REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

The following procedures are for BD20 (w/o Differential Lock).

PROCEDURE


  1. ASSEMBLE DIFFERENTIAL CASE


    1. A01WBCV

      Install the rear No. 1 differential side gear thrust washer to the side gear.

      Tech Tips

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

      Standard Washer Thickness
      Part No. Thickness mm (in.) Part No. Thickness mm (in.)
      41361-0K010 1.48 to 1.52 (0.0583 to 0.0598) 41361-0K060 1.73 to 1.77 (0.0682 to 0.0696)
      41361-0K020 1.53 to 1.57 (0.0603 to 0.0618) 41361-0K070 1.78 to 1.82 (0.0701 to 0.0716)
      41361-0K030 1.58 to 1.62 (0.0622 to 0.0637) 41361-0K080 1.83 to 1.87 (0.0721 to 0.0736)
      41361-0K040 1.63 to 1.67 (0.0642 to 0.0657) 41361-0K090 1.88 to 1.92 (0.0741 to 0.0755)
      41361-0K050 1.68 to 1.72 (0.0662 to 0.0677) - -
    2. A01W9F7

      Install 2 side gears, 2 pinion gears, 2 rear No. 1 differential side gear thrust washers, 2 pinion gear thrust washers and the pinion shaft in the differential case.

      Tech Tips

      Align the holes of the differential case and pinion shaft.

    3. A01WBIT

      Measure the side gear backlash.


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

        Backlash
        0.05 to 0.20 mm (0.00197 to 0.00787 in.)

        • If the backlash is not as specified, install 2 rear No. 1 differential side gear thrust washers with different thicknesses.

    4. A01W8K4

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

    5. Stake the differential case.

  2. INSTALL DIFFERENTIAL RING GEAR


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

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

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

    4. A01WBGTC01
      *a Matchmark

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

    5. After the ring gear cools down sufficiently, apply adhesive to the 10 bolts and Temporarily install them.

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

    6. Diametrically tighten the 10 bolts uniformly in several passes.

      Torque:
      92 N*m  { 938 kgf*cm, 68 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01WAYVN01

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

      SST
      09950-60010   ( 09951-00430, 09951-00470, 09951-00480, 09951-00550 )
      09950-70010   ( 09951-00560, 09951-00570, 09951-07150 )

  4. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. Install the differential case on the differential carrier, and install the 2 rear differential bearing adjusting nuts so that there is no play in the bearing.

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

      Torque:
      85.3 N*m  { 870 kgf*cm, 63 ft.*lbf }
    3. A01W8CZC01
      *a 92 mm (3.62 in.)

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

      Maximum runout
      0.07 mm (0.00276 in.)

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

  5. INSTALL DIFFERENTIAL OIL STORAGE RING

    Click here

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01W87ZN05

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

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

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01WBK1N05

      Using SST and a press, press the rear drive pinion rear tapered roller bearing (outer) into the differential carrier.

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

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


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

      Tech Tips

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

    2. A01W9X0N07

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

      SST
      09506-30012

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01WBJK

      Install the differential drive pinion, rear drive pinion front tapered roller bearing (inner) and rear differential drive pinion oil slinger.

      Tech Tips

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

    2. A01W8J0C06
      *a Turn
      *b Hold

      Using SST, install the rear drive pinion companion flange sub-assembly with dust deflector.

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

      Note

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

    3. A01WAY8N04

      Adjust the drive pinion preload by tightening the rear drive pinion nut.

    4. Using SST to hold the companion flange in place, tighten the rear drive pinion nut.

      SST
      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 a little at a time. Be careful not to overtighten the drive pinion nut.

      • Apply hypoid gear oil LSD to the differential drive pinion thread and drive pinion nut seat face.

    5. Using a torque wrench, measure the preload.

      Standard Drive Pinion Preload (Starting Torque)
      Reduction Ratio Bearing Preload

      3.583

      4.100

      4.300

      4.555

      		 New bearing 0.99 to 1.94 N*m (11 to 19 kgf*cm, 9 to 17 in.*lbf)
      Reused bearing 0.99 to 1.82 N*m (11 to 18 kgf*cm, 9 to 16 in.*lbf)

      Note


      • For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

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

  10. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A01W94C

      Place the 2 rear differential case bearings (outer) to their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

  11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01W905

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

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


    1. A01W8UEC01
      *a Matchmark

      Align the matchmarks on the bearing cap and differential carrier.

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

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

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

        Tech Tips

        Reinstall the adjusting nuts if necessary.

    3. A01WB2NC01
      *a for LH Side
      *b for RH Side

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

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

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

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

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

      SST
      09504-00011
      09960-10010   ( 09962-01000, 09963-00700 )
    7. A01WB4ON01

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

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

      Tech Tips


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

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

    8. A01W91B

      Tighten the bearing cap bolts.

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

  13. INSPECT TOTAL PRELOAD


    1. A01W8TG

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

    2. Using a torque wrench, measure the total preload.

      Standard Total Preload
      Reduction Ratio Item Specified Condition
      3.583 New bearing 1.38 to 2.69 N*m (15 to 27 kgf*cm, 13 to 23 in.*lbf)
      Reused bearing 1.38 to 2.46 N*m (15 to 25 kgf*cm, 13 to 21 in.*lbf)
      4.100 New bearing 1.33 to 2.59 N*m (14 to 26 kgf*cm, 12 to 22 in.*lbf)
      Reused bearing 1.33 to 2.38 N*m (14 to 24 kgf*cm, 12 to 21 in.*lbf)
      4.300 New bearing 1.31 to 2.56 N*m (14 to 26 kgf*cm, 12 to 22 in.*lbf)
      Reused bearing 1.32 to 2.35 N*m (14 to 23 kgf*cm, 12 to 20 in.*lbf)
      4.555 New bearing 1.3 to 2.53 N*m (14 to 25 kgf*cm, 12 to 22 in.*lbf)
      Reused bearing 1.3 to 2.32 N*m (14 to 23 kgf*cm, 12 to 20 in.*lbf)

      If necessary, disassemble and inspect the differential.

      Note

      Record the differential ring gear preload.

  14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01W8YL

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

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

    3. Inspect the tooth contact pattern.


      • A01WBBDC02
        *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 - -
      • A01WBTBC06
        *1 Rear Differential Drive Pinion Plate Washer

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

        Tech Tips

        There are two different sizes of rear differential drive pinion plate washers (outer diameter of 52 mm (2.047 in.) or 47 mm (1.850 in.)), but either can be used.

        Standard Plate Washer Thickness
        Out Side Diameter 52 mm (2.047 in.)
        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) 90564-35129 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)
        Out Side Diameter 47 mm (1.850 in.)
        Part No. Thickness mm (in.) Part No. Thickness mm (in.)
        90201-35497 1.69 to 1.71 (0.0666 to 0.0673) 90201-35508 2.02 to 2.04 (0.0796 to 0.0803)
        90201-35498 1.72 to 1.74 (0.0678 to 0.0685) 90201-35509 2.05 to 2.07 (0.0807 to 0.0814)
        90201-35499 1.75 to 1.77 (0.0689 to 0.0696) 90201-35510 2.08 to 2.10 (0.0819 to 0.0826)
        90201-35500 1.78 to 1.80 (0.0701 to 0.0708) 90201-35511 2.11 to 2.13 (0.0831 to 0.0838)
        90201-35501 1.81 to 1.83 (0.0713 to 0.0720) 90201-35512 2.14 to 2.16 (0.0843 to 0.0850)
        90201-35502 1.84 to 1.86 (0.0725 to 0.0732) 90201-35513 2.17 to 2.19 (0.0855 to 0.0862)
        90201-35503 1.87 to 1.89 (0.0737 to 0.0744) 90201-35514 2.20 to 2.22 (0.0867 to 0.0874)
        90201-35504 1.90 to 1.92 (0.0748 to 0.0755) 90201-35515 2.23 to 2.25 (0.0878 to 0.0885)
        90201-35505 1.93 to 1.95 (0.0760 to 0.0767) 90201-35516 2.26 to 2.28 (0.0890 to 0.0897)
        90201-35506 1.96 to 1.98 (0.0772 to 0.0779) 90201-35517 2.29 to 2.31 (0.0902 to 0.0909)
        90201-35507 1.99 to 2.01 (0.0784 to 0.0791) 90201-35518 2.32 to 2.34 (0.0914 to 0.0921)

  15. REMOVE REAR DRIVE PINION NUT

    Click here

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

    Click here

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    Click here

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

    Click here

  20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01WBNR

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

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

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

    Click here

  24. INSPECT TOTAL PRELOAD


    1. A01W8TG

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

    2. Using a torque wrench, measure the total preload.

      Standard Total Preload
      Reduction Ratio Bearing Preload
      3.583 New bearing 1.48 to 2.79 N*m (16 to 28 kgf*cm, 14 to 24 in.*lbf)
      Reused bearing 1.48 to 2.56 N*m (16 to 26 kgf*cm, 14 to 22 in.*lbf)
      4.100 New bearing 1.43 to 2.69 N*m (15 to 27 kgf*cm, 13 to 23 in.*lbf)
      Reused bearing 1.43 to 2.48 N*m (15 to 25 kgf*cm, 13 to 21 in.*lbf)
      4.300 New bearing 1.41 to 2.66 N*m (15 to 27 kgf*cm, 13 to 23 in.*lbf)
      Reused bearing 1.42 to 2.45 N*m (15 to 24 kgf*cm, 13 to 21 in.*lbf)
      4.555 New bearing 1.4 to 2.63 N*m (15 to 26 kgf*cm, 13 to 23 in.*lbf)
      Reused bearing 1.4 to 2.42 N*m (15 to 24 kgf*cm, 13 to 21 in.*lbf)

      • If necessary, disassemble and inspect the differential.

  25. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01W830

      Using a dial indicator, check the backlash of the differential ring gear.

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

      • If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.

        Tech Tips

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

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

    Click here

  27. STAKE DRIVE PINION NUT

    Click here

  28. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01W896

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

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

    2. Bend the nut locks.