Part 1

AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

HINT
Use an overhaul stand as necessary.

1. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and differential ring gear.

(b) Heat the differential ring gear in boiling water.

Text in Illustration

(c) Carefully remove the differential ring gear from the boiling water.

CAUTION:
Do not burn yourself.

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

NOTICE:
Do not overtighten the vise.

(e) After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the rear differential case sub-assembly.

(f) Align the matchmarks on the rear differential case sub-assembly and differential ring gear, and install the differential ring gear.

Text in Illustration

(g) Temporarily install 12 new rear differential case bolts to which thread lock has been applied.

Adhesive:

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

(h) After the ring gear has cooled sufficiently, tighten the 12 new rear differential case bolts.

Torque : 99 Nm (1005 kgf-cm, 73 ft-lbf)

NOTICE:
* New rear differential case bolts should be used every time the ring gear is installed.
* Install the new rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.
* Tighten the rear differential case bolts after the differential ring gear has cooled down sufficiently.
* Do not allow any oil to contact the rear differential case bolt, differential ring gear threads or differential case seating surface.

2. INSTALL REAR DIFFERENTIAL CASE BEARING (for LH Side)

HINT
Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.

(a) Using SST and a press, install a new rear differential case bearing (LH side inner race) to the rear differential case sub-assembly.

SST : 09223-46011

NOTICE:
Replace the inner and outer races as a set.

3. INSTALL REAR DIFFERENTIAL CASE BEARING (for RH Side)

HINT
Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.

(a) Using SST and a press, install the rear differential case bearing (RH side inner race) to the rear differential case sub-assembly.

SST : 09223-46011

NOTICE:
Replace the inner and outer races as a set.

4. INSTALL STRAIGHT PIN

(a) Using a plastic hammer, install the 4 straight pins to the rear differential carrier.

Protrusion (A):

8 to 9 mm (0.315 to 0.354 in.)

(b) Thoroughly remove oil and water from the surface of the rear differential carrier that will face the differential ring gear.

5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST, bolt, nuts and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier.

Text in Illustration

SST : 09950-60010

09951-00500

09951-00530

SST : 09950-60020

09951-00680

09951-00890

HINT
Use M12 x P1.5 bolts with shaft lengths of 124 mm and M12 x P1.5 nuts for installation.

6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

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

Text in Illustration

SST : 09950-60010

09951-00610

SST : 09950-70010

09951-07150

7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Install the rear differential drive pinion plate washer to the differential drive pinion.

NOTICE:
Install each rear differential drive pinion plate washer to the position it was removed from.

(b) Using SST and a press, install the rear drive pinion rear tapered roller bearing (inner race) to the differential drive pinion.

SST : 09506-30012

8. INSTALL REAR DIFFERENTIAL CASE BEARING (for LH Side)

HINT
Replace the rear differential case bearing (LH side outer race) when removing the rear differential case bearing (LH side inner race) from the rear differential case sub-assembly.

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

Text in Illustration

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07150

NOTICE:
* Install each rear differential side gear shaft plate washer to the position it was removed from.
* Replace the inner and outer races as a set.
* Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

9. INSTALL REAR DIFFERENTIAL CASE BEARING (for RH Side)

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

Text in Illustration

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07150

NOTICE:
* Install each rear differential side gear shaft plate washer to the position it was removed from.
* Replace the inner and outer races as a set.
* Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

10. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Install the differential drive pinion with rear drive pinion rear tapered roller bearing (inner race) to the rear differential carrier.

(b) Apply hypoid gear oil LSD to the threads of a new rear drive pinion nut and its seating surface.

(c) Install the rear drive pinion front tapered roller bearing (inner race) and rear drive pinion nut to the differential drive pinion.

NOTICE:
New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.

(d) Using SST, gradually tighten the rear drive pinion nut until the specified preload is reached. Do not exceed the torque limit shown below.

SST : 09556-16011

SST : 09564-16020

without SST - Torque : 321 Nm (3273 kgf-cm, 237 ft-lbf) or less

with SST - Torque : 301 Nm (3069 kgf-cm, 222 ft-lbf) or less

NOTICE:
Tighten the rear drive pinion nut gradually. Never tighten it excessively.

HINT
Use a torque wrench with a fulcrum length of 750 mm (2.46 ft.).

(e) Using SST and a torque wrench, measure the preload (starting torque) of the differential drive pinion.

SST : 09556-16011

Standard Drive Pinion Preload (Starting Torque)

HINT
For a more accurate measurement, rotate the bearing forward and backward before inspection.

11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY

(a) Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.

NOTICE:
* Do not damage the installation surface.
* Be sure to completely remove all seal packing from the rear differential carrier assembly and differential side bearing retainer.
* Do not allow the removed seal packing to enter the rear differential carrier.

(b) Install the rear differential case assembly to the rear differential carrier.

Torque : 42 Nm (430 kgf-cm, 31 ft-lbf)

12. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole and set it perpendicular to a differential ring gear tooth surface tip.

(b) Using SST, hold the differential drive pinion in place.

SST : 09556-16011

(c) 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.)

HINT
Measure at 3 or more areas on the circumference of the ring gear.

(d) If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

HINT
* When the backlash is smaller than the specified value, select a thick rear differential side gear shaft plate washer for the RH side and thin rear differential side gear shaft plate washer for the LH side.
* When the backlash is larger than the specified value, select a thin rear differential side gear shaft plate washer for the RH side and thick rear differential side gear shaft plate washer for the LH side.

Rear Differential Side Gear Shaft Plate Washer

13. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Remove the 10 bolts and the differential side bearing retainer.

(b) Remove the rear differential case assembly from the rear differential carrier.

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

(d) Install the rear differential case assembly to the rear differential carrier.

(e) Install the differential side bearing retainer with the 10 bolts.

Torque : 42 Nm (430 kgf-cm, 31 ft-lbf)

(f) Turn the differential drive pinion at last 10 times.

(g) Remove the 10 bolts and the differential side bearing retainer.

(h) Remove the rear differential case assembly from the rear differential carrier.

(i) Inspect the tooth contact pattern.

HINT
Check the tooth contact pattern at 2 or more positions on the circumference of the differential ring gear.

(j) Perform the following procedure for face or flank contact:

(1) If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).

(2) Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

HINT
If the tooth contact pattern is not correct, reselect rear differential side gear shaft plate washers and reinspect the tooth contact pattern.

(3) Repeat the differential ring gear and differential drive pinion backlash inspection.

HINT
If the differential ring gear and differential drive pinion backlash are not as specified, reselect rear differential drive pinion plate washer and then readjust the differential drive pinion preload, differential ring gear and differential drive pinion backlash and reinspect tooth contact pattern.

(k) Perform the following procedure for heel or toe contact:

(1) Select a rear differential drive pinion plate washer again and install the rear drive pinion rear tapered roller bearing (inner race).

Text in Illustration

Rear Differential Drive Pinion Plate Washer

(l) Readjust the differential drive pinion preload, differential ring gear and differential drive pinion backlash and reinspect tooth contact pattern.

14. MEASURE TOTAL PRELOAD

(a) Using SST and a torque wrench, measure 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 (Starting Torque)

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

(b) If the results are not within the specification, perform the procedure below:

(1) Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

(2) Repeat the total preload measurement.

(3) Repeat the differential ring gear backlash inspection.

(4) Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

15. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

(a) Remove the 10 bolts and differential side bearing retainer.

16. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY

(a) Remove the rear differential case assembly from the rear differential carrier.

17. REMOVE DIFFERENTIAL DRIVE PINION

(a) Remove the rear differential drive pinion from the rear differential carrier.

18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new rear differential drive pinion bearing spacer to the differential drive pinion.

HINT
Face the smaller inside diameter towards the front of the vehicle.

19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Install the rear differential drive pinion oil slinger to the differential drive pinion.