FRONT DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

PROCEDURE

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH

    C258297E01

    1. Using SST and a press, press in the shaft bearing.

      09223-00010

    2. Using a snap ring expander, install the snap ring.

      Tip:

      Install the snap ring securely.

  2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

    C258286

    1. Install the shaft to the differential tube.

    2. Using needle nose pliers, install the snap ring.

      Tip:

      Install the snap ring securely.

  3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

    C258299C01

    *a

    Oil Seal Depth

    1. Coat the lip of a new oil seal with MP grease.

      Standard oil seal depth

      4.8 to 5.8 mm (0.189 to 0.228 in.)

    2. Using SST and a plastic-faced hammer, tap in the oil seal.

      09223-15020

  4. INSTALL DIFFERENTIAL CASE ASSEMBLY

    C236671

    1. Install the 2 thrust washers to the 2 side gears.

      Standard Thrust Washer

      Thickness

      Thickness

      1.48 to 1.52 mm (0.0583 to 0.0598 in.)

      1.73 to 1.77 mm (0.0682 to 0.0696 in.)

      1.53 to 1.57 mm (0.0603 to 0.0618 in.)

      1.78 to 1.82 mm (0.0701 to 0.0716 in.)

      1.58 to 1.62 mm (0.0622 to 0.0637 in.)

      1.83 to 1.87 mm (0.0721 to 0.0736 in.)

      1.63 to 1.67 mm (0.0642 to 0.0657 in.)

      1.88 to 1.92 mm (0.0741 to 0.0755 in.)

      1.68 to 1.72 mm (0.0662 to 0.0677 in.)

      -
    2. C236669

      Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion thrust washers and pinion shaft to the differential case.

      Tip:

      Align the holes of the differential case and pinion shaft.

    3. C236672

      Measure the side gear backlash.

      1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.

        Standard backlash

        0.15 mm (0.00591 in.) or less

        • If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.

    4. C236668

      Using a 5 mm pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

    5. Stake the differential case.

  5. INSTALL DIFFERENTIAL RING GEAR

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

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

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

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

    5. C326819C01

      *a

      Matchmark

      Align the matchmarks on the ring gear with those of the differential case.

    6. After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.

      Adhesive

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

      115 N*m

      1173 kgf*cm

      85 ft.*lbf

  6. INSTALL FRONT DIFFERENTIAL CASE BEARING

    C237495N02

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

      09950-60010

      09951-00520

      09951-00610

      09950-70010

      09951-07150

  7. INSTALL FRONT DIFFERENTIAL CASE BEARING

    Tip:

    When replacing the 3 differential case bearings, install the 2 thinnest new front differential case plate washers onto each bearing. When reusing the bearings, install the new front differential case plate washers to the same places they were removed from.

    1. C237496C01

      *1

      Front Differential Case Plate Washer

      Using SST and a press, press the case bearing (outer race) into the differential case bearing retainer.

      09950-60020

      09951-00810

      09950-70010

      09951-07150

    2. C237497C01

      *1

      Front Differential Case Plate Washer

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

      09950-60020

      09951-00810

      09950-70010

      09951-07150

  8. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

    1. C326826C01

      *1

      Front Drive Pinion Rear Tapered Roller Bearing (Outer)

      *a

      Turn

      *b

      Hold

      Using SST, install the front drive pinion rear tapered roller bearing (outer race).

      09950-60020

      09951-00720

      09951-00890

  9. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

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

    2. C327401C01

      *1

      Front Drive Pinion Front Tapered Roller Bearing (Outer)

      *a

      Turn

      *b

      Hold

      Using SST, install the front drive pinion front tapered roller bearing (outer race).

      09950-60020

      09951-00720

      09951-00890

  10. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

    1. C236679N06

      Install the washer to the drive pinion.

      Tip:

      First, install a washer that has the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

    2. Using SST and a press, press the front bearing onto the drive pinion.

      09506-30012

  11. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

    C237303

    1. Install the drive pinion, roller bearing and oil slinger to the differential case.

      Tip:

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

    2. C237304C11

      *a

      Turn

      *b

      Hold

      Using SST, install the companion flange.

      09950-30012

      09951-03010

      09953-03010

      09954-03010

      09955-03030

      09956-03020

      Note:

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

    3. Adjust the drive pinion preload by tightening the companion flange nut.

    4. C282254C10

      *a

      Turn

      *b

      Hold

      Using SST to hold the companion flange in place, then slowly tighten the nut within the drive pinion preload adjustment range so that it reaches the specified drive pinion preload (at Starting).

      09330-00021

      09330-00030

      Limit Torque Value

      370 N*m (3773 kgf*cm, 273 ft.*lbf) or less

      Note:

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

      • Apply hypoid gear oil LSD to the nut.

    5. C237317

      Using a torque wrench, measure the preload.

      Standard Preload (at Starting)

      Item

      Specified Condition

      New bearing

      0.98 to 1.92 N*m (10 to 19 kgf*cm, 9 to 16 in.*lbf)

      Used bearing

      0.49 to 0.78 N*m (5 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.

  12. INSTALL DIFFERENTIAL CASE ASSEMBLY

  13. ADJUST DIFFERENTIAL RING GEAR BACKLASH

    1. Install the side bearing retainer with the 10 bolts.

      75 N*m

      765 kgf*cm

      55 ft.*lbf

    2. C258277N02

      Using SST and a dial indicator, measure the ring gear backlash.

      09564-32011

      Standard backlash

      0.11 to 0.21 mm (0.00433 to 0.00826 in.)

      • If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.

        Tip:

        There should be no clearance between the plate washer and case. Make sure that the ring gear has backlash.

        Standard Washer LH Thickness (Side Opposite Ring Gear)

        Part No.

        Thickness mm (in.)

        Part No.

        Thickness

        90564-50184

        1.57 to 1.59 (0.0619 to 0.0625)

        90564-50136

        1.95 to 1.97 (0.0768 to 0.0775)

        90564-50124

        1.59 to 1.61 (0.0626 to 0.0633)

        90564-50197

        1.97 to 1.99 (0.0776 to 0.0783)

        90564-50185

        1.61 to 1.63 (0.0634 to 0.0641)

        90564-50198

        1.99 to 2.01 (0.0784 to 0.0791)

        90564-50186

        1.63 to 1.65 (0.0642 to 0.0649)

        90564-50138

        2.01 to 2.03 (0.0792 to 0.0799)

        90564-50126

        1.65 to 1.67 (0.0650 to 0.0657)

        90564-50199

        2.03 to 2.05 (0.0800 to 0.0807)

        90564-50187

        1.67 to 1.69 (0.0658 to 0.0665)

        90564-50200

        2.05 to 2.07 (0.0808 to 0.0814)

        90564-50188

        1.69 to 1.71 (0.0666 to 0.0673)

        90564-50140

        2.07 to 2.09 (0.0815 to 0.0822)

        90564-50128

        1.71 to 1.73 (0.0674 to 0.0681)

        90564-50201

        2.09 to 2.11 (0.0823 to 0.0830)

        90564-50189

        1.73 to 1.75 (0.0682 to 0.0688)

        90564-50202

        2.11 to 2.13 (0.0831 to 0.0838)

        90564-50190

        1.75 to 1.77 (0.0689 to 0.0696)

        90564-50142

        2.13 to 2.15 (0.0839 to 0.0846)

        90564-50130

        1.77 to 1.79 (0.0697 to 0.0704)

        90564-50203

        2.15 to 2.17 (0.0847 to 0.0854)

        90564-50191

        1.79 to 1.81 (0.0705 to 0.0712)

        90564-50231

        2.17 to 2.19 (0.0855 to 0.0862)

        90564-50192

        1.81 to 1.83 (0.0713 to 0.0720)

        90564-50232

        2.19 to 2.21 (0.0863 to 0.0870)

        90564-50132

        1.83 to 1.85 (0.0721 to 0.0728)

        90564-50233

        2.21 to 2.23 (0.0871 to 0.0877)

        90564-50193

        1.85 to 1.87 (0.0729 to 0.0736)

        90564-50234

        2.23 to 2.25 (0.0878 to 0.0885)

        90564-50194

        1.87 to 1.89 (0.0737 to 0.0744)

        90564-50235

        2.25 to 2.27 (0.0886 to 0.0893)

        90564-50134

        1.89 to 1.91 (0.0745 to 0.0751)

        90564-50236

        2.27 to 2.29 (0.0894 to 0.0901)

        90564-50195

        1.91 to 1.93 (0.0752 to 0.0759)

        90564-50237

        2.29 to 2.31 (0.0902 to 0.0909)

        90564-50196

        1.93 to 1.95 (0.0760 to 0.0767)

        -

        -
        Table 1. Standard Washer RH Thickness (ring gear side):

        Part No.

        Thickness mm (in.)

        Part No.

        Thickness mm (in.)

        90564-50224

        1.43 to 1.45 (0.0563 to 0.0570)

        90564-50212

        1.81 to 1.83 (0.0713 to 0.0720)

        90564-50225

        1.45 to 1.47 (0.0571 to 0.0578)

        90564-50162

        1.83 to 1.85 (0.0721 to 0.0728)

        90564-50226

        1.47 to 1.49 (0.0579 to 0.0586)

        90564-50213

        1.85 to 1.87 (0.0729 to 0.0736)

        90564-50227

        1.49 to 1.51 (0.0587 to 0.0594)

        90564-50214

        1.87 to 1.89 (0.0737 to 0.0744)

        90564-50228

        1.51 to 1.53 (0.0595 to 0.0602)

        90564-50164

        1.89 to 1.91 (0.0745 to 0.0751)

        90564-50229

        1.53 to 1.55 (0.0603 to 0.0610)

        90564-50215

        1.91 to 1.93 (0.0752 to 0.0759)

        90564-50230

        1.55 to 1.57 (0.0611 to 0.0618)

        90564-50216

        1.93 to 1.95 (0.0760 to 0.0767)

        90564-50204

        1.57 to 1.59 (0.0619 to 0.0625)

        90564-50166

        1.95 to 1.97 (0.0768 to 0.0775)

        90564-50154

        1.59 to 1.61 (0.0626 to 0.0633)

        90564-50217

        1.97 to 1.99 (0.0776 to 0.0783)

        90564-50205

        1.61 to 1.63 (0.0634 to 0.0641)

        90564-50218

        1.99 to 2.01 (0.0784 to 0.0791)

        90564-50206

        1.63 to 1.65 (0.0642 to 0.0649)

        90564-50168

        2.01 to 2.03 (0.0792 to 0.0799)

        90564-50156

        1.65 to 1.67 (0.0650 to 0.0657)

        90564-50219

        2.03 to 2.05 (0.0800 to 0.0807)

        90564-50207

        1.67 to 1.69 (0.0658 to 0.0665)

        90564-50220

        2.05 to 2.07 (0.0808 to 0.0814)

        90564-50208

        1.69 to 1.71 (0.0666 to 0.0673)

        90564-50170

        2.07 to 2.09 (0.0815 to 0.0822)

        90564-50158

        1.71 to 1.73 (0.0674 to 0.0681)

        90564-50221

        2.09 to 2.11 (0.0823 to 0.0830)

        90564-50209

        1.73 to 1.75 (0.0682 to 0.0688)

        90564-50222

        2.11 to 2.13 (0.0831 to 0.0838)

        90564-50210

        1.75 to 1.77 (0.0689 to 0.0696)

        90564-50172

        2.13 to 2.15 (0.0839 to 0.0846)

        90564-50160

        1.77 to 1.79 (0.0697 to 0.0704)

        90564-50223

        2.15 to 2.17 (0.0847 to 0.0854)

        90564-50211

        1.79 to 1.81 (0.0705 to 0.0712)

        -

        -

  14. INSPECT TOTAL PRELOAD

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

      Standard Total Preload (at Starting)

      Item

      Specified Condition

      New bearing

      1.2 to 2.8 N*m (13 to 28 kgf*cm, 11 to 24 in.*lbf)

      Used bearing

      0.71 to 1.66 N*m (8 to 16 kgf*cm, 7 to 14 in.*lbf)

      • If necessary, disassemble and inspect the differential.

  15. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    1. Remove the differential case bearing retainer and differential case.

    2. C258312

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

    3. Install the differential case and differential case bearing retainer.

      75 N*m

      765 kgf*cm

      55 ft.*lbf

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

    5. Remove the differential case bearing retainer and differential case.

    6. Inspect the tooth contact pattern.

      C205651C01

      *A

      Drive Side

      *B

      Coast Side

      *a

      Proper Contact

      *b

      Toe Contact

      *c

      Face Contact

      *d

      Select an adjusting washer that will shift the drive pinion closer to the ring gear.

      *e

      Heel Contact

      *f

      Flank Contact

      *g

      Select an adjusting washer that will shift the drive pinion away from the ring gear.

      *h

      Heel Contact

      *i

      Flank Contact

      *j

      Toe Contact

      *k

      Face Contact

      -

      -
    7. C258313C01

      *1

      Drive Pinion Washer

      If the teeth are not contacting properly, use the following chart to select an appropriate washer.

      Standard Washer

      Part No.

      Thickness mm (in.)

      Part No.

      Thickness mm (in.)

      90564-35109

      1.69 to 1.71 (0.0666 to 0.0673)

      90564-35120

      2.02 to 2.04 (0.0796 to 0.0803)

      90564-35110

      1.72 to 1.74 (0.0678 to 0.0685)

      90564-35121

      2.05 to 2.07 (0.0807 to 0.0814)

      90564-35111

      1.75 to 1.77 (0.0689 to 0.0696)

      90564-35123

      2.08 to 2.10 (0.0819 to 0.0826)

      90564-35112

      1.78 to 1.80 (0.0701 to 0.0708)

      90564-35124

      2.11 to 2.13 (0.0831 to 0.0838)

      90564-35113

      1.81 to 1.83 (0.0713 to 0.0720)

      90564-35125

      2.14 to 2.16 (0.0843 to 0.0850)

      90564-35114

      1.84 to 1.86 (0.0725 to 0.0732)

      90564-35126

      2.17 to 2.19 (0.0855 to 0.0862)

      90564-35115

      1.87 to 1.89 (0.0737 to 0.0744)

      90564-35127

      2.20 to 2.22 (0.0867 to 0.0874)

      90564-35116

      1.90 to 1.92 (0.0748 to 0.0755)

      90564-35128

      2.23 to 2.25 (0.0878 to 0.0885)

      90564-35117

      1.93 to 1.95 (0.0760 to 0.0767)

      90564-36129

      2.26 to 2.28 (0.0890 to 0.0897)

      90564-35118

      1.96 to 1.98 (0.0772 to 0.0779)

      90564-35130

      2.29 to 2.31 (0.0902 to 0.0909)

      90564-35119

      1.99 to 2.01 (0.0784 to 0.0791)

      90564-35131

      2.32 to 2.34 (0.0914 to 0.0921)

  16. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

    Click here

  17. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  18. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  19. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

    Click here

  20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

    Click here

  21. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

    1. Install the bearing spacer.

  22. INSTALL FRONT DIFFERENTIAL OIL STORAGE RING

    Click here

  23. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

    C310122N01

    1. Using SST and a hammer, install the roller bearing (outer).

      09316-60011

      09316-00011

      09316-00021

  24. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

    1. Install the roller bearing (inner).

  25. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  26. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

    Click here

  27. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR

    C258315C01

    *1

    Steel Plate

    1. Using a steel plate and press, press in a new dust deflector.

      Note:

      Do not damage the dust deflector.

  28. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    Click here

  29. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

    1. Remove any old FIPG material from the side bearing retainer.

      Note:

      Do not drop oil on the contact surfaces of the differential carrier and side bearing retainer.

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

    3. C237503C04

      *a

      Seal Packing

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

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Tip:

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

    4. Install the side bearing retainer with the 10 bolts.

      75 N*m

      765 kgf*cm

      55 ft.*lbf

  30. INSPECT TOTAL PRELOAD

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

      Standard Total Preload (at Starting)

      Item

      Specified Condition

      New bearing

      1.3 to 2.9 N*m (14 to 29 kgf*cm, 12 to 25 in.*lbf)

      Used bearing

      0.81 to 1.76 N*m (9 to 17 kgf*cm, 8 to 15 in.*lbf)

      • If necessary, disassemble and inspect the differential.

  31. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    C258277N03

    1. Using SST and a dial indicator, measure the ring gear backlash.

      09564-32011

      Standard backlash

      0.11 to 0.21 mm (0.0043 to 0.00826 in.)

      • If the backlash is not within the specification, adjust the side bearing preload.

  32. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    C258278C05

    *a

    Vertical runout

    *b

    Lateral runout

    *c

    30 mm

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

      Distance from center to runout measurement point

      30 mm (1.18 in.)

      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.

  33. STAKE FRONT DRIVE PINION COMPANION FLANGE NUT

    Click here

  34. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

    C336074E01

    1. Coat the lip of a new oil seal with MP grease.

    2. Using SST and a plastic-faced hammer, tap in the oil seal until its surface is flush with the differential carrier end.

      09608-32010

      Standard oil seal depth

      -0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

  35. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

    C237651

    1. Using a brass bar and hammer, tap in the side bearing retainer deflector.

      Note:

      Install the side bearing retainer deflector so that it is facing in the correct direction.

  36. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY

    1. Remove any old FIPG material from the contact surfaces of the differential and clutch case.

      Note:

      Do not drop oil on the contact surfaces of the differential and clutch case.

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

    3. C237504C04

      *a

      Seal Packing

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

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Tip:

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

    4. Install the differential tube to the differential.

    5. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

    6. Apply adhesive to 2 or 3 threads at the tip of each bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    7. Using an E14 "TORX" socket wrench, install the 4 bolts.

      110 N*m

      1122 kgf*cm

      81 ft.*lbf