Part 1
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY (PART 1)
1. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case and ring gear.
(b) Clean the differential ring gear set bolt hole.
(c) 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.
(d) Carefully take the ring gear out of the boiling water.
(e) Secure the differential case between aluminum plates in a vise.
NOTICE:
Do not overtighten the vise.
(f) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
(g) Align the matchmarks on the ring gear and the differential case.
(h) After the ring gear has cooled sufficiently, install 10 new ring gear set bolts to which thread lock has been applied.
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent.
NOTICE:
* New ring gear set bolts should be used every time the ring gear is installed.
* Do not allow oil to adhere to the ring gear set bolt during installation.
(i) Tighten the 10 set bolts uniformly, a little at a time.
Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)
(j) Tighten the bolts further 60° to 90°.
NOTICE:
Tighten diagonally opposite bolts in pairs.
2. INSTALL REAR 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
09951-00560
09951-00570
SST : 09950-70010
09951-07100
NOTICE:
* Do not apply hypoid gear oil to a new bearing.
* Do not deform the bearing cage. Set SST to the center of the differential case.
* If the bearing is replaced, replace it and its outer race as a set.
3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the rear drive pinion rear tapered roller bearing inner race to the drive pinion.
SST : 09316-60011
09316-00031
SST : 09612-24014
09613-22011
(b) Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and plate washer.
SST : 09255-10012
SST : 09950-70010
09951-07200
HINT
Select a plate washer of the same thickness as the removed one.
4. 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.
SST : 09950-60020
09951-00710
SST : 09950-70010
09951-07100
(b) Install the rear drive pinion front tapered roller bearing to the differential carrier.
5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
HINT
Perform this procedure only when replacing the dust deflector.
(a) Using SST and a press, insert a new dust deflector to the companion flange.
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.
6. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, install the differential drive pinion.
SST : 09316-60011
09316-00011
09316-00041
SST : 09608-04031
HINT
Install the rear differential drive pinion bearing spacer and oil seal after adjusting the tooth contact pattern.
7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the drive pinion oil slinger.
8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST, install the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTICE:
* Install the companion flange so that there is a slight looseness on the drive pinion because the bearing spacer is not yet installed.
* Apply grease to the threads and tip of the SST center bolt before use.
(b) Coat the threads of the drive pinion nut with hypoid gear oil LSD.
(c) Using SST to hold the flange, tighten the drive pinion nut.
SST : 09229-55010
SST : 09330-00021
SST : 09950-30012
09955-03040
HINT
Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
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.
(d) Turn the bearing clockwise and counterclockwise several times to stabilize it.
(e) Using SST and a torque wrench, measure the preload.
SST : 09229-55010
Drive pinion preload (at starting):
New bearing
1.12 to 1.70 N*m (11.4 to 17.3 kgf*cm, 9.9 to 15.0 in.*lbf)
Reused bearing
0.40 to 0.70 N*m (4.1 to 7.1 kgf*cm, 3.5 to 6.2 in.*lbf)
NOTICE:
Record the preload for total preload measurement.
If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary.
9. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Insert the differential case from the ring gear tooth side to install the differential case.
NOTICE:
Do not damage the case bearing and ring gear.
10. INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE RH
(a) Using SST and a hammer, install the ring gear tooth side differential side bearing outer race RH.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
Tap in the differential side bearing outer race RH until half of the side gear shaft snap ring groove of the differential carrier can be seen.
11. INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE LH
(a) Install SST to the differential carrier with the 2 bolts.
SST : 09571-50010
(b) Tighten the SST bolt (A) until the SST disc lightly touches the differential side bearing outer race LH.
(c) Using SST and a hammer, install the ring gear back surface side differential side bearing outer race LH.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
Tap in the differential side bearing outer race LH until it touches the case bearing inner race roller.
12. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
(a) Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.
HINT
* If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft snap ring and install it.
* If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft snap ring with the same thickness as the removed one.
(b) Install a dial indicator to the differential carrier.
(c) Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.00394 in.).
SST : 09571-50010
NOTICE:
Observe the dial indicator to ensure that the clearance does not change more than 0.2 mm (0.00787 in.).
HINT
* Set the dial indicator to the rearmost position (upper side in the illustration) of the area around 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 at 3 positions.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
NOTICE:
The difference between the maximum and minimum values must be within 0.05 mm (0.00197 in.).
HINT
* Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
* If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the ring gear tooth side with a snap ring of different thickness as described in the following procedure.
* Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
(f) Loosen the SST bolt and separate the SST disc from the differential side bearing outer race RH on the ring gear tooth side.
(g) Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear back surface side and differential side bearing outer race LH.
SST : 09608-32010
SST : 09950-70010
09951-07200
(h) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
(i) Using snap ring pliers, install a side gear shaft snap ring with a different thickness.
HINT
When the side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash also changes by 0.02 mm (0.000787 in.).
Snap Ring Thickness
(j) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.
(k) Install a dial indicator to the differential carrier.
(l) Tighten the SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.
SST : 09571-50010
HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
(m) Using a dial indicator, measure the backlash of the ring gear at 3 positions.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
(n) If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness.
HINT
* Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
* Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install a dial indicator to the differential carrier.
(b) Tighten the SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.
SST : 09571-50010
NOTICE:
Observe the dial indicator to ensure that the clearance does not change more than 0.2 mm (0.00787 in.).
HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
(c) Using snap ring pliers, install the thinnest side gear shaft snap ring on the ring gear tooth side.
(d) Remove the dial indicator and loosen the bolt until the SST disc is separated from the differential side bearing outer race RH.
(e) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.
(f) Using a dial indicator, measure the backlash of the ring gear at 3 positions. If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
HINT
If a value is not within the specified range, replace it with one of a different thickness in the following procedure.
(g) Loosen the 2 SST bolts and separate the SST disc from the differential side bearing outer race RH on the ring gear tooth side.
14. 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):
New bearing
1.71 to 3.46 N*m (17.4 to 35.3 kgf*cm, 15.1 to 30.6 in.*lbf)
Reused bearing
0.99 to 2.46 N*m (10.1 to 25.1 kgf*cm, 8.8 to 21.8 in.*lbf)
NOTICE:
* If the measured preload is less than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thicker one.
* If the preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thinner one.
HINT
When the rear differential side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the total preload will change by approximately 0.1 N*m (1 kgf*cm, 1 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 ring gear and measure the backlash.
Backlash:
0.08 to 0.13 mm (0.00315 to 0.00512 in.)
NOTICE:
* If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft snap rings equally.
* When the side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash will also change by approximately 0.02 mm (0.000787 in.).
(d) Recheck the total preload.
15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Testing and Inspection
16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
(a) Install SST to the rear differential carrier with the 2 bolts.
SST : 09571-50010
(b) Install a dial indicator to the rear differential carrier.
(c) Tighten the SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.
NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.00787 in.).
HINT
* Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.
* Approximately 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and the side gear shaft snap ring is sufficient for the washer to move slightly.
(d) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.
(e) Remove the dial indicator and loosen the SST bolt.
NOTICE:
Do not remove SST.
17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
(a) Using SST and a hammer, create a clearance between the differential side bearing outer race LH on the ring gear and side gear shaft snap ring.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.
(b) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
18. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH
(a) Tighten the SST bolt and push out the differential side bearing outer race LH on the ring gear back surface side.
SST : 09571-50010
NOTICE:
Do not drop the side bearing outer race.
HINT
* To use as a reference for installation, clearly write the installation positions (back side or teeth side) of the differential side bearing outer race and the rear differential side gear shaft snap ring.
* Put identification marks on the differential side bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
(b) Remove the 2 bolts and SST.
19. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH
(a) Raise the ring gear side of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.
HINT
* For reassembly, check the installation position of the differential side bearing outer race and the side gear shaft snap ring before removing the differential side bearing outer race. Write down the result.
* Put identification marks on the differential side bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Remove the rear differential case assembly.
NOTICE:
Do not damage the case bearing.
21. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the flange, remove the drive pinion nut.
SST : 09229-55010
SST : 09330-00021
SST : 09950-30012
09955-03040
22. REMOVE REAR DRIVE PINION COMPANION FLANGE
(a) Using SST, remove the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.
23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Remove the differential drive pinion oil slinger.
24. REMOVE DIFFERENTIAL DRIVE PINION
(a) Using a press, remove the drive pinion from the differential carrier.
NOTICE:
Do not drop the drive pinion.