Front Differential Carrier Assembly Reassembly

Using SST and a press, press in the shaft RH bearing.

SST

09223-00010

Using a snap ring expander, install the snap ring.

HINT:

Install the snap ring securely.

Install the shaft to the differential tube.

Using a snap ring expander, install a new snap ring.

HINT:

Install the snap ring securely.

Using SST, tap out the oil seal.

SST

09308-00010

Install the clutch hub to the side gear inter shaft.

Using snap ring pliers, install the snap ring.

HINT:

Install the snap ring securely.

NOTICE:

Make sure to install the differential clutch hub in the correct direction.

Using SST and a press, press in 2 new bearings.

SST

09950-60010(09951-00380)

Needle roller bearing depth:

1.7 +/-0.3 mm (0.0669 +/-0.0118 in.)

Install 2 thrust washers to the 2 side gears.

HINT:

Using the table below, select 2 thrust washers which will ensure that the backlash is within the specifications.

Standard Thrust Washer Thickness:

Thickness mm (in.)	Thickness mm (in.)
1.48 to 1.52 (0.0583 to 0.0598)	1.73 to 1.77 (0.0681 to 0.0696)
1.53 to 1.57 (0.0603 to 0.0618)	1.78 to 1.82 (0.0701 to 0.0716)
1.58 to 1.62 (0.0622 to 0.0637)	1.83 to 1.87 (0.0720 to 0.0736)
1.63 to 1.67 (0.0642 to 0.0657)	1.88 to 1.92 (0.0740 to 0.0755)
1.68 to 1.72 (0.0662 to 0.0677)	-

Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion gear thrust washers and pinion shaft to the differential case.

HINT:

Align the holes of the differential case and pinion shaft.

Measure the side gear backlash.

1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
   

   Backlash:

   0.15 mm (0.00591 in.) or less
   

   1. If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.
      

Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

Stake the differential case.

Clean the contact surface of the differential case and ring gear.

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

Carefully remove the ring gear from the boiling water.

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

Align the matchmarks on the ring gear and differential case.

After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.

Thread lock:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

Torque:

97 N*m{984 kgf*cm, 71 ft.*lbf}

Using SST and a press, press the bearing onto the differential case.

SST

09950-60010(09951-00520,09951-00610)
09950-70010(09951-07150)

Using SST and a press, press in the case bearing (outer) to the differential side bearing retainer.

SST

09950-60020(09951-00810)
09950-70010(09951-07150)

Using SST and a press, press in the case bearing (outer) to the differential carrier.

SST

09950-60020(09951-00810)
09950-70010(09951-07150)

Using SST, install the outer race front.

SST

09950-60020(09951-00720,09951-00890)

Using a brass bar and hammer, tap in a new oil storage ring.

Using SST, install the outer race rear.

SST

09950-60020(09951-00720,09951-00890)

Install the washer to the drive pinion.

HINT:

First, install a washer that has the same thickness as the removed washer. After checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

Using SST and a press, press the front bearing onto the drive pinion.

SST

09506-30012

Install the drive pinion, rear drive pinion tapered roller bearing (inner) and oil slinger.

HINT:

Install the spacer and oil seal after adjusting the gear contact pattern.

Using SST, install the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03020)

NOTICE:

Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

Adjust the drive pinion preload by tightening the companion flange nut.

Using SST to hold the flange in place, tighten the nut.

SST

09330-00021(09330-00030)

Torque:

370 N*m{3773 kgf*cm, 273 ft.*lbf}or less

NOTICE:

1. As there is no spacer, tighten the nut a little at a time. Be careful not to overtighten it.
   
2. Apply hypoid gear oil LSD to drive pinion thread and nut seat face.
   

Using a torque wrench, measure the preload.

Standard Preload (Starting Torque):

Item	Specified Condition
New bearing	0.7 to 1.2 N*m (8 to 12 kgf*cm, 7 to 10 in.*lbf)
Reused bearing	0.2 to 0.4 N*m (2 to 4 kgf*cm, 2 to 3 in.*lbf)

NOTICE:

1. For a more accurate measurement, rotate the bearing forward and backward several times before measuring.
   
2. Record the differential drive pinion preload for the total preload measurement.
   

Install the side bearing retainer with the 10 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Using SST and a dial indicator, measure the ring gear backlash.

SST

09564-33010

Standard backlash:

0.11 to 0.21 mm (0.00433 to 0.00826 in.)

1. If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.
   

   HINT:

   There should be no clearance between the plate washer and case. Make sure that the ring gear has backlash.

   
   

   Standard Washer Thickness:

   
   

   Thickness mm (in.)	Thickness mm (in.)	Thickness mm (in.)
   1.57 to 1.59 (0.0618 to 0.0625)	1.79 to 1.81 (0.0705 to 0.0712)	2.01 to 2.03 (0.0792 to 0.0799)
   1.59 to 1.61 (0.0626 to 0.0633)	1.81 to 1.83 (0.0713 to 0.0720)	2.03 to 2.05 (0.0800 to 0.0807)
   1.61 to 1.63 (0.0634 to 0.0641)	1.83 to 1.85 (0.0720 to 0.0728)	2.05 to 2.07 (0.0808 to 0.0814)
   1.63 to 1.65 (0.0642 to 0.0649)	1.85 to 1.87 (0.0729 to 0.0736)	2.07 to 2.09 (0.0815 to 0.0822)
   1.65 to 1.67 (0.0650 to 0.0657)	1.87 to 1.89 (0.0737 to 0.0744)	2.09 to 2.11 (0.0823 to 0.0830)
   1.67 to 1.69 (0.0658 to 0.0665)	1.89 to 1.91 (0.0744 to 0.0751)	2.11 to 2.13 (0.0831 to 0.0838)
   1.69 to 1.71 (0.0666 to 0.0673)	1.91 to 1.93 (0.0752 to 0.0759)	2.13 to 2.15 (0.0839 to 0.0846)
   1.71 to 1.73 (0.0674 to 0.0681)	1.93 to 1.95 (0.0760 to 0.0767)	2.15 to 2.17 (0.0847 to 0.0854)
   1.73 to 1.75 (0.0682 to 0.0688)	1.95 to 1.97 (0.0768 to 0.0775)	-
   1.75 to 1.77 (0.0689 to 0.0696)	1.97 to 1.99 (0.0776 to 0.0783)	-
   1.77 to 1.79 (0.0697 to 0.0704)	1.99 to 2.01 (0.0784 to 0.0791)	-

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

Standard total preload (starting torque):

0.3 to 0.8 N*m (4 to 8 kgf*cm, 3 to 7 in.*lbf) + drive pinion preload

NOTICE:

Record the differential ring gear preload.

Remove the differential case bearing retainer and differential case.

Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

Install the differential case and differential case bearing retainer.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Hold the companion flange firmly in place and rotate the ring gear in both directions.

Remove the differential case bearing retainer and differential case.

Inspect the tooth contact pattern.

If the teeth are not contacting properly, use the following chart to select a proper washer.

Standard Washer Thickness:

Thickness mm (in.)	Thickness mm (in.)	Thickness mm (in.)
1.69 to 1.71 (0.0666 to 0.0673)	1.93 to 1.95 (0.0760 to 0.0767)	2.17 to 2.19 (0.0855 to 0.0862)
1.72 to 1.74 (0.0678 to 0.0685)	1.96 to 1.98 (0.0772 to 0.0779)	2.20 to 2.22 (0.0867 to 0.0874)
1.75 to 1.77 (0.0689 to 0.0696)	1.99 to 2.01 (0.0784 to 0.0791)	2.23 to 2.25 (0.0878 to 0.0885)
1.78 to 1.80 (0.0701 to 0.0708)	2.02 to 2.04 (0.0796 to 0.0803)	2.26 to 2.28 (0.0890 to 0.0897)
1.81 to 1.83 (0.0713 to 0.0720)	2.05 to 2.07 (0.0807 to 0.0814)	2.29 to 2.31 (0.0902 to 0.0909)
1.84 to 1.86 (0.0725 to 0.0732)	2.08 to 2.10 (0.0819 to 0.0826)	2.32 to 2.34 (0.0914 to 0.0921)
1.87 to 1.89 (0.0737 to 0.0744)	2.11 to 2.13 (0.0831 to 0.0838)	-
1.90 to 1.92 (0.0748 to 0.0755)	2.14 to 2.16 (0.0843 to 0.0850)	-

Using SST and a hammer, loosen the staked part of the nut.

SST

09930-00010(09931-00010,09931-00020)

Using SST to hold the companion flange, remove the nut.

SST

09330-00021(09330-00030)

Using SST, remove the companion flange with dust deflector.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03020)

NOTICE:

Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

Remove the oil slinger from the drive pinion.

Using SST, remove the roller bearing (inner) from the drive pinion.

SST

09556-22010

Install a new bearing spacer to the drive pinion.

Install the roller bearing to the drive pinion.

Install the oil slinger to the drive pinion.

Apply MP grease to the lip of a new oil seal.

Using SST and a hammer, tap in the oil seal.

SST

09554-22010

Oil seal depth:

4.35 +/-0.45 mm (0.171 +/-0.0177 in.)

Using SST, install the companion flange with dust deflector.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03020)

NOTICE:

Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

Apply hypoid gear oil LSD to drive pinion thread and nut seat face.

Using SST to hold the companion flange, install a new nut.

SST

09330-00021(09330-00030)

Torque:

370 N*m{3773 kgf*cm, 27 ft.*lbf}or less

Remove any old seal packing material from the side bearing retainer.

NOTICE:

Do not drop oil on the contact surfaces of the differential carrier and side bearing retainer.

Clean residual seal packing material on the contact surface using gasoline or alcohol.

Apply seal packing to the side bearing retainer as shown in the illustration.

Seal packing:

Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

HINT:

Install the side bearing retainer within 3 minutes after applying seal packing.

Install the side bearing retainer with the 10 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

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

Standard Preload (Starting Torque):

Item	Specified Condition
New bearing	1.0 to 1.5 N*m (11 to 15 kgf*cm, 9 to 13 in.*lbf) + ring gear preload
Reused bearing	0.5 to 0.7 N*m (6 to 7 kgf*cm, 5 to 6 in.*lbf) + ring gear preload

1. If necessary, disassemble and inspect the differential.
   

Using SST and a dial indicator, measure the ring gear backlash.

SST

09564-32011

Standard backlash:

0.11 to 0.21 mm (0.00433 to 0.00826 in.)

1. If the backlash is not within the specification, adjust the side bearing preload.
   

Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Maximum Runout:

Item	Specified Condition
Vertical runout	0.10 mm (0.00394 in.)
Lateral runout	0.10 mm (0.00394 in.)

1. If the runout is more than the maximum, replace the companion flange.
   

Using a chisel and hammer, stake the nut.

Using SST and a hammer, tap in 2 new oil seals.

SST

09554-47010
09950-70010(09951-07100)

NOTICE:

1. Make sure the LH and RH oil seals are installed to the proper locations.
   
2. As a different side of SST is used for each oil seal, be sure to confirm that the correct side of SST is being used before tapping in an oil seal.
   
3. Make sure that the lip of the oil seal is inserted into SST before tapping in the oil seal.
   
4. As each side of SST is designed to tap in the corresponding oil seal to the proper depth, be sure to fully tap in the oil seal.
   
5. Do not damage the oil seals.
   

Standard Oil Seal Depth:

Item	Specified Condition
for LH Side	2.9 +/-0.45 mm (0.114 +/-0.0177 in.)
for RH Side	8.1 +/-0.45 mm (0.319 +/-0.0177 in.)

Apply MP grease to the lip of each oil seal.

Using a brass bar and hammer, tap in the side bearing retainer deflector.

NOTICE:

Make sure to install the side bearing retainer deflector in the correct direction.

Install a new snap ring to the side gear inter shaft.

Using a plastic-faced hammer, tap the side gear inter shaft into the differential case.

Check that there is 2 to 3 mm (0.0788 to 0.118 in.) of axial play.

Check that the side gear inter shaft cannot be completely pulled out by hand.

Install the differential clutch sleeve.

Remove any old seal packing material on the contact surfaces of the differential and clutch case.

NOTICE:

Do not drop oil on the contact surfaces of the differential and clutch case.

Clean residual seal packing material on the contact surface using gasoline or alcohol.

Apply seal packing to the differential as shown in the illustration.

Seal packing:

Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

HINT:

Install the differential tube within 3 minutes after applying seal packing.

Install the differential tube to the differential.

Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

Install the 4 bolts.

Torque:

110 N*m{1122 kgf*cm, 81 ft.*lbf}

Remove any seal packing material from the contact surface of the differential and clutch case. Also, do not drop oil on the contact surfaces.

Clean residual seal packing material from the contact surfaces using gasoline or alcohol.

Apply seal packing to the differential tube as shown.

Seal packing:

Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

HINT:

Install the actuator within 3 minutes after applying seal packing.

Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

Install the actuator to the differential tube.

Install the 4 bolts.

Torque:

21 N*m{210 kgf*cm, 15 ft.*lbf}