Part 2

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

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.

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

(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.

NOTICE:
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.

NOTICE:
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.

NOTICE:
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.

NOTICE:
* 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.

NOTICE:
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

NOTICE:
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.

NOTICE:
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

NOTICE:
* 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.)

NOTICE:
* 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

NOTICE:
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)

NOTICE:
* 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):

NOTICE:
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.

HINT
* 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.

NOTICE:
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.

NOTICE:
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

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.

(d) Install the retainer with the 11 bolts.

Torque : 58 Nm (591 kgf-cm, 43 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 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.