in.) Thickness mm (in.)
      0.88 to 0.92 (0.0347 to 0.0362) 1.18 to 1.22 (0.0465 to 0.0480)
      0.98 to 1.02 (0.0386 to 0.0401) 1.28 to 1.32 (0.0504 to 0.0519)
      1.08 to 1.12 (0.0426 to 0.0440) -
    10. A01J3E8E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks and assemble the RH and LH cases.

    11. Using a plastic-faced hammer, install the differential case.

    12. Install the 8 bolts.

      Torque:
      54 N*m  { 547 kgf*cm, 40 ft.*lbf }

    13. Install the rear differential lock sleeve to the differential case LH.

  2. INSTALL DIFFERENTIAL RING GEAR


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

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

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

    4. A01J7ESE01
      Text in Illustration
      *1 Matchmark

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

    5. Temporarily install 5 new lock plates and the 10 bolts.

    6. After the ring gear cools down, diametrically tighten the 10 bolts uniformly in several passes.

      Torque:
      87 N*m  { 891 kgf*cm, 64 ft.*lbf }
    7. A01J6LRE01

      Using a chisel and hammer, stake the 5 lock plates.

      Tech Tips

      Strike the tab labeled A so that it is flush with the flat surface of the bolt. Strike the tab labeled B so that half of the tab contacts the bolt as shown in the illustration.

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01J6JKE01

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

      SST
      09950-60010   ( 09951-00560, 09951-00570 )
      09950-70010   ( 09951-07150 )

  4. INSPECT DIFFERENTIAL RING GEAR RUNOUT

    A01J79W

    1. Install the differential case and 2 case bearings (outer) to the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.

    2. Install the 2 bearing caps with the 4 bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }

    3. Using a dial indicator, measure the runout of the ring gear.

      Maximum runout
      0.07 mm (0.00276 in.)

      If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

    4. Remove the 4 bolts, 2 bearing caps, 2 adjusting nuts and differential case.

  5. INSTALL DIFFERENTIAL OIL STORAGE RING


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

      Note

      Be careful not to damage the oil storage ring.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01J71SE01

      Using SST and a press, press the bearing (outer) into the carrier.

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

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01J72WE01

      Using SST and a press, press the bearing (outer) into the carrier.

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

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the plate washer to the drive pinion.

      Tech Tips

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

    2. A01J3R8E01

      Using SST and a press, press the bearing (inner) onto the drive pinion.

      SST
      09506-30012

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01J60E

      Install the drive pinion, bearing (inner) and oil slinger.

      Tech Tips

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

    2. A01J40AE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

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

      Tech Tips

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

    3. Adjust the drive pinion preload by installing the drive pinion nut.

    4. A01J4NZE01

      Using SST to hold the companion flange in place, tighten the nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3773 kgf*cm, 273 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 drive pinion thread and nut seat face.

    5. Using a torque wrench, measure the preload.

      Standard Drive Pinion Preload (Starting Torque)
      Bearing Specified Condition
      New bearing 1.0 to 1.5 N*m (11 to 15 kgf*cm, 9 to 13 in.*lbf)
      Reused bearing 0.5 to 0.7 N*m (6 to 7 kgf*cm, 5 to 6 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.

  10. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A01J3XT

      Apply MP grease to the rack of the shift fork and connecting part of the indicator switch.

      Text in Illustration
      A01J5O1 MP grease

    2. Insert the shift fork into the differential carrier as shown in the illustration.

    3. A01J5H3

      Place the outer race and adjusting nut on the left side of the sleeve.

      Tech Tips

      Check that the sleeve moves smoothly.

    4. A01J3OM

      Insert the shift fork into the groove of the sleeve while holding the sleeve by hand, and install the case to the carrier.

      Tech Tips

      Make sure that there is backlash between the ring gear and drive pinion.

  11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01J41J

      Install the 2 adjusting nuts to the carrier, making sure the nuts are threaded properly.

  12. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. A01J43HE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the cap and carrier.

    2. A01J3G7

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

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }

      • If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly.

        Tech Tips

        Reinstall the adjusting nuts if necessary.

    3. A01J68HE01
      Text in Illustration
      *a for LH Side
      *b for RH Side

      Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned by SST.

    4. Using SST, tighten the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.00787 in.).

      SST
      09504-00011
      09960-10010   ( 09962-01000, 09963-00700 )

    5. While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side.

      SST
      09504-00011
      09960-10010   ( 09962-01000, 09963-00700 )

    6. Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

    7. A01J5J4

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

      Standard backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      Tech Tips


      • The backlash is adjusted by turning the left and right adjusting nuts by an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.

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

    8. A01J43H

      Tighten the bearing cap bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }

  13. INSPECT TOTAL PRELOAD


    1. A01J34Z

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

      Standard Total Preload
      Bearing Specified Condition
      New 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
      Reused 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload

      If the result is not as specified, adjust the preload.

      Note

      Record the differential ring gear preload.

  14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    A01J7EX

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

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

    3. Inspect the tooth contact pattern.


      • A01J3CIE02
      • A01J6NQE01
        Text in Illustration
        *1 Plate Washer

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

        Standard Plate Washer Thickness
        Thickness mm (in.) Thickness mm (in.)
        1.69 to 1.71 (0.0666 to 0.0673) 2.02 to 2.04 (0.0796 to 0.0803)
        1.72 to 1.74 (0.0678 to 0.0685) 2.05 to 2.07 (0.0807 to 0.0814)
        1.75 to 1.77 (0.0689 to 0.0696) 2.08 to 2.10 (0.0819 to 0.0826)
        1.78 to 1.80 (0.0701 to 0.0708) 2.11 to 2.13 (0.0831 to 0.0838)
        1.81 to 1.83 (0.0713 to 0.0720) 2.14 to 2.16 (0.0843 to 0.0850)
        1.84 to 1.86 (0.0725 to 0.0732) 2.17 to 2.19 (0.0855 to 0.0862)
        1.87 to 1.89 (0.0737 to 0.0744) 2.20 to 2.22 (0.0867 to 0.0874)
        1.90 to 1.92 (0.0748 to 0.0755) 2.23 to 2.25 (0.0878 to 0.0885)
        1.93 to 1.95 (0.0760 to 0.0767) 2.26 to 2.28 (0.0890 to 0.0897)
        1.96 to 1.98 (0.0772 to 0.0779) 2.29 to 2.31 (0.0902 to 0.0909)
        1.99 to 2.01 (0.0784 to 0.0791) 2.32 to 2.34 (0.0914 to 0.0921)

  15. REMOVE REAR DRIVE PINION NUT


    1. A01J42JE01

      Using SST and a hammer, loosen the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01J6L7E01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09330-00021   ( 09330-00030 )

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


    1. A01J3YB

      Using SST, remove the companion flange 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.

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01J3D4

      Remove the oil slinger from the drive pinion.

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01J5EUE01

      Using SST, remove the roller bearing (inner).

      SST
      09556-22010
    2. A01J6QZE01

      Using SST, tap out the roller bearing (outer).

      SST
      09308-00010

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01J56K

      Install a new bearing spacer.

      Tech Tips

      Make sure the spacer is installed correctly.

  20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01J5UR

      Install the bearing (inner) to the drive pinion.

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01J3D4

      Install the oil slinger to the drive pinion.

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. Apply MP grease to the lip of the oil seal.

    2. A01J46AE01
      Text in Illustration
      *a Oil Seal Depth

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

      SST
      09554-30011
      Standard oil seal depth
      0 +/-0.3 mm (0 +/-0.0118 in.)

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


    1. A01J5ZV

      Using SST, install the companion flange 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 drive pinion thread and nut seat face.

    3. A01J32OE01
      Text in Illustration
      *1 Turn
      *1 Hold

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

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3773 kgf*cm, 273 ft.*lbf, or less }

  24. INSPECT TOTAL PRELOAD


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

    2. A01J3TE

      Using a torque wrench, measure the total preload.

      Standard Total Preload
      Bearing Specified Condition
      New bearing 1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf) + ring gear preload
      Reused bearing 0.6 to 0.8 N*m (7 to 8 kgf*cm, 6 to 7 in.*lbf) + ring gear preload

      • If necessary, disassemble and inspect the differential.

  25. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01J5J4

      Using a dial indicator, measure the backlash of the ring gear.

      Standard backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      • If the backlash is not within the specification, 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.

  26. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01J4U6E01
      Text in Illustration
      *a 30 mm (1.18 in.)

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

      Maximum Runout
      Item 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.

  27. STAKE DRIVE PINION NUT


    1. A01J623

      Using a chisel and hammer, stake the nut.

  28. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01J68A

      Install 2 new adjusting nut locks to the bearing caps with the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Bend the nut locks.

  29. INSTALL REAR DIFFERENTIAL LOCK SHIFT FORK SHAFT


    1. A01J5UKE01
      Text in Illustration
      *1 Groove
      *2 Hole

      Apply MP grease to the outer circuit of the fork shaft.

    2. Install the fork shaft so that the hole of the shift fork aligns with that of the shift fork shaft.

    3. A01J2YHE01
      Text in Illustration
      *1 Seal packing

      Remove any seal packing material.

      Note

      Be careful not to drop oil on the contact surface of the differential carrier and shaft retainer.

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

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

      Tech Tips

      Install the shaft retainer within 3 minutes after applying seal packing.

    5. A01J46M

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

    6. Apply adhesive to 2 or 3 threads at the end of the mounting bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    7. Tighten the shaft retainer with the 2 bolts.

      Torque:
      23 N*m  { 237 kgf*cm, 17 ft.*lbf }
    8. A01J3H7

      Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the shift fork.

    9. A01J57YE01
      Text in Illustration
      *1 Lock

      Shift the fork to the lock side.

    10. A01J687E01
      Text in Illustration
      *1 Steel Ball
      *2 Spring
      *3 Spring Seat
      *4 Screw Plug

      Install the steel ball, spring and spring seat.

    11. Clean the threads of the 2 plug holes with toluene or trichloroethylene.

    12. Apply adhesive to the plug threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    13. Using a 6 mm hexagon wrench, install the screw plugs.

      Torque:
      23 N*m  { 237 kgf*cm, 17 ft.*lbf }

  30. INSPECT REAR DIFFERENTIAL LOCK SLEEVE

    A01J662

    1. Measure the distance between the sleeve and tip of the differential case when the differential is free, and when it is locked.

      Standard Distance
      Position Specified Condition
      Lock 17.44 to 18.86 mm (0.6866 to 0.7425 in.)
      Free 32.40 to 33.90 mm (1.2756 to 1.3346 in.)

  31. INSTALL NO. 4 TRANSFER INDICATOR SWITCH


    1. A01J5GX

      Install the indicator switch and a new gasket.

      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }

    2. Connect the connector.

  32. INSTALL DIFFERENTIAL LOCK SHIFT ACTUATOR


    1. A01J40FE01
      Text in Illustration
      *1 Shift Fork
      *2 Actuator Installation Hole
      A01J5O1 Outside

      Install a new O-ring to the actuator.

    2. Install the actuator with the bolt and nut.

      Torque:
      for Bolt
      27 N*m  { 270 kgf*cm, 20 ft.*lbf }
      for Nut
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    3. Check that the outermost rack tooth of the shift fork is almost directly above the center line of the actuator installation hole.

    4. A01J6RZE01
      Text in Illustration
      *1 Matchmark
      *a 5°
      *b 108°
      *c 1.5 V

      Check that the matchmarks on the pinion of the actuator are in the range between 2 and 8° clockwise of the center line of the actuator.

      Note


      • If the matchmarks are not within the specified range, use dry cell batteries to rotate the pinion until the matchmarks are within the range.

      • Do not apply positive (+) battery voltage directly between terminals.

      • If the matchmarks come to the limit of the rotation range, do not apply any more voltage.

    5. Install a new O-ring to the actuator.

    6. Apply a light coat of gear oil to the O-ring.

    7. Apply MP grease to the gear parts.

    8. A01J3F0E01
      Text in Illustration
      *1 Knock Pin

      Check that the outermost rack tooth of the shift fork aligns with the matchmarks on the pinion of the actuator.

    9. Install the actuator so that the long hole in the actuator fits with the knock pin on the carrier.

      Tech Tips

      Do not damage the O-ring of the actuator.

    10. Rotate the actuator counterclockwise so that the knock pin slides to the end of the hole as shown in the illustration.

    11. Install the bolts.

      Torque:
      27 N*m  { 270 kgf*cm, 20 ft.*lbf }
    12. A01J5RG

      Connect the breather hose.

    13. Connect the connector.