REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL DIFFERENTIAL RING GEAR


    1. Clean the contact surfaces of the rear differential case sub-assembly and differential ring gear.

    2. Clean the rear differential ring gear set bolt hole.

    3. A004IKNE01
      Text in Illustration
      *a Boiling Water

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

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

      CAUTION:

      Use thick gloves to protect your hands as the differential ring gear is hot.

    5. Secure the rear differential case sub-assembly between aluminum plates in a vise.

      Note

      Do not overtighten the vise.

    6. After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the rear differential case sub-assembly.

    7. A004HN9E10
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the differential ring gear and rear differential case sub-assembly.

    8. Temporarily install 5 new rear differential ring gear set bolt lock plates with the 10 rear differential ring gear set bolts.

    9. After the differential ring gear cools down, tighten the 10 ring gear set bolts uniformly.

      Torque:
      97 N*m  { 984 kgf*cm, 71 ft.*lbf }
    10. A004K7Y

      Using a chisel and hammer, stake the 5 rear differential ring gear set bolt lock plates.


      1. Stake one claw so that it is flush against the flat surface of the bolt.

      2. Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.

  2. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. Using SST and a press, install the rear differential case bearing inner races LH and RH to the rear differential case sub-assembly.

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00430, 09951-00580, 09951-00590, 09952-06010 )
      09950-70010   ( 09951-07100 )
      A004KSZE08
      Text in Illustration
      *a LH Side *b RH Side

      Note


      • Do not apply hypoid gear oil to a new bearing.

      • Do not deform the bearing cage. Set SST to the center of the rear differential case sub-assembly.

      • If the bearing is replaced, replace it and its outer race as a set.

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A004H9Q

      Install the rear differential case bearing outer races differential ring gear back side and differential ring gear teeth side to the rear differential case bearing inner races LH and RH respectively.

      Note


      • Be sure to install the rear differential case bearing outer races in the correct position.

      • Do not damage the rear differential case bearing or differential ring gear.

    2. Install the rear differential case sub-assembly to the rear differential carrier.

    3. Install the differential ring gear back side and differential ring gear teeth side rear differential side gear shaft plate washers so that there is no looseness in the rear differential case bearings.

      A004JAME13
      Text in Illustration
      *a Differential Ring Gear Back Side *b Differential Ring Gear Teeth Side

      Tech Tips


      • If the rear differential case bearing is new, select a thinner rear differential side gear shaft plate washer and install it.

      • If the rear differential case bearing is reused, install a rear differential side gear shaft plate washer with the same thickness as the removed one.

    4. A004J30E02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the bearing cap and the rear differential carrier and install the 2 bearing caps.

      Note

      Make sure that the right and left bearing caps are not interchanged.

    5. Tighten both bearing caps with the 4 bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    6. A004J1G

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

      Maximum runout
      0.07 mm (0.00275 in.)
    7. A004J30E02
      Text in Illustration
      *a Matchmark

      Remove the 4 bolts and 2 bearing caps.

      Note

      Do not exchange the bearing caps, as each cap is only suitable for its original location and the installation direction relative to the carrier for which it was manufactured.

    8. Remove the 2 rear differential side gear shaft plate washers.

    9. A004H9Q

      Remove the rear differential case sub-assembly and the rear differential case bearing outer races differential ring gear back side and differential ring gear teeth side from the rear differential carrier.

      Note

      Do not damage the rear differential case bearing or differential ring gear.

  4. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A004HYJE06
      Text in Illustration
      *1 Rear Differential Drive Pinion Plate Washer

      Install the rear differential drive pinion plate washer to the differential drive pinion.

      Tech Tips


      • Temporarily install the rear drive pinion rear tapered roller bearing (inner race) to prevent the rear differential drive pinion plate washer from being dropped.

      • The rear differential drive pinion plate washer can be installed in either direction.

    2. A004HWQE06

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

      SST
      09506-30012
    3. A004H6KE04
      Text in Illustration
      *1 Rear Drive Pinion Rear Tapered Roller Bearing (Outer Race)

      Using SST and a press, install the rear drive pinion rear tapered roller bearing (outer race) to the differential carrier assembly rear.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07200 )

  5. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A004KP1E03
      Text in Illustration
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Outer Race)

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

      SST
      09950-60020   ( 09951-00720 )
      09950-70010   ( 09951-07100 )

  6. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when replacing the rear differential dust deflector.


    1. A004KSQE01

      Using SST and a press, install a new rear differential dust deflector to the rear drive pinion companion flange.

      SST
      09636-20010

      Note


      • Slowly press in the rear differential dust deflector.

      • If any burrs remain after pressing in the rear differential dust deflector, remove them.

  7. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A004K53

      Install the differential drive pinion and the rear drive pinion front tapered roller bearing (inner race) to the differential carrier assembly rear.

      Note


      • Do not drop the differential drive pinion.

      • Install the rear differential drive pinion bearing spacer and the differential carrier assembly rear oil seal after adjusting the tooth contact pattern.

    2. A004KOQ

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

    3. A004KSVE04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange to the differential carrier assembly rear.

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

      Note


      • Hold the differential drive pinion until SST is installed.

      • Install the rear drive pinion companion flange so that there is a slight looseness in the differential drive pinion because the rear differential drive pinion bearing spacer is not yet installed.

      • Apply grease to the threads and tip of SST center bolt before use.

    4. Coat the threads of a new rear drive pinion nut with hypoid gear oil LSD.

    5. A004IL4E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and tighten the rear drive pinion nut.

      SST
      09330-00021
      Torque:
      338 N*m  { 3445 kgf*cm, 249 ft.*lbf }
      or less

      Note


      • Tighten the rear drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and then tighten it further while checking the differential drive pinion preload.

      • Apply hypoid gear oil LSD to the rear drive pinion nut and the threads of the differential drive pinion.

      • As there is no rear differential drive pinion bearing spacer, tighten the rear drive pinion nut a little at a time. Do not overtighten it.

    6. Turn the bearing clockwise and counterclockwise several times to stabilize it.

    7. A004J5J

      Using a torque wrench, measure the starting torque of the differential drive pinion.

      Tech Tips


      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

      Differential Drive Pinion Preload (at Starting)
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.77 to 2.14 N*m (18.05 to 21.82 kgf*cm, 15.66 to 18.94 in.*lbf)
      Reused rear drive pinion tapered roller bearing 1.77 to 2.07 N*m (18.05 to 21.11 kgf*cm, 15.66 to 18.32 in.*lbf)

      Note


      • Record the differential drive pinion preload for the total preload measurement.

      • Do not apply hypoid gear oil to a new rear drive pinion tapered roller bearing.

      If the preload is not within the specified range, adjust the differential drive pinion preload or perform repairs as necessary.

  8. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A004H9Q

      Install the rear differential case bearing outer races differential ring gear back side and differential ring gear teeth side to the rear differential case bearing inner races LH and RH respectively.

      Note


      • Be sure to install the rear differential case bearing outer races in the correct position.

      • Do not damage the rear differential case bearing or differential ring gear.

    2. Install the rear differential case sub-assembly to the differential carrier assembly rear.

    3. Install the differential ring gear back side and differential ring gear teeth side rear differential side gear shaft plate washers so that the rear differential case bearing is not loose.

      A004JAME14
      Text in Illustration
      *a Differential Ring Gear Back Side *b Differential Ring Gear Teeth Side

      Tech Tips


      • If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are new, select a thinner rear differential side gear shaft plate washer and install it.

      • If the final gear set (differential drive pinion and differential ring gear) and rear differential case bearing are reused, install a rear differential side gear shaft plate washer with the same thickness as the removed one.

  9. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH


    1. A004I27

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

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

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft plate washer.

    2. A004H3E

      Select a new rear differential side gear shaft plate washer so that the differential ring gear backlash will be within the specified range, and install it to the differential ring gear back side.

      Standard Plate Washer
      Part No. Mark Thickness Part No. Mark Thickness
      90201-52001 01 2.58 mm (0.1016 in.) 90564-46029 47 3.04 mm (0.1200 in.)
      90564-46014 32 2.60 mm (0.1024 in.) 90201-52017 17 3.06 mm (0.1205 in.)
      90564-46015 33 2.62 mm (0.1031 in.) 90564-46030 48 3.08 mm (0.1213 in.)
      90201-52003 03 2.64 mm (0.1039 in.) 90564-46031 49 3.10 mm (0.1221 in.)
      90564-46016 34 2.66 mm (0.1047 in.) 90201-52019 19 3.12 mm (0.1228 in.)
      90564-46017 35 2.68 mm (0.1055 in.) 90564-46032 50 3.14 mm (0.1236 in.)
      90201-52005 05 2.70 mm (0.1063 in.) 90564-46033 51 3.16 mm (0.1244 in.)
      90564-46018 36 2.72 mm (0.1070 in.) 90201-52021 21 3.18 mm (0.1252 in.)
      90564-46019 37 2.74 mm (0.1078 in.) 90564-46034 52 3.20 mm (0.1260 in.)
      90201-52007 07 2.76 mm (0.1087 in.) 90564-46035 53 3.22 mm (0.1268 in.)
      90564-46020 38 2.78 mm (0.1094 in.) 90201-52023 23 3.24 mm (0.1276 in.)
      90564-46021 39 2.80 mm (0.1102 in.) 90564-46036 54 3.26 mm (0.1283 in.)
      90201-52009 09 2.82 mm (0.1110 in.) 90564-46037 55 3.28 mm (0.1291 in.)
      90564-46022 40 2.84 mm (0.1118 in.) 90201-52025 25 3.30 mm (0.1299 in.)
      90564-46023 41 2.86 mm (0.1126 in.) 90564-46038 56 3.32 mm (0.1307 in.)
      90201-52011 11 2.88 mm (0.1134 in.) 90564-46039 57 3.34 mm (0.1315 in.)
      90564-46024 42 2.90 mm (0.1142 in.) 90201-52027 27 3.36 mm (0.1323 in.)
      90564-46025 43 2.92 mm (0.1150 in.) 90564-46040 58 3.38 mm (0.1331 in.)
      90201-52013 13 2.94 mm (0.1157 in.) 90564-46041 59 3.40 mm (0.1339 in.)
      90564-46026 44 2.96 mm (0.1165 in.) 90201-52029 29 3.42 mm (0.1346 in.)
      90564-46027 45 2.98 mm (0.1173 in.) 90564-46042 60 3.44 mm (0.1354 in.)
      90201-52015 15 3.00 mm (0.1181 in.) 90564-46043 61 3.46 mm (0.1362 in.)
      90564-46028 46 3.02 mm (0.1189 in.) 90201-52031 31 3.48 mm (0.1370 in.)
    3. A004JRV

      Make the rear differential case bearing and the rear differential side gear shaft plate washer snug by tapping on the rear differential carrier with a plastic-faced hammer.

    4. A004I27

      Set a dial indicator perpendicular to the end of the differential ring gear face.

    5. While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Standard Backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)
    6. A004H3E

      If the backlash is not within the specified range, select a new rear differential side gear shaft plate washer so that the differential ring gear backlash will be within the specified range, and install it to the differential ring gear back side.

    7. A004KJJE06
      Text in Illustration
      *1 Rear Differential Side Gear Shaft Plate Washer
      *2 Rear Differential Case Bearing LH

      Select a thicker rear differential side gear shaft plate washer so that the clearance (A) becomes zero or close to zero.

    8. A004JRV

      Make the rear differential case bearing and the rear differential side gear shaft plate washer snug by tapping on the rear differential carrier with a plastic-faced hammer.

    9. A004I27

      Set a dial indicator perpendicular to the end of the differential ring gear face.

    10. While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

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

      If the backlash is not within the specified range, adjust the thickness of the right and left rear differential side gear shaft plate washers by an equal amount so that the backlash is within the specified range.

  10. ADJUST REAR DIFFERENTIAL CASE BEARING PRELOAD


    1. A004JUB

      After adjusting the backlash of the differential ring gear, remove the differential ring gear teeth side rear differential side gear shaft plate washer.

    2. Using a micrometer, measure the thickness of the removed rear differential side gear shaft plate washer.

    3. Select a new rear differential side gear shaft plate washer which is 0.06 to 0.09 mm (0.00236 to 0.00354 in.) thicker than the removed one.

      Tech Tips

      Select a rear differential side gear shaft plate washer which can be pressed in 2/3 of the way with a finger.

    4. A004H8XE03

      Using SST and a plastic-faced hammer, drive in the rear differential side gear shaft plate washer.

      SST
      09504-22011
    5. A004J30E02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the bearing cap and rear differential carrier and install the 2 bearing caps.

      Note

      Make sure that the right and left bearing caps are not interchanged.

    6. Tighten both bearing caps with the 4 bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    7. A004I27

      Set a dial indicator perpendicular to the end of the differential ring gear face.

    8. While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

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

      If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both the right and left rear differential side gear shaft plate washers equally.

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft plate washer.

  11. INSPECT TOTAL PRELOAD


    1. A004J5J

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

      Total Preload (at Starting)
      Item Specified Condition
      New rear drive pinion tapered roller bearing New differential case bearing 2.17 to 2.77 N*m (22.13 to 28.25 kgf*cm, 19.21 to 24.52 in.*lbf)
      Reused differential case bearing 2.09 to 2.67 N*m (21.31 to 27.23 kgf*cm, 18.50 to 23.63 in.*lbf)
      Reused rear drive pinion tapered roller bearing New differential case bearing 2.17 to 2.70 N*m (22.13 to 27.53 kgf*cm, 19.21 to 23.90 in.*lbf)
      Reused differential case bearing 2.09 to 2.60 N*m (21.31 to 26.51 kgf*cm, 18.50 to 23.01 in.*lbf)

      If the measured preload is less than the specified value, replace the rear differential side gear shaft plate washer of the differential ring gear tooth surface side with a new thicker one.

      If the preload is more than the specified value, replace the rear differential side gear shaft plate washer of the differential ring gear tooth surface side with a new thinner one.

    2. A004I27

      Set a dial indicator to the end of the differential ring gear face.

    3. While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

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

      If the backlash is not within the specified range, change the thickness of the right and left rear differential side gear shaft plate washers by equal amounts to adjust it.

      Tech Tips


      • Record the measured backlash to use as a reference for selecting a rear differential side gear shaft plate washer.

      • Inspect the tooth contact and use the result as a reference for selecting a rear differential side gear shaft plate washer.

  12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A004JI6

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

    2. Rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A004K3CE01
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that brings the drive pinion closer to the ring gear
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that shifts the drive pinion away from the ring gear - -
    4. A004HCNE07
      Text in Illustration
      *1 Rear Differential Drive Pinion Plate Washer

      If the teeth are not contacting properly, use the following table to select a proper rear differential drive pinion plate washer for correction.

      Note


      • If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.

      • If the thickness of the rear differential drive pinion plate washer has been changed, adjust the backlash and measure the total preload.

      Standard Plate Washer
      Part No. Mark Thickness Part No. Mark Thickness
      90201-35497 - 1.70 mm (0.0669 in.) 90201-35508 - 2.03 mm (0.0799 in.)
      90201-35498 - 1.73 mm (0.0681 in.) 90201-35509 - 2.06 mm (0.0811 in.)
      90201-35499 - 1.76 mm (0.0693 in.) 90201-35510 - 2.09 mm (0.0823 in.)
      90201-35500 - 1.79 mm (0.0705 in.) 90201-35511 - 2.12 mm (0.0795 in.)
      90201-35501 - 1.82 mm (0.0717 in.) 90201-35512 - 2.15 mm (0.0846 in.)
      90201-35502 - 1.85 mm (0.0728 in.) 90201-35513 - 2.18 mm (0.0858 in.)
      90201-35503 - 1.88 mm (0.0740 in.) 90201-35514 - 2.21 mm (0.0870 in.)
      90201-35504 - 1.91 mm (0.0752 in.) 90201-35515 01 2.24 mm (0.0882 in.)
      90201-35505 - 1.94 mm (0.0764 in.) 90201-35516 02 2.27 mm (0.0894 in.)
      90201-35506 - 1.97 mm (0.0776 in.) 90201-35517 03 2.30 mm (0.0906 in.)
      90201-35507 - 2.00 mm (0.0787 in.) 90201-35518 04 2.33 mm (0.0917 in.)

  13. REMOVE REAR DRIVE PINION NUT


    1. A004I5ZE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the rear drive pinion companion flange, remove the differential carrier assembly rear.

      SST
      09330-00021

  14. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  15. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  16. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    Click here

  17. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A004IL2

      Install a new rear differential drive pinion bearing spacer to the differential drive pinion.

      Note

      Be sure to install the spacer so that the side with the larger inner diameter faces the rear differential carrier as shown in the illustration.

  18. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A004JBL

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

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A004KOQ

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

  20. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A004K6JE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange.

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

      Note

      Apply grease to the threads of SST center bolt before use.

  21. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A004ILXE04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange.

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

      Note

      Apply grease to the threads of SST center bolt before use.

    2. Coat the threads of the rear drive pinion nut with hypoid gear oil LSD.

    3. A004IL4E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST and a torque wrench, hold the rear drive pinion companion flange and tighten the rear drive pinion nut.

      SST
      09330-00021
      Torque:
      338 N*m  { 3445 kgf*cm, 249 ft.*lbf }
      or less

      Note


      • Tighten the rear drive pinion nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and then tighten it further while checking the differential drive pinion preload.

      • Apply hypoid gear oil LSD to the rear drive pinion nut and the threads of the differential drive pinion.

  24. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A004J5J

      Using a torque wrench, measure the starting torque of the differential drive pinion.

      Tech Tips


      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

      Differential Drive Pinion Preload (at Starting)
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.87 to 2.24 N*m (19.07 to 22.84 kgf*cm, 16.55 to 19.83 in.*lbf)
      Reused rear drive pinion tapered roller bearing 1.87 to 2.17 N*m (19.07 to 22.13 kgf*cm, 16.55 to 19.21 in.*lbf)

      • If the preload is less than the specified minimum value, check the preload while retightening the rear drive pinion nut by 5 to 10° to adjust it so that it is within the specified range.

        Torque
        338 N*m (3445 kgf*cm, 249 ft.*lbf) or less

      • If the preload is less than the specified minimum value even when the tightening torque of the rear drive pinion nut is more than the specified maximum value, loosen the rear drive pinion nut and check that the threads of the rear drive pinion nut and differential drive pinion are not stripped.

      • If the threads are not stripped, replace the rear differential drive pinion bearing spacer. Apply hypoid gear oil LSD to the threads of the differential drive pinion and repeat the procedure.

  25. INSPECT TOTAL PRELOAD


    1. A004J5J

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

      Total Preload (at Starting)
      Item Specified Condition
      New rear drive pinion tapered roller bearing New differential case bearing 2.27 to 2.87 N*m (23.15 to 29.27 kgf*cm, 20.09 to 25.40 in.*lbf)
      Reused differential case bearing 2.19 to 2.77 N*m (22.33 to 28.25 kgf*cm, 19.38 to 24.52 in.*lbf)
      Reused rear drive pinion tapered roller bearing New differential case bearing 2.27 to 2.80 N*m (23.15 to 28.55 kgf*cm, 20.09 to 24.78 in.*lbf)
      Reused differential case bearing 2.19 to 2.70 N*m (22.33 to 27.53 kgf*cm, 19.38 to 23.90 in.*lbf)

      If the total preload is not within the specified range, adjust the total preload or perform repairs as necessary.

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. Set a dial indicator perpendicular to the end of the differential ring gear face.

    2. A004I27

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

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

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


    1. A004HNZE05
      Text in Illustration
      *a Vertical Runout
      *b Lateral Runout
      *c 30 mm (1.181 in.)

      Using a dial indicator, measure the vertical and lateral runout of the rear drive pinion companion flange.

      Maximum Runout
      Item Specified Condition
      Vertical runout 0.09 mm (0.00354 in.)
      Lateral runout 0.09 mm (0.00354 in.)

      Note

      Measure the runout of the rear drive pinion companion flange horizontally at a position 30 mm (1.181 in.) away from the center of the differential drive pinion shaft.

      If the runout is more than the maximum, replace the rear drive pinion companion flange and differential ring gear.

  28. STAKE REAR DRIVE PINION NUT


    1. A004K9VE01

      Using SST and a hammer, stake the rear drive pinion nut.

      SST
      09930-00010

  29. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

    Click here

  30. INSTALL REAR DIFFERENTIAL DRAIN PLUG


    1. Using a hexagon wrench 10 mm, install the rear differential drain plug and a new gasket.

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

  31. REMOVE REAR DIFFERENTIAL CARRIER SUB-ASSEMBLY


    1. A004HQP

      Remove the rear differential carrier sub-assembly from the overhaul stand.

  32. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. Clean the seal packing attached to the rear differential carrier and the rear differential carrier cover using a scraper and wire brush. Then, remove the oil with a non-residue solvent or equivalent.

      Note

      Do not scratch the sealing surface.

    2. A004I82

      Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  33. INSTALL REAR DIFFERENTIAL CARRIER COVER


    1. A004KE4E03
      Text in Illustration
      *a Seal packing
      *b 2 to 3 mm (0.0787 to 0.118 in.)

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

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

      Note


      • Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and end of application.

      • Install the rear differential carrier cover within 3 minutes of application.

    2. A004KVV

      Install the rear differential carrier cover with the 8 bolts.

      Torque:
      47 N*m  { 475 kgf*cm, 35 ft.*lbf }

      Note

      Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.

  34. INSTALL REAR DIFFERENTIAL BREATHER PLUG


    1. A004JTM

      Install the rear differential breather plug to the rear differential carrier cover.

      Torque:
      21 N*m  { 210 kgf*cm, 16 ft.*lbf }