Reassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REASSEMBLY

1. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Install the following parts to the differential case.

HINT
* Differential pinion gear [A]
* Differential pinion thrust washer [B]
* Differential pinion shaft [C]
* Differential side gear [D]
* Differential side gear thrust washer [E]

NOTICE:
* Make sure that there is no dirt or foreign matter on the thrust washer, side gear, etc. before installing them.
* If replacing either the side gears or pinion gears, replace them as a set.
* Apply gear oil API GL-5 to all sliding and rotating parts.

(b) Install the 2 side gears and 2 side gear thrust washers to the differential case.

(d) Insert the differential pinion shaft into the differential case.

HINT
Align the holes of the differential case and differential pinion shaft.

2. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Front Differential Carrier Assembly

3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

(a) Using a pin punch (3 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.

(b) Using a chisel and a hammer, stake the outside of the differential case pin hole.

4. INSTALL DIFFERENTIAL RING GEAR

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

(b) Hold the differential case in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(c) Heat the ring gear to approximately 100°C (212°F) in boiling water.

CAUTION:
Use thick gloves to protect hands as the ring gear is hot.

(d) Carefully take the ring gear out of the boiling water.

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

(f) Align the matchmarks on the ring gear and differential case.

(g) Temporarily install 4 new lock plates and the 8 bolts.

(h) After the ring gear cools down, tighten the 8 bolts.

Torque : 97 Nm (985 kgf-cm, 71 ft-lbf)

(i) Using a chisel and a hammer, stake the 4 lock plates.

(1) Stake one claw so that it is flush against the flat surface of the bolt.

(2) Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.

5. INSTALL FRONT DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the case bearing inner races LH and RH to the differential case.

SST : 09950-60010

09951-00510

SST : 09636-20010

NOTICE:
* Do not apply hypoid gear oil to a new bearing.
* Do not deform the bearing cage.
* Place the SST carefully on the inner race of the bearings or on the center of the differential case (as applicable).
* If the bearing is replaced, replace it and the bearing outer race as a set.

6. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST, the bolt, nut (M12 X P1.25) and washer, install the outer race of the rear tapered roller bearing.

SST : 09950-60020

09951-00710

09951-00720

NOTICE:
Do not apply hypoid gear oil to a new bearing.

HINT
* Bolt: M12 X P1.25, bolt length: 186 mm (7.3 in.)
* Nut: M12 X P1.25

7. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Install the front adjust shim to the differential carrier.

(b) Using SST, the bolt, nut (M12 X P1.25) and washer, install the outer race of the front tapered roller bearing.

SST : 09950-60010

09951-00640

SST : 09950-60020

09951-00810

NOTICE:
Do not apply hypoid gear oil to a new bearing.

HINT
* Bolt: M12 X P1.25, bolt length: 186 mm (7.3 in.)
* Nut: M12 X P1.25

(c) Using SST and a press, install the inner race of the front drive pinion front tapered roller bearing to the drive pinion.

SST : 09506-30012

NOTICE:
Do not apply hypoid gear oil to a new bearing.

8. INSTALL FRONT DIFFERENTIAL CASE BEARING

(a) Install the case plate washer to the differential carrier.

HINT
* If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft plate washer and install it.
* If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft plate washer with the same thickness as the removed one.

(b) Using SST and a press, install the outer race of the front differential case bearing LH to the differential carrier.

SST : 09950-60020

09951-00600

09951-00730

09952-06010

SST : 09950-70010

09951-07100

NOTICE:
Do not apply hypoid gear oil to a new bearing.

9. INSTALL FRONT DIFFERENTIAL CASE BEARING

(a) Install the case plate washer to the differential side bearing retainer.

HINT
* If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft plate washer and install it.
* If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft plate washer with the same thickness as the removed one.

(b) Using SST and a press, install the outer race of the front differential case bearing RH to the differential side bearing retainer.

SST : 09950-60020

09951-00600

09951-00730

09952-06010

SST : 09950-70010

09951-07100

NOTICE:
Do not apply hypoid gear oil to a new bearing.

10. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR

(a) Using SST and a press, install a new dust deflector.

SST : 09316-60011

09316-00011

NOTICE:
* Slowly press in the dust deflector but not press it excessively.
* If any burrs remain after pressing in the deflector, remove them.

11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Install the drive pinion (with the inner race of the front drive pinion front tapered roller bearing already installed) to the differential carrier. While holding the drive pinion, install the inner race of the front drive pinion rear tapered roller bearing and the drive pinion oil slinger.

NOTICE:
* Do not drop the drive pinion.
* Install the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.

(b) Using SST, install the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

NOTICE:
* Hold the drive pinion until the SST is installed.
* Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
* Apply grease to the threads and tip of the SST center bolt before use.

(c) Using SST to hold the flange, tighten the drive pinion nut.

SST : 09330-00021

SST : 09950-30012

09955-03030

Torque:

235 N*m (2,400 kgf*cm, 173 ft.*lbf) or less

NOTICE:
* Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
* As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.

HINT
Tighten the nut approximately 108 N*m (1,100 kgf*cm, 80 ft.*lbf), and tighten it further while checking the preload.

(d) Turn the bearing clockwise and counterclockwise several times to stabilize it.

(e) Using a torque wrench, measure the drive pinion preload.

Drive pinion preload (at starting):

New bearing
0.81 to 1.40 N*m (8.3 to 14.3 kgf*cm, 7.2 to 12.4 in.*lbf)

Reused bearing
0.32 to 0.61 N*m (3.3 to 6.2 kgf*cm, 2.8 to 5.4 in.*lbf)

NOTICE:
* Record the preload for total preload measurement.
* Do not apply hypoid gear oil to a new bearing.

If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

12. INSTALL FRONT DIFFERENTIAL CASE

(a) Install the differential case to the differential carrier.

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

13. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH Front Differential Carrier Assembly

14. INSPECT AND ADJUST TOTAL PRELOAD

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

Preload (at starting):

New bearing
1.10 to 1.89 N*m (11.2 to 19.3 kgf*cm, 9.7 to 16.7 in.*lbf)

Reused bearing
0.62 to 1.1 N*m (6.2 to 11.2 kgf*cm, 5.5 to 9.7 in.*lbf)

HINT
* If the measured preload is less than the specified value, replace the case plate washer of the ring gear tooth surface side with a thicker one.
* If the preload is greater than the specified value, replace the case plate washer of the ring gear tooth surface side with a thinner one.

(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 : 09564-32011

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT
* If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.
* Record the measured backlash to use as a reference for selecting a case washer.
* Inspect tooth contact to use the result as a reference for selecting a case washer.

15. TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Front Differential Carrier Assembly

16. REMOVE FRONT DIFFERENTIAL CASE Disassembly

17. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

(a) Using SST to hold the flange, remove the drive pinion nut.

SST : 09330-00021

SST : 09950-30012

09955-03030

18. REMOVE FRONT DRIVE PINION COMPANION FLANGE Disassembly

19. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER Disassembly

20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Disassembly

21. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

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

NOTICE:
Be sure to face the larger inner diameter side rearward as shown in the illustration.

22. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

(a) While holding the drive pinion, install the inner race of the front drive pinion rear tapered roller bearing.

NOTICE:
Do not drop the drive pinion.

(b) Using the companion flange, install the inner race of the front drive pinion rear tapered roller bearing to the drive pinion.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09956-03020

09955-03030

NOTICE:
* Hold the drive pinion until the SST is installed.
* Apply grease to the threads and tip of the SST center bolt before use.

(c) Using SST, remove the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09956-03020

09955-03030

NOTICE:
* Apply grease to the threads and tip of the SST center bolt before use.
* Hold the drive pinion until the SST is installed.

23. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

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

24. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

(a) Join the 2 SST and secure them with vinyl tape.

SST : 09309-36010

SST : 09502-12010

(b) Using SST and a hammer, install a new oil seal.

SST : 09309-36010

SST : 09502-12010

Oil seal installation depth:

0.7 to 1.3 mm (0.028 to 0.051 in.)

(c) Apply MP grease to the oil seal lip.

25. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

(a) Install the differential side bearing retainer deflector with the bolt.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

26. INSTALL FRONT DRIVE PINION COMPANION FLANGE

(a) Using SST, install the companion flange to the drive pinion.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

(b) Coat the threads of a new drive pinion nut with hypoid gear oil LSD.

(c) Using SST to hold the flange, tighten the drive pinion nut.

SST : 09330-00021

SST : 09950-30012

09955-03030

Torque : 108 to 235 Nm (1,100 to 2,400 kgf-cm, 80 to 173 ft-lbf)

27. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using a torque wrench, measure the preload of the drive pinion.

Preload (at starting):

New bearing
0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf)

Reused bearing
0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf)

(b) If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.

(c) If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.

(d) If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

28. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Install the differential case to the differential carrier.

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

29. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER

(a) Check that there are no foreign objects or damage to the installation surface of the side bearing retainer.

(b) Apply FIPG to the side bearing retainer.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

HINT
* Apply FIPG in a continuous bead, approximately 1 to 2 mm (0.04 to 0.08 in.) in diameter on the entire sealing surface.
* Overlap FIPG at least 10 mm (0.39 in.) or more at the beginning and the end of application.
* Install the carrier cover within 3 minutes after applying FIPG.
* Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least at least 12 hours after installation of parts using FIPG sealant.

(c) Install the differential side bearing retainer with the 8 bolts.

Torque : 58 Nm (590 kgf-cm, 43 ft-lbf)

30. INSTALL FRONT DIFFERENTIAL BREATHER PLUG

(a) Install the differential breather plug to the differential carrier.

Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)

31. INSPECT TOTAL PRELOAD Front Differential Carrier Assembly

32. INSPECT DIFFERENTIAL RING GEAR BACKLASH Front Differential Carrier Assembly

33. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE Front Differential Carrier Assembly

34. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

(a) Using a chisel and hammer, stake the drive pinion nut.

SST : 09930-00010

35. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL

(a) Using SST and a hammer, install 2 new oil seals.

SST : 09613-22011

SST : 09950-60010

09951-00560

Oil seal installation depth:

LH Side
1.0 to 2.0 mm (0.039 to 0.079 in.)

RH Side
7.5 to 8.5 mm (0.295 to 0.335 in.)

(b) Apply MP grease to the oil seal lips.

36. INSTALL FRONT DIFFERENTIAL DRAIN PLUG

(a) Install the differential drain plug and a new gasket.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

37. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY

(a) Remove the differential carrier from the overhaul stand, etc.