REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

Note


  • Before installation, thoroughly clean and dry each part and then apply Toyota Genuine Differential gear oil LT SAE 75W-85 GL-5 or equivalent to them.

  • Do not use alkaline cleaner for aluminum or rubber parts and rear differential case bolts.

  • Do not clean rubber parts such as oil seals with non-residue solvent.

  • Use an overhaul stand as necessary.

PROCEDURE


  1. SEPARATE ELECTRO MAGNETIC CONTROL COUPLING WIRE HARNESS

    B005MGA

    1. Disengage the claw and separate the electro magnetic control coupling wire harness from the 2 clamps.

      Note

      Do not damage the electro magnetic control coupling wire harness.

  2. REMOVE CONNECTOR BRACKET


    1. B005N10C01
      *1 Clamp

      Remove the 3 bolts and 2 connector brackets from the rear differential carrier assembly.

    2. Remove the 2 clamps from the 2 connector brackets.

  3. REMOVE STUD BOLT

    B005NEPC01
    *a Upper Nut
    *b Lower Nut
    *c Turn
    *d Hold

    1. 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.)

    2. Turn the lower nut and remove the other 3 stud bolts in the same way.

      Note

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

      Tech Tips


      • Lock the lower nut using the upper nut.

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

  4. REMOVE REAR DIFFERENTIAL FILLER PLUG


    1. B005NZU

      Remove the rear differential filler plug and gasket.

  5. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. Using a chisel and hammer, lift the rear differential carrier cover breather plug slightly.

    2. A01RBJH

      Using a screwdriver, remove the rear differential carrier cover breather plug.

  6. INSPECT RUNOUT OF ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. B005P4DC02
      *a Vertical Runout
      *b Lateral Runout

      Install a dial indicator and magnetic base 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.

  7. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. B005OTK

      Remove the 4 bolts.

    2. Using a brass bar and a hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier assembly.

      Note


      • Set the brass bar on the ribbed part of the electro magnetic control coupling sub-assembly.

      • Do not damage the contact surface.

      Tech Tips

      Temporarily install 2 bolts by approximately 5 or 6 threads to prevent the electro magnetic control coupling sub-assembly from falling.

  8. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


    1. B005PXAC01
      *a Protective Tape
      *b Matchmark

      Put matchmarks on the rear differential dust deflector and electro magnetic control coupling sub-assembly.

    2. Using a screwdriver, remove the rear differential dust deflector.

      Note


      • Pry around the circumference of the rear differential dust deflector uniformly to prevent deformation.

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

      Tech Tips


      • Tape the screwdriver tip before use.

      • If the end surface of the electro magnetic control coupling sub-assembly is damaged while removing the rear differential dust deflector, replace the electro magnetic control coupling sub-assembly with a new one.

  9. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER


    1. B005MEAC01
      *1 Transmission Coupling Conical Spring Washer

      Remove the transmission coupling conical spring washer from the rear differential carrier assembly.

  10. REMOVE TRANSMISSION COUPLING SPACER


    1. B005OPAC01
      *1 Transmission Coupling Spacer

      Remove the transmission coupling spacer from the rear differential carrier assembly.

  11. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. B005MA9N02

      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.

  12. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. B005M41N01

      Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.

      SST
      09556-16011
      Standard Drive Pinion Preload
      1.51 to 2.52 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

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

      Tech Tips

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

  13. INSPECT TOTAL PRELOAD


    1. B005M41N01

      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
      2.80 to 5.34 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

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

      Tech Tips

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

  14. REMOVE REAR DRIVE SHAFT OIL SEAL LH


    1. B005N3ZC01
      *1 Rear Drive Shaft Oil Seal LH

      Using SST, remove the rear drive shaft oil seal LH from the rear differential carrier assembly.

      SST
      09308-00010

  15. REMOVE REAR DRIVE SHAFT OIL SEAL RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  16. REMOVE DIAPHRAGM OIL SEAL


    1. B005QB4C02
      *1 Diaphragm Oil Seal

      Using SST, remove the diaphragm oil seal from the rear differential carrier assembly.

      SST
      09308-00010

  17. REMOVE REAR DRIVE PINION NUT


    1. B005P61C01
      *1 Rear Drive Pinion Nut

      Using SST and a hammer, release the staked part of the rear drive pinion nut.

      SST
      09930-00010

      Note


      • When using SST, make sure that the flat portion is on the differential drive pinion side.

      • Do not modify the SST tip with a grinder or equivalent.

      • Loosen the staked part of the rear drive pinion nut completely, otherwise the threads of the differential drive pinion may be damaged.

    2. B005PVSC02
      *a Turn
      *b Hold

      Using SST, hold the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.

      SST
      09556-16011

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B005OJRC01
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Inner Race)
      *a Hold
      *b Turn

      Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the differential drive pinion.

      SST
      09556-40010

  19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. B005Q12

      Remove the 10 bolts from the rear differential carrier.

    2. A01RFL6

      Using a brass bar and a hammer, disengage the 2 pins and remove the differential side bearing retainer from the rear differential carrier.

      Note


      • Set the brass bar on the ribbed part of the differential side bearing retainer.

      • Do not damage the contact surface.

      Tech Tips

      Temporarily install 2 bolts by approximately 5 or 6 threads to prevent the differential side bearing retainer from falling.

  20. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY


    1. B005ND8

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

  21. REMOVE DIFFERENTIAL DRIVE PINION


    1. B005QCN

      Remove the differential drive pinion from the rear differential carrier.

  22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    B005LCX

    1. Remove the rear differential drive pinion oil slinger from the differential drive pinion.

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B005OMM

      Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

  24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B005LSON05

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

      SST
      09950-00020

      Note

      Do not drop the differential drive pinion.

      Tech Tips

      If the differential driver pinion or differential ring gear is damaged, replace them both.

    2. Remove the rear differential drive pinion plate washer.

  25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B005N3KC01
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Outer Race)
      *a Hold
      *b Turn

      Using SST, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier.

      SST
      09387-00041   ( 09387-01030, 09387-01041 )
      09387-02020

  26. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01REWJ

      Using a brass bar and a hammer, lightly and uniformly tap out the rear drive pinion rear tapered roller bearing (outer race) from the rear differential carrier.

      Note

      Set the brass bar on the notch.

  27. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)


    1. B005MJMC01
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

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

      SST
      09950-60010   ( 09951-00540 )
      09950-70010   ( 09951-07100 )

  28. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)


    1. B005LU0C01
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

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

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07100 )

  29. REMOVE 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. B005NJCC01
      *1 Rear Differential Case Bearing (LH Side Inner Race)
      *a Hold
      *b Turn

      Using SST, remove the rear differential case bearing (LH side inner race) from the rear differential case sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00340 )

      Note

      Before using the SST center bolt (09953-04020), apply grease to its threads and tip.

      Tech Tips


      • If the race remains on the rear differential case sub-assembly, repeat the step above to remove the race.

      • If the rear differential case bearing (LH side inner race) is deformed, replace it with a new one.

  30. REMOVE 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. B005L47C01
      *1 Rear Differential Case Bearing (RH Side Inner Race)
      *a Hold
      *b Turn

      Using SST, remove the rear differential case bearing (RH side inner race) from the rear differential case sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00370 )

      Note

      Before using the SST center bolt (09953-04020), apply grease to its threads and tip.

      Tech Tips


      • If the race remains on the rear differential case sub-assembly, repeat the step above to remove the race.

      • If the rear differential case bearing (RH side inner race) is deformed, replace it with a new one.

  31. REMOVE DIFFERENTIAL RING GEAR


    1. B005LHRC01
      *a Matchmark

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

      Note

      Do not overtighten the vise.

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

    3. Remove the 12 rear differential case bolts.

    4. Using a plastic hammer, lightly and uniformly tap the outer circumference of the differential ring gear to remove it from the rear differential case sub-assembly.

      Note


      • Be careful not to damage the edges of the differential ring gear.

      • Do not drop the differential ring gear.

      Tech Tips


      • Place a cloth on the teeth side of the differential ring gear to prevent damage.

      • If it is difficult to remove, tap the outer circumference of the differential ring gear using a brass bar and a hammer.

      • If the differential drive pinion or differential ring gear is damaged, replace them both.

  32. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. B005OEI

      Remove the 2 bolts and rear differential breather plug oil deflector from the rear differential carrier.

  33. REMOVE STRAIGHT PIN


    1. Remove the 4 straight pins from the rear differential carrier.

      A01RDNO

  34. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check the differential pinion gears and differential side gears for wear.

      If the differential pinion gears and differential side gears are damaged, replace the rear differential case sub-assembly.

  35. INSPECT DIFFERENTIAL CASE


    1. Check the differential case for cracks or damage.

      If the differential case is damaged, replace the rear differential case sub-assembly.