FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Toyota >> 2010 >> Venza AWD L4-2.7L (1AR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Reassembly >> Part 2

Part 2





AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY (Continued)

26. MEASURE TOTAL PRELOAD

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





SST : 09556-16011

Standard total preload (New bearing):

Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

Standard total preload (Reused bearing):

Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

HINT
For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

(b) If the results are not within the specification, perform the procedure below:

(1) Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

(2) Repeat the total preload measurement.

(3) Repeat the differential ring gear backlash inspection.

(4) Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

(a) Remove the 10 bolts and differential side bearing retainer.

(b) Install the 2 bolts and rear differential breather plug oil deflector to the differential side bearing retainer.





Torque : 4.9 Nm (50 kgf-cm, 43 in-lbf)

(c) Using SST and a hammer, tap in the rear differential carrier cover breather plug to the differential side bearing retainer.

SST : 09612-10093

09612-10061





(d) Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.

NOTICE:
Do not damage the installation surface.

(e) Apply seal packing to the areas indicated in the illustration of the differential side bearing retainer.





Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
* Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
* Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.
* Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).
* Perform the installation within 3 minutes after applying seal packing.
* Start applying seal packing within range (A).
(f) Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.





Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)

NOTICE:
After installing the differential side bearing retainer, do not immediately add oil or drive the vehicle for at least 1 hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.

28. INSPECT TOTAL PRELOAD

(a) Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.





SST : 09556-16011

Standard total preload (New bearing):

Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

Standard total preload (Reused bearing):

Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

NOTICE:
For a more accurate measurement, rotate the rear differential case bearing forward and backward before inspection.

29. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.

(b) Using SST, hold the drive pinion in place.

SST : 09556-16011

(c) Using SST, rotate the rear differential case sub-assembly forward and backward, and measure the backlash.

SST : 09564-32011





Backlash:

0.10 to 0.15 mm (0.00394 to 0.00591 in.)

NOTICE:
Measure at 3 or more areas on the circumference of the differential ring gear.

30. INSTALL REAR DRIVE PINION NUT

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

31. INSTALL DIFFERENTIAL PRESSURE CONTROL HOSE ELBOW

(a) Align the matchmarks on the 2 differential pressure control hose elbows and rear differential carrier assembly.





Text in Illustration:





32. INSTALL DIFFERENTIAL PRESSURE CONTROL HOSE

(a) Using the 2 differential pressure control hose clips, install the differential pressure control hose to the 2 differential pressure control hose elbows in the order shown in the illustration.





Text in Illustration:





NOTICE:
* Be sure to install the clips in the direction shown in the illustration.
* Confirm that the differential pressure control hose and the differential pressure control hose clips do not interfere with other parts.
* Confirm that the differential pressure control hose is not cracked.
33. INSTALL DIAPHRAGM OIL SEAL

(b) Using SST and a hammer, install a new diaphragm oil seal into the rear differential carrier assembly.





Text in Illustration:





SST : 09506-35010

SST : 09554-22010

Diaphragm oil seal driven in depth:

0.7 to 1.3 mm (0.0276 to 0.0512 in.)

NOTICE:
* Tap the diaphragm oil seal uniformly so that it is driven in straight.
* Do not excessively tap the diaphragm oil seal.
(c) Apply a light coat of MP grease to the lip of the new diaphragm oil seal.

34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST and a hammer, install 2 new rear differential side gear shaft oil seals into the rear differential carrier and differential side bearing retainer.





Text in Illustration:





SST : 09554-22010

Oil seal driven in depth (A):

4.2 to 4.8 mm (0.165 to 0.189 in.)

NOTICE:
* Tap the rear differential side gear shaft oil seal uniformly so that it is driven in straight.
* Do not excessively tap the rear differential side gear shaft oil seal.
(b) Apply a light coat of MP grease to the lip of the 2 new rear differential side gear shaft oil seals.

35. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

(a) Using SST and a press, install the rear differential dust deflector.





Text in Illustration:





SST : 09518-36020

SST : 09950-70010

09951-07150

NOTICE:
* Be sure to press in the rear differential dust deflector until it contacts the bearing end surface.
* Do not damage the end surface of the electro magnetic control coupling sub-assembly.
36. INSTALL CONNECTOR CLAMP BRACKET

(a) Install the connector clamp bracket with the bolt.





Torque : 15 Nm (150 kgf-cm, 11 ft-lbf)

NOTICE:
Do not damage the electro magnetic control coupling wire harness.

(b) Install the connector with the claw.

37. INSTALL TRANSMISSION COUPLING SPACER

(a) Install the transmission coupling spacer to the rear differential carrier assembly.





Text in Illustration:





NOTICE:
Keep the transmission coupling spacer free of oil and foreign matter.

38. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER

(a) Install the transmission coupling conical spring washer to the rear differential carrier assembly.





Text in Illustration:





NOTICE:
* Install the transmission coupling conical spring washer so that the marked surface faces the front of the vehicle (coupling side).
* Keep the transmission coupling conical spring washer free of oil and foreign matter.
39. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY

(a) Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

NOTICE:
Do not scratch the installation area.

(b) Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier assembly and the electro magnetic control coupling sub-assembly.

(c) Apply seal packing to the areas indicated in the illustration of the electro magnetic control coupling sub-assembly.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent





NOTICE:
* Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.
* Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).
* Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing.
* Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
HINT
* (B) : 1.0 mm (0.0394 in.)
* (C) : 2.0 mm (0.0787 in.)
* (D) : 3.0 mm (0.118 in.)
* (E) : 5.0 mm (0.197 in.)
(d) Apply hypoid gear oil to the splines of the rear drive pinion.

(e) Install the electro magnetic control coupling sub-assembly with the 4 bolts.





Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

NOTICE:
* Do not damage the diaphragm oil seal.
* Do not damage the contact surface of the electro magnetic control coupling sub-assembly.
40. INSTALL REAR DIFFERENTIAL FILLER PLUG

(a) Install a new gasket with the rear differential filler plug (inspection plug).





Torque : 98 Nm (999 kgf-cm, 72 ft-lbf)

41. INSPECT ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY

(a) Install a dial indicator and magnetic base so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.





(b) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

SST : 09564-32011

Maximum runout:

0.04 mm (0.00157 in.)

(c) If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

(d) Install a dial indicator and magnetic base so that it is perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

(e) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

SST : 09564-32011

Maximum runout:

0.063 mm (0.00248 in.)

(f) If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.
42. INSTALL STUD BOLT

(a) Temporarily install 4 new stud bolts to the electro magnetic control coupling sub-assembly.

(b) Install 2 service nuts to the stud bolt.





Text in Illustration:





Recommended service nut:

Thread diameter
8 mm (0.3150 in.)

Thread pitch
1.25 mm (0.0492 in.)

(c) Lock the upper nut using the lower nut.

(d) Turn the upper nut and tighten the other 3 stud bolts to the electro magnetic control coupling sub-assembly in the same way.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(A):

29.1 to 32.3 mm (1.15 to 1.27 in.)

HINT
If the threads of the electro magnetic control coupling sub-assembly are damaged while installing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

43. REMOVE DIFFERENTIAL CARRIER ASSEMBLY

(a) Remove the differential carrier assembly from the overhaul attachment.
pro multis Credits:Operation CHARM About Operation CHARM