Part 2

REAR DIFFERENTIAL CARRIER ASSEMBLY(continued)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REASSEMBLY

1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

HINT: Perform this procedure only when replacing the dust deflector.

(a) Using SST and a press, press a new dust deflector into the companion flange.
SST 09316-60011 (09316-00011)

NOTICE:
^ Slowly press a new dust deflector into the companion flange while observing the dust deflector. Do not press excessively.
^ If necessary, remove any burrs after inserting the new dust deflector.

2. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case and ring gear.
(b) Heat the ring gear in boiling water that is approximately 100°C (212°F).
(c) Carefully take the ring gear out of the boiling water.

(d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

HINT: Align the matchmarks on the ring gear and the differential case.

(e) Temporarily install 2 new ring gear set bolts so that the bolt holes in the ring gear and differential case are not misaligned.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.

3. INSTALL REAR DIFFERENTIAL CASE BOLT
(a) Clean the differential ring gear set bolt holes.
(b) Wait until the ring gear has cooled sufficiently.
(c) Apply thread lock to 8 new ring gear set bolts.
Seal Packing: Toyota Genuine thread lock 1360, Three Bond 1360 or equivalent

NOTICE: Always use new ring gear set bolts.

(d) Install the 8 ring gear set bolts to the ring gear.

(e) Torque the 10 set bolts uniformly and a little at a time.

NOTICE: Tighten the bolts in diametrically opposite pairs.
Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf)

(f) Tighten the bolts further by 60 to 90°.

4. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press in the 2 differential case bearings.
SST 09950-60010 (09951-00560), 09950-60020 (09951-00810), 09950-70010 (0995107100, 09951-07200)

NOTICE:
^ Align SST with the center of the differential case.
^ Replace the bearing outer race when bearing is replaced.
^ Be careful as the 2 bearings are different. The ring gear tooth side's bearing is part No. 90366-50087 and the other side's bearing is part No. 90366-50027.

5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press in the rear bearing.
SST 09502-24010

(b) Using SST and a press, press in the rear bearing outer race and adjusting washer.
SST 09255-10012, 09950-70010 (09951-07100)

HINT: Select a thrust shim of the same thickness as the removed one.

6. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, press in the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07200)
(b) Install the drive pinion in the differential carrier.

(c) Using SST and a press, press the front bearing into the drive pinion.
SST 09316-60011 (09316-00011), 09608-04031

HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern.

7. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST, install the companion flange onto the differential carrier.
SST
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)

NOTICE: Because the spacer is not installed, maintain a little looseness between the companion flange and the drive pinion when installing.

(b) Adjust the drive pinion preload by tightening the companion flange nut.

HINT: Tighten the nut using approximately 98 N*m (1,000 kgf*cm, 72 ft.*lbf) of force. Then tighten it further while observing the preload.

(1) Using SST to hold the flange, tighten the nut.
SST 09229-55010 (09955-03040), 09330-00021 (09330-00030)

Standard preload (at starting):

HINT:
^ Do not apply hypoid gear oil if a new bearing is used.
^ If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.

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

8. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Insert the differential case from the ring gear tooth side to install it.

NOTICE: Do not damage the case bearing and ring gear.

9. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a hammer, tap in the drive pinion side outer race.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: Tap in the outer race until half of the side gear shaft shaft snap ring groove of the differential carrier can be seen.

(b) Install SST to the differential carrier.
SST 09571-50010
(c) Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race).

(d) Using SST and a hammer, tap in the ring gear side outer race.
SST 09950-70010 (09951-07200), 09608-32010

HINT: Tap in the outer race until it touches the case bearing roller.

10. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING (for Ring gear side position)

HINT: This procedure is required only when the final gear set (drive pinion and ring gear) is replaced.

(a) Using snap ring pliers, install the thinnest side gear shaft shaft snap ring on the ring gear side.
(b) Install a dial indicator to the differential carrier.

(c) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).
SST 09571-50010

NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side gear shaft oil seal is tapped in.
^ Tighten the SST bolt to apply the preload to the case bearing.

(d) Turn the ring gear clockwise and counterclockwise several times.

(e) Using a dial indicator, measure the backlash of the ring gear.

HINT: Perform the measurements at 3 or more positions around the side bearing preload.

Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE: The difference between the maximum and minimum values must be within 0.05 mm (0.0020 in.).

HINT: Write the values for reference to select a side gear shaft shaft snap ring. If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

(f) Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion.

(g) Using SST and a hammer, create a clearance between the side gear shaft shaft snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)

(h) Using snap ring pliers, remove the snap ring on the ring gear side.
(i) Using snap ring pliers, install a snap ring with a different thickness.

HINT:
^ Side gear shaft shaft snap rings are available in 39 sizes, each with a 0.02 mm (0.0008 in.) thickness difference.
^ When the side gear shaft shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash changes by 0.02 mm (0.0008 in.).

Standard snap ring thickness:

(j) Using a plastic-faced hammer, lightly tap the drive pinion side of the differential carrier.

(k) Install a dial indicator onto the differential carrier.
(l) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).
SST 09571-50010

HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal is tapped in.

(m) Using a dial indicator, measure the ring gear backlash.
Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
If the backlash is not within the specified range, replace the side gear shaft shaft snap ring on the ring gear side with one of a different thickness.

11. ADJUST DIFFERENTIAL RING GEAR BACKLASH
(a) Install a dial indicator to the differential carrier.
(b) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).
SST 09571-50010

HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal is tapped in.

(c) Using snap ring pliers, install the thinnest side gear shaft shaft snap ring on the drive pinion side.
(d) Remove the dial indicator and loosen the bolt until the SST disc is separated from the outer race.

(e) Using a plastic-faced hammer, lightly tap the drive pinion side of the differential carrier.

(f) Check the backlash around the ring gear.
Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE: The difference between the maximum and minimum values must be within 0.05 mm (0.0020 in.).

If a value is not within the specified range, replace the snap ring with one of a different thickness (proceed to the next step).
(g) Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion.

(h) Using SST and a hammer, create a clearance between the side gear shaft shaft snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)

(i) Using snap ring pliers, remove the side gear shaft shaft snap ring on the ring gear side.
(j) Using snap ring pliers, install a side gear shaft shaft snap ring with different thickness.

HINT:
^ Side gear shaft shaft snap rings are available in 39 sizes, each with a 0.02 mm (0.0008 in.) thickness difference.
^ When the side gear shaft shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash changes by 0.02 mm (0.0008 in.).

Standard snap ring thickness (Part 1):

Standard snap ring thickness (Part 2):

(k) Using a plastic-faced hammer, lightly tap the drive pinion side of the differential carrier.

(l) Check the backlash around the ring gear.
Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE: The difference between the maximum and minimum values must be within 0.05 mm (0.0020 in.).

If a value is not within the specified range, replace it with one of a different thickness in the same procedure.

12. ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Standard total preload (at starting): Drive pinion preload plus 0.46 to 1.37 N*m (4.69 to 13.97 kgf*cm, 4.07 to 12.13 in.*lbf)
If the measured preload is less than the specification, replace the rear differential side gear shaft snap ring of the ring gear's tooth surface side with a thicker one.
If the preload is greater than the specification, replace the rear differential side gear shaft shaft snap ring of the ring gear's tooth surface side with a thinner one.

HINT: When the rear differential side gear shaft shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 0.9 in.*lbf).

(b) Set a dial indicator to the end of the differential ring gear face.
(c) While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
If the measured value is not as specified, adjust it by increasing or decreasing the thickness of the right and left side gear shaft shaft snap ring equally.

NOTICE: When the side gear shaft shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will change by approximately 0.02 mm (0.0008 in.).

(d) Recheck the total preload.
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with prussian blue.
(b) Hold the companion flange firmly and rotate the ring gear in both directions.
(c) Inspect the tooth contact pattern.

If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing.

NOTICE: Make sure to always replace the adjusting washer with a new one.

HINT: Refer to the adjusting washer table.

HINT: Rear differential drive pinion plate washers are available in 42 sizes, each with a 0.01 mm (0.0004 in.) thickness difference.

Standard drive pinion plate washers (Part 1):

Standard drive pinion plate washers (Part 2):

14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING (for Except ring gear side position)
(a) Install SST to the rear differential carrier.

(b) Install a dial indicator to the rear differential carrier.
(c) Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and snap ring. SST

NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.0008 in.).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal is tapped in.
^ Approximately 0.1 mm (0.0004 in.) clearance between the side bearing (outer race) and the snap ring is sufficient for the washer to move slightly.

(d) Using snap ring pliers, remove the snap ring on the drive pinion side.

HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.

(e) Remove the dial indicator and loosen the SST bolt.

NOTICE: Do not remove SST.