FRONT DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


    1. A01E17QE01

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

      SST
      09223-00010

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

      Tech Tips

      Install the snap ring securely.

  2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01E01C

      Install the shaft to the differential tube.

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

      Tech Tips

      Install the snap ring securely.

  3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH


    1. A01E118E01
      Text in Illustration
      *a for LH Side
      *b for RH Side
      *1 Differential
      *2 Seal

      Using SST and a hammer, tap in 2 new oil seals.

      SST
      09554-47010
      09950-70010   ( 09951-07100 )

      Note


      • Make sure the LH and RH oil seals are installed to the proper locations.

      • As a different side of SST is used for each oil seal, be sure to confirm that the correct side of SST is being used before tapping in an oil seal.

      • Make sure that the lip of the oil seal is inserted into SST before tapping in the oil seal.

      • As each side of SST is designed to tap in the corresponding oil seal to the proper depth, be sure to fully tap in the oil seal.

      • Do not damage the oil seals.

      Standard Oil Seal Depth
      Item Specified Condition
      for LH Side 2.9 +/-0.45 mm (0.114 +/-0.0177 in.)
      for RH Side 8.1 +/-0.45 mm (0.319 +/-0.0177 in.)

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

  4. INSTALL DIFFERENTIAL CLUTCH HUB


    1. A01DVIK

      Install the clutch hub to the side gear inter shaft.

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

      Tech Tips

      Install the snap ring securely.

      Note

      Make sure to install the differential clutch hub in the correct direction.

  5. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING


    1. A01E0W4E01

      Using SST and a press, press in 2 new bearings.

      SST
      09950-60010   ( 09951-00380 )
      Needle roller bearing depth
      1.7 +/-0.3 mm (0.0669 +/-0.0118 in.)

  6. ASSEMBLE DIFFERENTIAL CASE


    1. A01DX6F

      Install 2 thrust washers to the 2 side gears.

      Tech Tips

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

      Standard Thrust Washer Thickness
      Thickness mm (in.) Thickness mm (in.)
      1.48 to 1.52 (0.0583 to 0.0598) 1.73 to 1.77 (0.0681 to 0.0696)
      1.53 to 1.57 (0.0603 to 0.0618) 1.78 to 1.82 (0.0701 to 0.0716)
      1.58 to 1.62 (0.0622 to 0.0637) 1.83 to 1.87 (0.0720 to 0.0736)
      1.63 to 1.67 (0.0642 to 0.0657) 1.88 to 1.92 (0.0740 to 0.0755)
      1.68 to 1.72 (0.0662 to 0.0677) -
    2. A01E0UI

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

      Tech Tips

      Align the holes of the differential case and pinion shaft.

    3. A01DYNA

      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
        0.15 mm (0.00591 in.) or less

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

    4. A01E2BY

      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.

  7. INSTALL DIFFERENTIAL RING GEAR


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

    2. Heat the ring gear in boiling 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. A01DVNWE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the ring gear and differential case.

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

      Thread lock
      Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
      Torque:
      97 N*m  { 984 kgf*cm, 71 ft.*lbf }

  8. INSTALL FRONT DIFFERENTIAL CASE BEARING


    1. A01DW2VE01

      Using SST and a press, press the bearing onto the differential case.

      SST
      09950-60010   ( 09951-00520, 09951-00610 )
      09950-70010   ( 09951-07150 )

  9. INSTALL FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

    When replacing the 2 differential case bearings, install the thinnest washer to each bearing. When reusing the bearings, install a new washer of the same thickness as the one that was removed to each bearing.


    1. A01DX8AE01

      Using SST and a press, press in the case bearing (outer) to the differential side bearing retainer.

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07150 )
    2. A01DVB1E01

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

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07150 )

  10. INSTALL BEARING OUTER RACE


    1. A01E2Q0E01
      Text in Illustration
      *a for Front
      *b for Rear
      *c Turn
      *d Hold

      Using SST, install the outer race front.

      SST
      09950-60020   ( 09951-00720, 09951-00890 )

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

    3. Using SST, install the outer race rear.

      SST
      09950-60020   ( 09951-00720, 09951-00890 )

  11. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. Install the washer to the drive pinion.

      Tech Tips

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

    2. A01E0DDE01

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

      SST
      09506-30012

  12. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01E2PU

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

      Tech Tips

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

    2. A01DZADE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange.

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

      Using SST to hold the flange in place, tighten the nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      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 drive pinion thread and nut seat face.

    5. A01DWNB

      Using a torque wrench, measure the preload.

      Standard Preload (Starting Torque)
      Item Specified Condition
      New bearing 0.7 to 1.2 N*m (8 to 12 kgf*cm, 7 to 10 in.*lbf)
      Reused bearing 0.2 to 0.4 N*m (2 to 4 kgf*cm, 2 to 3 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.

  13. INSTALL DIFFERENTIAL CASE ASSEMBLY

  14. ADJUST DIFFERENTIAL RING GEAR BACKLASH


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

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }
    2. A01DUZOE01

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

      SST
      09564-33010
      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.

        Tech Tips

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

        Standard Washer Thickness
        Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
        1.57 to 1.59 (0.0618 to 0.0625) 1.79 to 1.81 (0.0705 to 0.0712) 2.01 to 2.03 (0.0792 to 0.0799)
        1.59 to 1.61 (0.0626 to 0.0633) 1.81 to 1.83 (0.0713 to 0.0720) 2.03 to 2.05 (0.0800 to 0.0807)
        1.61 to 1.63 (0.0634 to 0.0641) 1.83 to 1.85 (0.0720 to 0.0728) 2.05 to 2.07 (0.0808 to 0.0814)
        1.63 to 1.65 (0.0642 to 0.0649) 1.85 to 1.87 (0.0729 to 0.0736) 2.07 to 2.09 (0.0815 to 0.0822)
        1.65 to 1.67 (0.0650 to 0.0657) 1.87 to 1.89 (0.0737 to 0.0744) 2.09 to 2.11 (0.0823 to 0.0830)
        1.67 to 1.69 (0.0658 to 0.0665) 1.89 to 1.91 (0.0744 to 0.0751) 2.11 to 2.13 (0.0831 to 0.0838)
        1.69 to 1.71 (0.0666 to 0.0673) 1.91 to 1.93 (0.0752 to 0.0759) 2.13 to 2.15 (0.0839 to 0.0846)
        1.71 to 1.73 (0.0674 to 0.0681) 1.93 to 1.95 (0.0760 to 0.0767) 2.15 to 2.17 (0.0847 to 0.0854)
        1.73 to 1.75 (0.0682 to 0.0688) 1.95 to 1.97 (0.0768 to 0.0775) -
        1.75 to 1.77 (0.0689 to 0.0696) 1.97 to 1.99 (0.0776 to 0.0783) -
        1.77 to 1.79 (0.0697 to 0.0704) 1.99 to 2.01 (0.0784 to 0.0791) -

  15. INSPECT TOTAL PRELOAD


    1. A01DWNB

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

      Standard total preload (starting torque)
      0.3 to 0.8 N*m (4 to 8 kgf*cm, 3 to 7 in.*lbf) + drive pinion preload

      Note

      Record the differential ring gear preload.

  16. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


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

    2. A01DY32

      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.

      Torque:
      50 N*m  { 510 kgf*cm, 37 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.

      A01DWGCE01
    7. A01DY8NE01
      Text in Illustration
      *1 Drive Pinion Water

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

      Standard Washer Thickness
      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      1.69 to 1.71 (0.0666 to 0.0673) 1.93 to 1.95 (0.0760 to 0.0767) 2.17 to 2.19 (0.0855 to 0.0862)
      1.72 to 1.74 (0.0678 to 0.0685) 1.96 to 1.98 (0.0772 to 0.0779) 2.20 to 2.22 (0.0867 to 0.0874)
      1.75 to 1.77 (0.0689 to 0.0696) 1.99 to 2.01 (0.0784 to 0.0791) 2.23 to 2.25 (0.0878 to 0.0885)
      1.78 to 1.80 (0.0701 to 0.0708) 2.02 to 2.04 (0.0796 to 0.0803) 2.26 to 2.28 (0.0890 to 0.0897)
      1.81 to 1.83 (0.0713 to 0.0720) 2.05 to 2.07 (0.0807 to 0.0814) 2.29 to 2.31 (0.0902 to 0.0909)
      1.84 to 1.86 (0.0725 to 0.0732) 2.08 to 2.10 (0.0819 to 0.0826) 2.32 to 2.34 (0.0914 to 0.0921)
      1.87 to 1.89 (0.0737 to 0.0744) 2.11 to 2.13 (0.0831 to 0.0838) -
      1.90 to 1.92 (0.0748 to 0.0755) 2.14 to 2.16 (0.0843 to 0.0850) -

  17. REMOVE FRONT DRIVE PINION COMPANION FLANGE 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, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

  18. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR


    1. A01E2D1E01

      Using SST, remove the companion flange with dust deflector.

      SST
      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.

  19. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Remove the oil slinger from the drive pinion.

  20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01DVWEE01

      Using SST, remove the roller bearing (inner) from the drive pinion.

      SST
      09556-22010

  21. REMOVE DIFFERENTIAL DRIVE PINION

  22. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DVN3

      Install a new bearing spacer to the drive pinion.

  23. INSTALL DIFFERENTIAL DRIVE PINION

  24. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01E0HQ

      Install the roller bearing to the drive pinion.

  25. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Install the oil slinger to the drive pinion.

  26. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

    2. A01E0NVE01
      Text in Illustration
      *a Oil Seal Depth

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

      SST
      09554-22010
      Oil seal depth
      4.35 +/-0.45 mm (0.171 +/-0.0177 in.)

  27. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR


    1. A01DZSUE01

      Using SST, install the companion flange with dust deflector.

      SST
      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.

    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, install a new nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3773 kgf*cm, 27 ft.*lbf, or less }

  28. INSTALL DIFFERENTIAL SIDE BEARING RETAINER


    1. Remove any old seal packing material from the side bearing retainer.

      Note

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

    2. Clean residual seal packing material on the contact surface using gasoline or alcohol.

    3. A01DXQJE01
      Text in Illustration
      *1 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

      Tech Tips

      Install the side bearing retainer within 3 minutes after applying seal packing.

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

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  29. INSPECT TOTAL PRELOAD


    1. A01DWNB

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

      Standard Preload (Starting Torque)
      Item Specified Condition
      New bearing 1.0 to 1.5 N*m (11 to 15 kgf*cm, 9 to 13 in.*lbf) + ring gear preload
      Reused bearing 0.5 to 0.7 N*m (6 to 7 kgf*cm, 5 to 6 in.*lbf) + ring gear preload

      • If necessary, disassemble and inspect the differential.

  30. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. A01DUZOE01

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

      SST
      09564-32011
      Standard backlash
      0.11 to 0.21 mm (0.00433 to 0.00826 in.)

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

  31. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01E280E01
      Text in Illustration
      *a 30 mm (1.18 in.)

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

      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.

  32. STAKE FRONT DRIVE PINION COMPANION FLANGE NUT


    1. A01DW40

      Using a chisel and hammer, stake the nut.

  33. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH


    1. A01E118E01
      Text in Illustration
      *a for LH Side
      *b for RH Side
      *1 Differential
      *2 Seal

      Using SST and a hammer, tap in 2 new oil seals.

      SST
      09554-47010
      09950-70010   ( 09951-07100 )

      Note


      • Make sure the LH and RH oil seals are installed to the proper locations.

      • As a different side of SST is used for each oil seal, be sure to confirm that the correct side of SST is being used before tapping in an oil seal.

      • Make sure that the lip of the oil seal is inserted into SST before tapping in the oil seal.

      • As each side of SST is designed to tap in the corresponding oil seal to the proper depth, be sure to fully tap in the oil seal.

      • Do not damage the oil seals.

      Standard Oil Seal Depth
      Item Specified Condition
      for LH Side 2.9 +/-0.45 mm (0.114 +/-0.0177 in.)
      for RH Side 8.1 +/-0.45 mm (0.319 +/-0.0177 in.)

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

  34. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR


    1. A01DV80

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

      Note

      Make sure to install the side bearing retainer deflector in the correct direction.

  35. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY


    1. Install a new snap ring to the side gear inter shaft.

    2. A01DW6R

      Using a plastic-faced hammer, tap the side gear inter shaft into the differential case.

    3. Check that there is 2 to 3 mm (0.0788 to 0.118 in.) of axial play.

    4. Check that the side gear inter shaft cannot be completely pulled out by hand.

  36. INSTALL DIFFERENTIAL CLUTCH SLEEVE


    1. Install the differential clutch sleeve.

  37. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY


    1. Remove any old seal packing material on 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. Clean residual seal packing material on the contact surface using gasoline or alcohol.

    3. A01DVW3E01
      Text in Illustration
      *1 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

      Tech Tips

      Install the differential tube within 3 minutes after applying seal packing.

    4. Install the differential tube to the differential.

    5. A01DZAO

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

    6. Install the 4 bolts.

      Torque:
      110 N*m  { 1122 kgf*cm, 81 ft.*lbf }

  38. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY


    1. A01DYXW

      Remove any seal packing material from the contact surface of the differential and clutch case. Also, do not drop oil on the contact surfaces.

    2. Clean residual seal packing material from the contact surfaces using gasoline or alcohol.

    3. Apply seal packing to the differential tube as shown.

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

      Tech Tips

      Install the actuator within 3 minutes after applying seal packing.

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

    5. Install the actuator to the differential tube.

    6. A01DWLU

      Install the 4 bolts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }