Reassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD): REASSEMBLY

REASSEMBLY

1. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the differential ring gear set bolt hole.

(b) Heat the ring gear to approximately 100°C (212°F) in boiling water.
CAUTION:
Use thick gloves to protect your hands as the ring gear is hot.

(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, differential case bolt holes and ring gear screw holes.

(e) Hold the differential case in a vise between aluminum plates.
NOTE:
Do not overtighten the vise.

(f) Apply adhesive to the threads and flanges of 10 new ring gear set bolts.
Torque: 97 Nm (989 kgf-cm, 72 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
- Tighten the bolts after the ring gear has sufficiently cooled down.
- Install the differential case bolts by tightening diametrically opposite pairs uniformly in several passes.

2. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE

(a) Using SST, a bolt, nut, and washer, install the bearing outer race to the differential carrier.
SST: 09950-60020
09951-00730
09951-00810
NOTE:
Do not apply hypoid gear oil to a new bearing.
HINT: If there are not enough threads, add another SST accordingly.

3. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Install the adjust shim to the differential carrier.
HINT: Select a adjusting shim of the same thickness as the one removed.

(b) Using SST, a bolt, nut, and washer, install the bearing outer race to the differential carrier.
SST: 09950-60020
09951-00730
09951-00810
NOTE:
Do not apply hypoid gear oil to a new bearing.

4. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE

(a) Using SST and a press, press in the front drive pinion front tapered roller bearing inner race to the drive pinion.
SST: 09309-14020
NOTE:
Do not apply hypoid gear oil to a new bearing.

5. INSTALL FRONT DIFFERENTIAL CASE BEARING OUTER RACE LH
(a) Remove the differential carrier from the overhaul attachment.
(b) Install the differential case washer to the differential carrier.
HINT:
- If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential case washer first.
- If the drive pinion, ring gear or differential case are reused, select and install a differential case washer with the same thickness as the one before the disassembly first.

(c) Using SST and a press, press in the case bearing outer race to the differential carrier.
SST: 09950-60020
09951-00680
09951-00790
09952-06010
SST: 09950-70010
09951-07100
NOTE:
Do not apply hypoid gear oil to a new bearing.

6. INSTALL FRONT DIFFERENTIAL CASE BEARING OUTER RACE RH
(a) Install the differential case washer to the differential carrier retainer.
HINT:
- If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential case washer first.
- If the drive pinion, ring gear or differential case are reused, select and install a differential case washer with the same thickness as the one before the disassembly first.

(b) Using SST and a press, press in the case bearing outer race to the differential carrier retainer.
SST: 09950-60020
09951-00790
09951-00890
09952-06010
SST: 09950-70010
09951-07100
NOTE:
Do not apply hypoid gear oil to a new bearing.

7. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR

(a) Using SST and a press, insert a new dust deflector into the companion flange.
SST: 09612-30012
SST: 09950-70010
09951-07100
- Slowly press in the dust deflector but not excessively.
- If any burrs remain after pressing in the deflector, remove them.

8. ADJUST DRIVE PINION PRELOAD
(a) Fix the differential carrier with an attachment.

(b) Install the drive pinion to the differential carrier, and then install the bearing inner race and oil slinger while supporting the drive pinion by hand.
- Do not apply hypoid gear oil to a new bearing.
- Do not drop the drive pinion.
HINT: Install the spacer and oil seal after performing the ring gear tooth contact pattern inspection adjustment.

(c) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
- As a bearing spacer is not installed, if SST is tightened excessively, SST, the companion flange, and drive pinion will be damaged.
- Support the drive pinion by hand until SST is installed.
- Be careful not to drop the drive pinion.
- Before using SST center bolt, apply hypoid gear oil to its threads and tip.
- Install the companion flange so that there is some free play in the drive pinion.

(d) Remove SST.

(e) Using SST and a torque wrench, tighten the flange nut little by little until it reaches the specified preload.
SST: 09213-58013
SST: 09330-00021
SST: 09229-55010
Maximum torque:
490 N*m (4997 kgf*cm, 361 ft.*lbf)
- Tighten the nut with a force of 100 N*m (1020 kgf*cm. 74 in.*lbf) while checking the starting torque of the drive pinion.
- As the bearing spacer is not installed, tighten the flange nut little by little. Do not overtighten the nut.
- Do not overtighten the nut, as the threads will become damaged.
- Coat the threads the flange nut and drive pinion with hypoid gear oil LSD.
- Perform the installment while supporting the overhaul attachment.

(f) Using SST and a torque wrench, measure the preload.
SST: 09229-55010
Drive Pinion Preload (at starting):

NOTE:
For a more accurate measurement, rotate the bearing forward and backward before the inspection.
HINT: Record the preload for total preload measurement.

9. INSTALL DIFFERENTIAL CASE
(a) Remove the differential carrier from the overhaul attachment.

(b) Install the differential case to the differential carrier.
NOTE:
Do not damage the case bearing and ring gear.

10. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Install the retainer to the differential carrier with the 11 bolts.
Torque: 58 Nm (591 kgf-cm, 43 ft-lbf)

(b) Install the differential carrier to the overhaul attachment.

(c) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.

(d) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
SST: 09564-50010
Standard backlash:
0.13 to 0.23 mm (0.00512 to 0.00905 in.)
- Measure at 3 or more areas around the circumference of the ring gear.
- Record the measured value, as it is used to select the differential case washer.
- If the result is outside of the standard range, replace the washer with one of a different thickness in accordance with the following procedure.
- Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.

(e) Select a washer from the table until the backlash measured value is in the standard range.
Washer Thickness (LH):

Washer Thickness (RH):

HINT:
- Make sure to increase the thickness of the LH and RH differential case washer by the same amount each time until the backlash is in the standard range.
- Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.
- When adjusting the backlash, adjust to within 0.18 mm (0.00709 in.) of the average of the measurements.

11. INSPECT AND 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
Total Preload (at starting):

- When the value is outside the standard range, adjust using the differential case washer on the ring gear tooth side.
- When the value is less than the lower limit of the standard range, replace the differential case washer with a thicker one.
- When the value is more than the upper limit of the standard range, replace the differential case washer with a thinner one.
- For reassembly purposes, record the measured value.

(b) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.

(c) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
SST: 09564-50010
Standard backlash:
0.13 to 0.23 mm (0.00512 to 0.00905 in.)
- Measure at 3 or more areas around the circumference of the ring gear.
- If the backlash is not in the standard range, increase the LH and RH differential case washer by the same amount until the backlash is in the standard range.
- Record the measured value and use it when selecting the differential case washer.
- Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.
- When adjusting the backlash, adjust to within 0.18 mm (0.00709 in.) of the average of the measurements.

(d) Recheck the total preload.
12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Remove the differential carrier from the overhaul attachment.

(b) Remove the 11 bolts and retainer from the differential carrier.

(d) Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

(e) Install the differential case to the differential carrier.
NOTE:
Do not damage the case bearing and ring gear.

(f) Install the retainer to the differential carrier with the 11 bolts.
Torque: 58 Nm (591 kgf-cm, 43 ft-lbf)

(g) Rotate the companion flange several times in the forward and backward rotation directions.

(h) Remove the 11 bolts and retainer from the differential carrier.

(i) Remove the differential case from the differential carrier.
NOTE:
Do not damage the case bearing and ring gear.

(j) Inspect the tooth contact pattern.

HINT: The patterns indicated by the Prussian blue are the tooth contact locations.
NOTE:
Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.

(k) If the tooth contact is not proper, select a drive pinion spacer adjust shim from the table and perform the tooth contact pattern inspection again.
- It is possible for the backlash to be adjusted within the standard range in instances of face contact and flank contact.
- If the thickness of the drive pinion spacer adjust shim changes, perform the backlash adjustment and inspect the total preload.

Adjust Shim Thickness:

13. REMOVE DIFFERENTIAL CASE

(a) Remove the 11 bolts and retainer from the differential carrier.

(b) Remove the differential case from the differential carrier.
NOTE:
Do not damage the case bearing and ring gear.

14. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
(a) Install the differential carrier to the overhaul attachment

(b) Using SST to hold the flange, remove the flange nut.
SST: 09213-58013
SST: 09330-00021
SST: 09229-55010
NOTE:
Perform the removal while supporting the overhaul attachment.

15. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY

(a) Using SST, remove the companion flange from the differential carrier.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
HINT: Before using SST center bolt, apply hypoid gear oil to its threads and tip.

16. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the oil slinger from the differential carrier.
17. REMOVE DIFFERENTIAL DRIVE PINION

(a) Remove the differential carrier together with the overhaul attachment from the engine stand.

(b) Set the differential carrier to an overhaul stand, etc., as shown in the illustration.

(c) Using a press, press out the drive pinion and bearing inner race.
NOTE:
Do not drop the drive pinion and bearing inner race.

(d) Install the differential carrier to the overhaul attachment as it was installed previously.
(e) Install the differential carrier together with overhaul attachment to the engine stand.
18. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new drive pinion bearing spacer to the drive pinion.
19. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE

(a) Using SST and the companion flange, press the bearing inner race into the differential carrier.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
- As the drive pinion is supported by hand until SST is installed, be careful not to drop the drive pinion.
- Apply grease to the threads and tip of SST center bolt before use.

(b) Using SST, remove the companion flange from the differential carrier.
HINT: Before using SST center bolt, apply hypoid gear oil to its threads and tip.

20. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Install the oil slinger to the differential carrier.
21. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal.
SST: 09309-36010
SST: 09502-24010
Standard depth:
6.2 to 7.2 mm (0.244 to 0.283 in.)
- Using a vernier caliper, measure the depth of the oil seal.
- Measure at 3 or more areas around the circumference of the oil seal.
- Make sure the difference between the maximum and minimum measured values is less than 0.75 mm (0.0295 in.), as a greater difference may lead to oil leaks.
- Tap the oil seal uniformly so that the oil seal is straight.
- Do not excessively tap the oil seal.
HINT: First, uniformly tap in the oil seal until it is flush with the edge of the carrier, then tap it little by little until the depth is within the standard range.

(b) Apply MP grease to the lip of the oil seal.
22. INSTALL FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Install the oil deflector to the differential carrier with the 2 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
23. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY

(a) Using SST, install the companion flange to the drive pinion.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTE:
Do not insert the companion flange excessively as the preload will be adjusted in the following procedure.
HINT: Before using SST center bolt, apply hypoid gear oil to its threads and tip.

24. INSPECT DRIVE PINION PRELOAD
(a) Coat the threads of a new drive pinion companion flange front nut with hypoid gear oil LSD.

(b) Using SST and a torque wrench, tighten the drive pinion companion flange front nut while checking the preload.
SST: 09213-58013
SST: 09330-00021
SST: 09229-55010
Maximum torque:
490 N*m (4996 kgf*cm, 361 ft.*lbf)
- Tighten the flange nut little by little to reach the specified preload, being careful not to exceed the maximum torque.
- Do not overtighten the nut, as the threads will become damaged.
- Measure the preload after rotating the companion flange several times in the forward and backward directions to make sure the bearing is operating correctly.
- Perform the installation while supporting the overhaul attachment.

(c) Using SST and a torque wrench, measure the drive pinion preload.
SST: 09229-55010
HINT: Record the drive pinion preload for the total preload inspection.

Drive Pinion Preload (at starting):

NOTE:
The bearing spacer is made of plastic and changes shape when used. If the starting torque of the drive pinion is exceeded by mistake, make sure to replace the bearing spacer with a new one.
- If the preload is insufficient, tighten the nut 5 to 10° at a time until the preload is in the standard range.
- If the tightening torque of the flange nut exceeds the specified torque but the preload is still insufficient, loosen the flange nut. Then check if the flange nut and drive pinion threads are damaged.
- If there are no problems, replace the bearing spacer, apply hypoid gear oil LSD to the threads of the drive pinion companion flange front nut and repeat the procedure above.

25. INSTALL NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Remove the differential carrier from the overhaul attachment.

(b) Install the differential case to the differential carrier.
NOTE:
Do not damage the case bearing and ring gear.

26. INSTALL FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY
(a) Remove the seal packing attached on the differential carrier and side bearing retainer using a scraper and wire brush.
NOTE:
Do not scratch the fitting surface.

(b) Check that there is no foreign matter or damage on the installation surface of the side bearing retainer.

(c) Apply seal packing to the differential carrier as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent
- Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
- Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.
- Install the differential carrier cover within 3 minutes of application.

(d) Install the retainer with the 11 bolts.
Torque: 58 Nm (591 kgf-cm, 43 ft-lbf)
NOTE:
Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.

(e) Set the differential carrier to an overhaul stand as shown in the illustration.
27. INSTALL FRONT DIFFERENTIAL BREATHER PLUG

(a) Install the breather plug to the differential carrier.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
28. INSPECT 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
Total Preload (at starting):

29. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.

(b) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
SST: 09564-50010
Standard backlash:
0.13 to 0.23 mm (0.00512 to 0.00905 in.)
HINT: Measure at 3 or more areas around the circumference of the ring gear.

30. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY

(a) Wipe the inside surface of the companion flange with a cloth or equivalent and remove dirt and foreign matter.
(b) Perform the vertical runout inspection.
(1) Set a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the companion flange.
(2) Measure the vertical runout of the companion flange.
Maximum runout:
0.12 mm (0.00472 in.)
(c) Perform the lateral runout inspection.
(1) Set a dial indicator at a right angle to the surface of the companion flange as shown in the illustration.
(2) Measure the horizontal runout of the companion flange.
Maximum runout:
0.08 mm (0.00314 in.)
31. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

(a) Using SST and a hammer, stake the flange nut.
SST: 09930-00010
32. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL

(a) LH:
(1) Using SST and a hammer, install a new oil seal LH.
SST: 09950-60010
09951-00570
SST: 09950-70010
09951-07100
Standard depth:
-0.5 to 0.5 mm (-0.0197 to 0.0196 in.)
NOTICE:
- Tap the oil seal uniformly so that the oil seal is straight.
- Do not excessively tap the oil seal.
- Make sure the difference between the maximum and minimum measured values is less than 0.57 mm (0.0224 in.), as a greater difference may lead to oil leaks.
(2) Apply MP grease to the lips of the oil seal.

(b) RH:
(1) Using SST and a hammer, install a new oil seal RH.
SST: 09608-32010
SST: 09950-70010
09951-07100
Standard depth:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)
NOTICE:
- Tap the oil seal uniformly so that the oil seal is straight.
- Do not excessively tap the oil seal.
- Make sure the difference between the maximum and minimum measured values is less than 0.47 mm (0.0185 in.), as a greater difference may lead to oil leaks.
(2) Apply MP grease to the lips of the oil seal.
33. INSTALL FRONT DIFFERENTIAL FILLER PLUG
HINT: Perform this procedure as necessary.

(a) Using a 10 mm socket hexagon wrench, install a new gasket and filler plug to the differential carrier.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
34. INSTALL FRONT DIFFERENTIAL DRAIN PLUG
HINT: Perform this procedure as necessary.

(a) Using a 10 mm socket hexagon wrench, install a new gasket and drain plug to the differential carrier.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
35. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY FROM OVERHAUL STAND

(a) Remove the differential carrier from the overhaul attachment stand's.