REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

Tech Tips

Use an overhaul stand as necessary.


  1. INSTALL DIFFERENTIAL RING GEAR


    1. A019KFEE03
      Text in Illustration
      *1 Boiling Water

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

    2. Heat the differential ring gear in boiling water.

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

      CAUTION:

      Do not burn yourself.

    4. A019OPUE01
      Text in Illustration
      *1 Matchmark

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

      Note

      Do not overtighten the vise.

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

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

    7. Temporarily install 12 new rear differential case bolts to which thread lock has been applied.

      Adhesive
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent.

    8. After the ring gear has cooled sufficiently, tighten the 12 new rear differential case bolts.

      Torque:
      99 N*m  { 1005 kgf*cm, 73 ft.*lbf }

      Note


      • New rear differential case bolts should be used every time the ring gear is installed.

      • Install the new rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.

      • Tighten the rear differential case bolts after the differential ring gear has cooled down sufficiently.

      • Do not allow any oil to contact the rear differential case bolt, differential ring gear threads or differential case seating surface.

  2. INSTALL REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Tech Tips

    Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A019N7JE02

      Using SST and a press, install a new rear differential case bearing (LH side inner race) to the rear differential case sub-assembly.

      SST
      09223-46011

      Note

      Replace the inner and outer races as a set.

  3. INSTALL REAR DIFFERENTIAL CASE BEARING (for RH Side)

    Tech Tips

    Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A019M6BE02

      Using SST and a press, install the rear differential case bearing (RH side inner race) to the rear differential case sub-assembly.

      SST
      09223-46011

      Note

      Replace the inner and outer races as a set.

  4. INSTALL STRAIGHT PIN


    1. Using a plastic hammer, install the 4 straight pins to the rear differential carrier.

      A019NS0E01
      Protrusion (A)
      8 to 9 mm (0.315 to 0.354 in.)

    2. Thoroughly remove oil and water from the surface of the rear differential carrier that will face the differential ring gear.

  5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A019KD5E01
      Text in Illustration
      *1 Rear Drive Pinion Rear Tapered Roller Bearing (Outer Race)

      Using SST, bolt, nuts and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier.

      SST
      09950-60010   ( 09951-00500, 09951-00530 )
      09950-60020   ( 09951-00680, 09951-00890 )

      Tech Tips

      Use M12 x P1.5 bolts with shaft lengths of 124 mm and M12 x P1.5 nuts for installation.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A019P4PE01
      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 rear differential carrier.

      SST
      09950-60010   ( 09951-00610 )
      09950-70010   ( 09951-07150 )

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


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

      Note

      Install each rear differential drive pinion plate washer to the position it was removed from.

    2. A019MZ0E01

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

      SST
      09506-30012

  8. INSTALL REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Tech Tips

    Replace the rear differential case bearing (LH side outer race) when removing the rear differential case bearing (LH side inner race) from the rear differential case sub-assembly.


    1. A019KTEE01
      Text in Illustration
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

      Using SST and a press, install the rear differential side gear shaft plate washer and rear differential case bearing (LH side outer race) to the differential side bearing retainer.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      Note


      • Install each rear differential side gear shaft plate washer to the position it was removed from.

      • Replace the inner and outer races as a set.

      • Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

  9. INSTALL REAR DIFFERENTIAL CASE BEARING (for RH Side)


    1. A019P59E01
      Text in Illustration
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

      Using SST and a press, install the rear differential side gear shaft plate washer and rear differential case bearing (RH side outer race) to the rear differential carrier.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      Note


      • Install each rear differential side gear shaft plate washer to the position it was removed from.

      • Replace the inner and outer races as a set.

      • Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

  10. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A019KK4

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

    2. Apply hypoid gear oil LSD to the threads of a new rear drive pinion nut and its seating surface.

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

      Note

      New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

    4. A019P3RE01

      Using SST, gradually tighten the rear drive pinion nut until the specified preload is reached. Do not exceed the torque limit shown below.

      SST
      09556-16011
      09564-16020
      Torque:
      without SST
      321 N*m  { 3273 kgf*cm, 237 ft.*lbf, or less }
      with SST
      301 N*m  { 3069 kgf*cm, 222 ft.*lbf, or less }

      Note

      Tighten the rear drive pinion nut gradually. Never tighten it excessively.

      Tech Tips

      Use a torque wrench with a fulcrum length of 750 mm (2.46 ft.).

    5. A019PMHE01

      Using SST and a torque wrench, measure the preload (starting torque) of the differential drive pinion.

      SST
      09556-16011
      Standard Drive Pinion Preload (Starting Torque)
      New bearing 1.8 to 3.0 N*m (19 to 30 kgf*cm, 17 to 26 in.*lbf)
      Reused bearing 1.5 to 2.5 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the bearing forward and backward before inspection.

  11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.

      Note


      • Do not damage the installation surface.

      • Be sure to completely remove all seal packing from the rear differential carrier assembly and differential side bearing retainer.

      • Do not allow the removed seal packing to enter the rear differential carrier.

    2. A019N8W

      Install the rear differential case assembly to the rear differential carrier.

    3. A019LD8

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42 N*m  { 430 kgf*cm, 31 ft.*lbf }

  12. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A019OE4E01

      Insert a dial indicator and magnetic base through the rear differential filler plug hole and set it perpendicular to a differential ring gear tooth surface tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

      Tech Tips

      Measure at 3 or more areas on the circumference of the ring gear.

    4. If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

      Tech Tips


      • When the backlash is smaller than the specified value, select a thick rear differential side gear shaft plate washer for the RH side and thin rear differential side gear shaft plate washer for the LH side.

      • When the backlash is larger than the specified value, select a thin rear differential side gear shaft plate washer for the RH side and thick rear differential side gear shaft plate washer for the LH side.

      Rear Differential Side Gear Shaft Plate Washer
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      75 1.74 to 1.76 (0.0685 to 0.0693) 96 2.34 to 2.36 (0.0921 to 0.0929)
      76 1.77 to 1.79 (0.0697 to 0.0705) 97 2.37 to 2.39 (0.0933 to 0.0941)
      77 1.80 to 1.82 (0.0709 to 0.0717) 98 2.40 to 2.42 (0.0945 to 0.0953)
      78 1.83 to 1.85 (0.0720 to 0.0728) 99 2.43 to 2.45 (0.0957 to 0.0965)
      79 1.86 to 1.88 (0.0732 to 0.0740) 00 2.46 to 2.48 (0.0969 to 0.0976)
      80 1.89 to 1.91 (0.0744 to 0.0752) 01 2.49 to 2.51 (0.0980 to 0.0988)
      81 1.92 to 1.94 (0.0756 to 0.0764) 02 2.52 to 2.54 (0.0992 to 0.1000)
      82 1.95 to 1.97 (0.0768 to 0.0776) 03 2.55 to 2.57 (0.1004 to 0.1012)
      83 1.98 to 2.00 (0.0780 to 0.0787) 04 2.58 to 2.60 (0.1016 to 0.1024)
      84 2.01 to 2.03 (0.0791 to 0.0799) 05 2.61 to 2.63 (0.1028 to 0.1035)
      85 2.04 to 2.06 (0.0803 to 0.0811) 06 2.64 to 2.66 (0.1039 to 0.1047)
      86 2.07 to 2.09 (0.0815 to 0.0823) 07 2.67 to 2.69 (0.1051 to 0.1059)
      88 2.10 to 2.12 (0.0827 to 0.0835) 08 2.70 to 2.72 (0.1063 to 0.1071)
      89 2.13 to 2.15 (0.0839 to 0.0846) 09 2.73 to 2.75 (0.1075 to 0.1083)
      90 2.16 to 2.18 (0.0850 to 0.0858) 10 2.76 to 2.78 (0.1087 to 0.1094)
      91 2.19 to 2.21 (0.0862 to 0.0870) 11 2.79 to 2.81 (0.1098 to 0.1106)
      92 2.22 to 2.24 (0.0874 to 0.0882) 12 2.82 to 2.84 (0.1110 to 0.1118)
      93 2.25 to 2.27 (0.0886 to 0.0894) 13 2.85 to 2.87 (0.1122 to 0.1130)
      94 2.28 to 2.30 (0.0898 to 0.0906) 14 2.88 to 2.90 (0.1134 to 0.1142)
      95 2.31 to 2.33 (0.0909 to 0.0917) - -

  13. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. Remove the 10 bolts and the differential side bearing retainer.

    2. Remove the rear differential case assembly from the rear differential carrier.

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

    4. Install the rear differential case assembly to the rear differential carrier.

    5. A019LD8

      Install the differential side bearing retainer with the 10 bolts.

      Torque:
      42 N*m  { 430 kgf*cm, 31 ft.*lbf }

    6. Turn the differential drive pinion at last 10 times.

    7. Remove the 10 bolts and the differential side bearing retainer.

    8. Remove the rear differential case assembly from the rear differential carrier.

    9. Inspect the tooth contact pattern.

      A019OLPE03

      Tech Tips

      Check the tooth contact pattern at 2 or more positions on the circumference of the differential ring gear.

    10. Perform the following procedure for face or flank contact:


      1. If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

      2. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

        Tech Tips

        If the tooth contact pattern is not correct, reselect rear differential side gear shaft plate washers and reinspect the tooth contact pattern.

      3. Repeat the differential ring gear and differential drive pinion backlash inspection.

        Tech Tips

        If the differential ring gear and differential drive pinion backlash are not as specified, reselect rear differential drive pinion plate washer and then readjust the differential drive pinion preload, differential ring gear and differential drive pinion backlash and reinspect tooth contact pattern.

    11. Perform the following procedure for heel or toe contact:


      1. A019NXXE02
        Text in Illustration
        *1 Rear Differential Drive Pinion Plate Washer

        Select a rear differential drive pinion plate washer again and install the rear drive pinion rear tapered roller bearing (inner race).

        Rear Differential Drive Pinion Plate Washer
        Mark Thickness mm (in.) Mark Thickness mm (in.)
        41 1.695 to 1.705 (0.0667 to 0.0671) 73 1.975 to 1.985 (0.0778 to 0.0781)
        42 1.705 to 1.715 (0.0671 to 0.0675) 74 1.985 to 1.995 (0.0781 to 0.0785)
        43 1.715 to 1.725 (0.0675 to 0.0679) 75 1.995 to 2.005 (0.0785 to 0.0789)
        44 1.725 to 1.735 (0.0679 to 0.0683) 76 2.005 to 2.015 (0.0789 to 0.0793)
        45 1.735 to 1.745 (0.0683 to 0.0687) 77 2.015 to 2.025 (0.0793 to 0.0797)
        46 1.745 to 1.755 (0.0687 to 0.0691) 78 2.025 to 2.035 (0.0797 to 0.0801)
        47 1.755 to 1.765 (0.0691 to 0.0695) 79 2.035 to 2.045 (0.0801 to 0.0805)
        48 1.765 to 1.775 (0.0695 to 0.0699) 80 2.045 to 2.055 (0.0805 to 0.0809)
        49 1.775 to 1.785 (0.0699 to 0.0703) 81 2.055 to 2.065 (0.0809 to 0.0813)
        50 1.785 to 1.795 (0.0703 to 0.0707) 82 2.065 to 2.075 (0.0813 to 0.0817)
        51 1.795 to 1.805 (0.0707 to 0.0711) 83 2.075 to 2.085 (0.0817 to 0.0821)
        52 1.805 to 1.815 (0.0711 to 0.0715) 84 2.085 to 2.095 (0.0821 to 0.0825)
        53 1.815 to 1.825 (0.0715 to 0.0719) 85 2.095 to 2.105 (0.0825 to 0.0829)
        54 1.825 to 1.835 (0.0719 to 0.0722) 86 2.105 to 2.115 (0.0829 to 0.0833)
        55 1.835 to 1.845 (0.0722 to 0.0726) 87 2.115 to 2.125 (0.0833 to 0.0837)
        56 1.845 to 1.855 (0.0726 to 0.0730) 88 2.125 to 2.135 (0.0837 to 0.0841)
        57 1.855 to 1.865 (0.0730 to 0.0734) 89 2.135 to 2.145 (0.0841 to 0.0844)
        58 1.865 to 1.875 (0.0734 to 0.0738) 90 2.145 to 2.155 (0.0844 to 0.0848)
        59 1.875 to 1.885 (0.0738 to 0.0742) 91 2.155 to 2.165 (0.0848 to 0.0852)
        60 1.885 to 1.895 (0.0742 to 0.0746) 92 2.165 to 2.175 (0.0852 to 0.0856)
        61 1.895 to 1.905 (0.0746 to 0.0750) 93 2.175 to 2.185 (0.0856 to 0.0860)
        62 1.905 to 1.915 (0.0750 to 0.0754) 94 2.185 to 2.195 (0.0860 to 0.0864)
        63 1.915 to 1.925 (0.0754 to 0.0758) 95 2.195 to 2.205 (0.0864 to 0.0868)
        64 1.925 to 1.935 (0.0758 to 0.0762) 96 2.205 to 2.215 (0.0868 to 0.0872)
        65 1.935 to 1.945 (0.0762 to 0.0766) 97 2.215 to 2.225 (0.0872 to 0.0876)
        70 1.945 to 1.955 (0.0766 to 0.0770) 98 2.225 to 2.235 (0.0876 to 0.0880)
        71 1.955 to 1.965 (0.0770 to 0.0774) 99 2.235 to 2.245 (0.0880 to 0.0884)
        72 1.965 to 1.975 (0.0774 to 0.0778) 00 2.245 to 2.255 (0.0884 to 0.0888)

    12. Readjust the differential drive pinion preload, differential ring gear and differential drive pinion backlash and reinspect tooth contact pattern.

  14. MEASURE TOTAL PRELOAD


    1. A019PMHE01

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

      SST
      09556-16011
      Standard Total Preload (Starting Torque)
      New bearing 3.1 to 5.9 N*m (32 to 59 kgf*cm, 28 to 51 in.*lbf)
      Reused bearing 2.8 to 5.3 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:


      1. Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

      2. Repeat the total preload measurement.

      3. Repeat the differential ring gear backlash inspection.

      4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

  15. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. Remove the 10 bolts and differential side bearing retainer.

  16. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY


    1. Remove the rear differential case assembly from the rear differential carrier.

  17. REMOVE DIFFERENTIAL DRIVE PINION


    1. Remove the rear differential drive pinion from the rear differential carrier.

  18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A019LA5

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

      Tech Tips

      Face the smaller inside diameter towards the front of the vehicle.

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A019MV5

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

  20. INSTALL DIFFERENTIAL DRIVE PINION


    1. A019KK4

      Install the differential drive pinion to the differential carrier.

  21. TEMPORARILY TIGHTEN REAR DRIVE PINION NUT


    1. Apply hypoid gear oil LSD to the threads of the rear drive pinion nut and its seating surface.

    2. A019P3RE01

      Using SST, temporarily install the rear drive pinion nut to the differential drive pinion.

      SST
      09556-16011
      09564-16020
    3. A019PMHE01

      Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque).

      SST
      09556-16011
      Standard Differential Drive Pinion Preload (Starting Torque)
      New bearing 1.8 to 3.0 N*m (19 to 30 kgf*cm, 17 to 26 in.*lbf)
      Reused bearing 1.5 to 2.5 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the bearing forward and backward before adjustment.

    4. A019P3RE01

      If the preload is insufficient, use SST to tighten the differential drive pinion nut 5 to 10° at a time. Measure the preload and repeat the adjustment as necessary until the preload matches the specified torque.

      SST
      09556-16011
      09564-16020
      Torque:
      without SST
      321 N*m  { 3273 kgf*cm, 237 ft.*lbf, or less }
      with SST
      301 N*m  { 3069 kgf*cm, 222 ft.*lbf, or less }

      Tech Tips

      Use a torque wrench with a fulcrum length of 750 mm (2.46 ft.).

    5. If the tightening torque of the rear drive pinion nut exceeds the specified torque but the preload is still insufficient, remove the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.

    6. If there is no defect, replace the rear differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

  22. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A019MDU

      Install the rear differential breather plug oil deflector with the 2 bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  23. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY


    1. A019N8W

      Install the rear differential case assembly to the rear differential carrier.

  24. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. A019LD8

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42 N*m  { 430 kgf*cm, 31 ft.*lbf }

  25. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A019OE4E01

      Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

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

      Tech Tips

      Measure at 3 or more areas on the circumference of the differential ring gear.

  26. MEASURE TOTAL PRELOAD


    1. A019PMHE01

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

      SST
      09556-16011
      Standard Total Preload (Starting Torque)
      New bearing 3.1 to 5.9 N*m (32 to 59 kgf*cm, 28 to 51 in.*lbf)
      Reused bearing 2.8 to 5.3 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:


      1. Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

      2. Repeat the total preload measurement.

      3. Repeat the differential ring gear backlash inspection.

      4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

  27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. Remove the 10 bolts and differential side bearing retainer.

    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.

      Note

      Do not damage the installation surface.

    3. A019OJHE01

      Apply seal packing to the areas indicated in the illustration of the rear differential carrier.

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

      Note


      • Start applying seal packing within range (C).

      • Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).

      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (C) in the illustration.

      • Install the differential side bearing retainer within 10 minutes after applying seal packing. If the differential side bearing retainer is not installed within 10 minutes after applying seal packing, completely remove and then reapply seal packing.

      Tech Tips


        The center of the bead

      • (A) : 2.0 mm (0.0787 in.)

      • (B) : 3.0 mm (0.118 in.)

    4. A019LD8

      Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque:
      42 N*m  { 430 kgf*cm, 31 ft.*lbf }

      Note

      After installing the differential side bearing retainer, do not immediately add oil or drive the vehicle for at least 1 hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.

  28. INSPECT TOTAL PRELOAD


    1. A019PMHE01

      Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09556-16011
      Standard Total Preload (Starting Torque)
      New bearing 3.1 to 5.9 N*m (32 to 59 kgf*cm, 28 to 51 in.*lbf)
      Reused bearing 2.8 to 5.3 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before inspection.

  29. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A019OE4E01

      Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.

    2. Using SST, hold the differential drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

      Tech Tips

      Measure at 3 or more areas on the circumference of the differential ring gear.

  30. STAKE REAR DRIVE PINION NUT


    1. A019N8U

      Using a chisel and a hammer, stake the rear drive pinion nut as shown in the illustration.

  31. INSTALL DIAPHRAGM OIL SEAL


    1. A019NZME01
      Text in Illustration
      *1 Diaphragm Oil Seal

      Using SST and a press, install a new diaphragm oil seal into the rear differential carrier assembly.

      SST
      09506-35010
      09554-22010

      Note


      • Install the diaphragm oil seal uniformly.

      • Press fit the diaphragm oil seal straight.

      Distance (A)
      0.7 to 1.3 mm (0.0276 to 0.0512 in.)

    2. Apply a light coat of MP grease to the lip of the new diaphragm oil seal.

  32. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for LH Side)


    1. A019PFGE01
      Text in Illustration
      *1 Rear Differential Side Gear Shaft Oil Seal

      Using SST and a press, install a new rear differential side gear shaft oil seal into the differential side bearing retainer.

      SST
      09223-46011
      09631-32020

      Note


      • Install the rear differential side gear shaft oil seal uniformly.

      • Press fit the rear differential side gear shaft oil seal straight.

      Distance (A)
      8.2 to 8.8 mm (0.323 to 0.346 in.)

    2. Apply a light coat of MP grease to the lip of the new rear differential side gear shaft oil seal.

  33. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for RH Side)


    1. A019KQQE01
      Text in Illustration
      *1 Rear Differential Side Gear Shaft Oil Seal

      Using SST and a press, install a new rear differential side gear shaft oil seal into the rear differential carrier.

      SST
      09223-46011
      09631-32020

      Note


      • Install the rear differential side gear shaft oil seal uniformly.

      • Press fit the rear differential side gear shaft oil seal straight.

      Distance (A)
      8.2 to 8.8 mm (0.323 to 0.346 in.)

    2. Apply a light coat of MP grease to the lip of the new rear differential side gear shaft oil seal.

  34. INSTALL SPACER


    1. A019NGXE01
      Text in Illustration
      *1 Spacer

      Install the spacer to the rear differential carrier assembly.

      Note

      Keep the spacer free of oil and foreign matter.

  35. INSTALL CONICAL WASHER


    1. A019N2XE01
      Text in Illustration
      *1 Conical Washer

      Install the conical washer to the rear differential carrier assembly.

      Note


      • Be sure to install the conical washer with the convex side facing the rear of the vehicle.

      • Keep the conical washer free of oil and foreign matter.

  36. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A019MODE01
      Text in Illustration
      *1 Block

      Using SST and a press, install the rear differential dust deflector.

      SST
      09608-36010
      09950-70010   ( 09951-07150 )

      Note


      • Be sure to press in the rear differential dust deflector until it contacts the bearing end surface.

      • Do not damage the end surface of the electro magnetic control coupling sub-assembly.

  37. INSTALL STUD BOLT


    1. Temporarily install 4 new stud bolts to the electro magnetic control coupling sub-assembly.

    2. A019L2DE14
      Text in Illustration
      *1 Upper Nut
      *2 Lower Nut
      *a Hold
      *b Turn

      Install 2 service nuts to the stud bolt.

      Recommended service nut
      Thread diameter
      10 mm (0.394 in.)
      Thread pitch
      1.0 mm (0.0394 in.)

    3. Lock the upper nut using the lower nut.

    4. A019JTKE01

      Turn the upper nut and tighten the other 3 stud bolts to the electro magnetic control coupling sub-assembly in the same way.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      (A)
      22.6 to 25.8 mm (0.888 to 1.02 in.)

      Note

      Prevent foreign matter from entering to the electro magnetic control coupling sub-assembly.

      Tech Tips

      If the threads of the electro magnetic control coupling sub-assembly are damaged while installing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

  38. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      Note


      • Do not damage the installation surface.

      • Be sure to completely remove all seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      • Do not allow the removed seal packing to enter the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier assembly and the electro magnetic control coupling sub-assembly.

      Note

      Do not damage the installation surface.

    3. A019L59E01

      Apply seal packing to the areas indicated in the illustration of the rear differential carrier assembly.

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

      Note


      • Start applying seal packing within range (A).

      • Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).

      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.

      • Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing. If the electro magnetic control coupling sub-assembly is not installed within 10 minutes after applying seal packing, completely remove and then reapply seal packing.

      • After installing the electro magnetic control coupling sub-assembly, do not immediately add oil or drive the vehicle for at least 1 hour.

      Tech Tips


        The center of the bead

      • (A) : 20 mm (0.787 in.)

      • (B) : 1.0 mm (0.0394 in.)

      • (C) : 1.4 mm (0.0551 in.)

      • (D) : 3.0 mm (0.118 in.)

      • (E) : 2.0 mm (0.0787 in.)

    4. A019LSA

      Install the electro magnetic control coupling sub-assembly with the 4 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note


      • Do not damage the diaphragm oil seal.

      • Do not damage the contact surface of the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

  39. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A019KEZ

      Using a socket wrench, service nut and a hammer, install the rear differential carrier cover breather plug to the rear differential carrier.

      Tech Tips


      • Use a service nut with an inner diameter of 13 mm (0.512 in.) and a socket wrench appropriate for the service nut.

      • Tap in the rear differential carrier cover breather plug until it sits flush with the rear differential carrier assembly.

  40. INSPECT ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A019O8LE01

      Install a dial indicator and magnetic base so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.

    2. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

      SST
      09564-32011
      Maximum runout
      0.06 mm (0.00236 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

    3. Install a dial indicator and magnetic base perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

    4. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

      SST
      09564-32011
      Maximum runout
      0.07 mm (0.00276 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

  41. INSTALL REAR DIFFERENTIAL FILLER PLUG


    1. A019O8W

      Install a new gasket with the rear differential filler plug.

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

  42. INSTALL CONNECTOR BRACKET


    1. A019JOU

      Install a new clamp to the connector bracket as shown in the illustration.

    2. A019LJI

      Install the 2 connector brackets with the 3 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  43. INSTALL ELECTRO MAGNETIC CONTROL COUPLING WIRE HARNESS


    1. A019JQ2E01
      Text in Illustration
      *1 Identification Mark
      *2 Clamp
      *3 Width of Clamp

      Install a new clamp to the electro magnetic control coupling wire harness as shown in the illustration.

      Note

      Be sure to install the new clamp so that the identification mark is aligned with the clamp.

      Distance (A)
      83.5 to 89.5 mm (3.29 to 3.52 in.)
    2. A019LGNE01

      Engage the claw to install the electro magnetic control coupling wire harness connector.

    3. Install the electro magnetic control coupling wire harness to the clamp (A).

    4. Install the clamp (B) to the connector bracket.

      Note

      Do not damage the electro magnetic control coupling wire harness.