Part 2
AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY (PART 2)
25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Remove the rear drive pinion front tapered roller bearing from the differential carrier.
26. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new drive pinion bearing spacer to the drive pinion.
HINT
The bearing spacer can be installed in either direction.
27. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the rear drive pinion front tapered roller bearing to the differential carrier.
28. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, install the differential drive pinion to the differential carrier.
SST : 09316-60011
09316-00011
09316-00041
SST : 09608-04031
29. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the differential drive pinion oil slinger to the differential drive pinion.
30. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Replacement
31. INSTALL REAR DRIVE PINION COMPANION FLANGE
(a) Using SST, install the companion flange to the drive pinion.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
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 and a torque wrench, hold the flange and tighten the drive pinion nut.
SST : 09229-55010
SST : 09330-00021
SST : 09950-30012
09955-03040
Torque:
490 N*m (5000 kgf*cm, 361 ft.*lbf) or less
NOTICE:
* Do not tighten excessively, otherwise the threads will be stripped.
* Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
HINT
Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.
32. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Insert the differential case from the ring gear tooth side.
NOTICE:
Do not damage the case bearing inner race or ring gear.
33. 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 until half of the side gear shaft snap ring groove of the differential carrier can be seen.
34. 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 RH.
(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 until it touches the case bearing inner race roller.
35. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
(a) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
HINT
Use the side gear shaft snap ring installed when performing tooth contact adjustment.
(b) Set a dial indicator on the 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 clearance does not change more that 0.2 mm (0.00787 in.).
(d) Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.
HINT
Use the side gear shaft snap ring installed when performing tooth contact adjustment.
(e) Remove the dial indicator and tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.
(f) Remove the 2 bolts and SST.
36. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST and a torque wrench, measure the preload.
SST : 09229-55010
Drive pinion preload (at starting):
New bearing
1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.8 to 15.9 in.*lbf)
Reused bearing
0.50 to 0.80 N*m (5.1 to 8.2 kgf*cm, 4.4 to 7.1 in.*lbf)
* If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut 5 to 10°.
Torque:
490 N*m (5000 kgf*cm, 361 ft.*lbf) or less
* 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.
* 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.
37. INSPECT TOTAL PRELOAD Testing and Inspection
38. INSPECT DIFFERENTIAL RING GEAR BACKLASH Testing and Inspection
39. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Testing and Inspection
40. STAKE REAR DRIVE PINION NUT
(a) Using SST and a hammer, stake the drive pinion nut.
SST : 09930-00010
41. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, install 2 new oil seals.
SST : 09223-15030
SST : 09950-70010
09951-07200
Oil seal installation depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
HINT
* Make sure to check the identification marks on the oil seals before installation because the parts numbers differ between the left and right sides.
* To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seals.
* After installing both oil seals, tap them in until both surfaces are flush with the rear differential carrier.
(b) Apply MP grease to the oil seal lips.
42. INSTALL REAR DIFFERENTIAL DRAIN PLUG
(a) Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
43. TEMPORARILY TIGHTEN REAR DIFFERENTIAL FILLER PLUG
(a) Using a hexagon wrench (10 mm), temporarily install the differential filler plug.
HINT
Add differential oil before installing the gasket and fully tightening the rear differential filler plug.
44. REMOVE REAR DIFFERENTIAL CARRIER
(a) Remove the 4 bolts and differential carrier from the overhaul attachment.
NOTICE:
Clean the fitting surface between the differential carrier and carrier cover.
45. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
(a) Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.
NOTICE:
Do not scratch the sealing surface.
(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover.
Torque : 7.0 Nm (70 kgf-cm, 62 in-lbf)
46. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN
(a) Install the 2 rear differential carrier straight pins to the differential carrier.
47. INSTALL REAR DIFFERENTIAL CARRIER COVER
(a) Apply seal packing to the differential carrier as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent
NOTICE:
* 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.
(b) Install the differential carrier cover with the 8 bolts and 2 pins.
Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
NOTICE:
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 72 hours after application.
48. INSTALL REAR DIFFERENTIAL BREATHER PLUG
(a) Install the breather plug to the differential carrier cover.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)