DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT


  1. DRAIN DIFFERENTIAL OIL


    1. for front differential:


      1. Stop the vehicle on a level surface.

      2. A01E32IE01
        Text in Illustration
        *1 10 mm Straight Hexagon Wrench
        *2 10 mm Union Nut Wrench
        *3 Socket Adaptor

        Using SST and the 10 mm straight hexagon wrench, 10 mm union nut wrench and socket adaptor, remove the differential filler plug and gasket.

        SST
        09961-00950

      3. Remove the drain plug and gasket, and drain the oil.

      4. Install a new gasket and the drain plug.

        Torque:
        65 N*m  { 660 kgf*cm, 48 ft.*lbf }

    2. for rear differential:


      1. Stop the vehicle on a level surface.

      2. Remove the differential filler plug and gasket.

      3. Remove the drain plug and gasket, and drain the oil.

      4. Install a new gasket and the drain plug.

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

  2. REMOVE REAR PROPELLER SHAFT ASSEMBLY


    1. for TSAM Made:

      Click here

    2. for TMT Made:

      Click here

  3. REMOVE REAR DRIVE PINION NUT


    1. A01DVN5E01

      Using SST and a hammer, loosen the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01DWE9E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the companion flange in place, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

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


    1. A01DW9H

      Using SST, remove the companion flange 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.

  5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01DZCPE01
      Text in Illustration
      *1 Oil Seal
      *2 Oil Slinger

      Using SST, remove the oil seal.

      SST
      09308-10010

  6. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Remove the oil slinger from the drive pinion.

  7. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E1CNE01

      Using SST, remove the roller bearing (inner).

      SST
      09556-22010
    2. A01E30HE01

      Using SST, tap out the roller bearing (outer).

      SST
      09308-00010

  8. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. Using a screwdriver and hammer, tap out the oil storage ring.

  9. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DZDP

      Remove the bearing spacer from the drive pinion.

  10. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DZDP

      Install a new bearing spacer.

      Tech Tips

      Make sure the spacer is installed correctly.

  11. INSTALL DIFFERENTIAL OIL STORAGE RING


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

      Note

      Be careful not to damage the oil storage ring.

  12. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01DXLOE01

      Using SST and a hammer, tap in the roller bearing (outer).

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

    2. Install the roller bearing (inner).

  13. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Install the oil slinger to the drive pinion.

  14. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01E0NVE01
      Text in Illustration
      *a Oil Seal Depth

      Using SST and a hammer, tap in a new oil seal.

      SST
      09554-30011
      Standard oil seal depth
      0 +/-0.3mm (0 +/-0.0118in.)

    2. Apply MP grease to the lip of the oil seal.

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


    1. A01DZYZ

      Using SST, install the companion flange 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.

    2. Apply hypoid gear oil LSD to drive pinion thread and nut seat face.

    3. A01DVBQE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the companion flange in place, install a new nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3773 kgf*cm, 273 ft.*lbf, or less }

  16. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01DZCY

      Using a torque wrench, measure the preload.

      Standard Preload (Starting Torque)
      Item Specified Condition
      New bearing 1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf)
      Reused bearing 0.6 to 0.8 N*m (7 to 8 kgf*cm, 6 to 7 in.*lbf)

      • If the result is not as specified, adjust the preload.

  17. INSPECT TOTAL PRELOAD


    1. A01DZCY

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

      Standard Total Preload
      Bearing Specified Condition
      New bearing 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
      Reused bearing 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload

      If the result is not as specified, adjust the preload.

  18. STAKE DRIVE PINION NUT


    1. A01DW40

      Using a chisel and hammer, stake the nut.

  19. INSTALL REAR PROPELLER SHAFT ASSEMBLY


    1. for TSAM Made:

      Click here

    2. for TMT Made:

      Click here

  20. ADD DIFFERENTIAL OIL


    1. A01E16LE51
      Text in Illustration
      *a 0 to 5 mm (0 to 0.196 in.)

      Add differential oil so that the oil level is within 5 mm (0 to 0.196 in.) from the bottom lip of the differential filler plug hole.

      Note


      • After changing the oil seal, drive the vehicle and then check the oil level again.

      • Too much or too little oil will lead to differential problems.

      Tech Tips

      If necessary, fill the differential carrier assembly with hypoid gear oil.

      Recommended viscosity
      Item Temperature Viscosity
      Front differential (w/ A.D.D.) SAE 75W-90

      Front differential (w/o A.D.D.)

      Rear differential

      		 Above -18°C (0°F) SAE 90
      Below -18°C (0°F) SAE 80W-90 or SAE 80W
      Differential oil type
      Item Oil type

      Front differential

      Rear differential

      		 Hypoid gear oil API GL-5 or equivalent
      Rear differential (for LSD) Hypoid gear oil LSD API GL-5 or equivalent
      Standard front differential oil capacity
      Item Capacity
      w/o A.D.D. 1.40 to 1.50 liters (1.48 to 1.58 US qts., 1.23 to 1.32 Imp. qts.)
      w/ A.D.D. 1.60 to 1.70 liters (1.69 to 1.79 US qts., 1.41 to 1.49 Imp. qts.)
      TMT made Standard rear differential oil capacity
      Item Capacity
      2WD and w/ LSD 3.15 to 3.25 liters (3.33 to 3.43 US qts., 2.78 to 2.86 Imp. qts.)
      4WD and w/o LSD 3.30 to 3.40 liters (3.49 to 3.59 US qts., 2.91 to 2.99 Imp. qts.)
      TSAM made
      Item Capacity
      2WD and made for DANA 2.30 to 2.40 liters (2.43 to 2.54 US qts., 2.02 to 2.11 Imp. qts.)

      4WD, Pre-runner and made for DANA

      (w/o LSD, A.D.D.)

      		 2.40 to 2.50 liters (2.54 to 2.64 US qts., 2.11 to 2.20 Imp. qts.)
      w/ LSD for 2WD 3.15 to 3.25 liters (3.33 to 3.43 US qts., 2.78 to 2.86 Imp. qts.)
      w/ LSD for 4WD 3.30 to 3.40 liters (3.49 to 3.59 US qts., 2.91 to 2.99 Imp. qts.)
      w/ Differential lock 2.85 to 2.95 liters (3.01 to 3.12 US qts., 2.51 to 2.60 Imp. qts.)

    2. Check for oil leakage when the oil level is low.

    3. for front differential:


      1. A01DY2AE01
        Text in Illustration
        *1 10 mm Straight Hexagon Wrench
        *2 10 mm Union Nut Wrench
        *3 Socket Adaptor

        Using SST and the 10 mm straight hexagon wrench, 10 mm union nut wrench and socket adaptor, install a new gasket and the differential filler plug.

        SST
        09961-00950
        Torque:
        39 N*m  { 400 kgf*cm, 29 ft.*lbf }

        Note


        • Make sure all the tools are connected in a straight line.

        • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

          Formula
          T' = T x L3 / (L1 + L2 + L3)
          - T' = Spec. value of torque wrench
          - T = Value of specified tightening torque
          - L1 = Length of union nut wrench
          - L2 = Length of SST
          - L3 = Length of torque wrench

    4. for rear differential:


      1. Install a new gasket and the differential filler plug.

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