Differential Carrier Assembly Reassembly

Install the bracket with the bolt.

Using a plastic-faced hammer, install the 4 straight pins to the rear differential carrier.

Standard depth:

8.0 to 9.0 mm (0.315 to 0.354 in.)

Thoroughly clean oil and water from the surface of the rear differential case that will face the differential ring gear.

Using a 5 mm socket hexagon wrench, install the rear differential breather plug oil deflector with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

NOTICE:

Install it so that the arrow mark faces the front (transmission coupling side) of the vehicle.

Align the matchmarks on the rear differential case and differential ring gear, and install the differential ring gear.

Install 10 new differential case bolts.

Torque:

90 N*m{918 kgf*cm, 66 ft.*lbf}

NOTICE:

1. The new bolts are coated with heat resistant oil. Do not wash it off.
   
2. Install the rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.
   

Using SST and a press, press-fit the rear differential case bearing RH (inner race) to the rear differential case.

SST

09223-50010

NOTICE:

If the rear differential case bearing inner race is damaged, replace it with a new one.

Using SST and a press, press-fit the rear differential case bearing LH (inner race) to the rear differential case.

SST

09223-50010

NOTICE:

If the rear differential case bearing inner race is damaged, replace it with a new one.

Using SST and a press, press-fit the rear differential side gear shaft washer and rear differential case bearing LH (outer race) to the differential side bearing retainer.

SST

09950-60010(09951-00510,09951-00620,09952-06010)
09950-70010(09951-07150)

NOTICE:

1. Install each rear differential side gear shaft washer to the place it was removed from.
   
2. When replacing a bearing, replace the inner and outer races as a set.
   
3. Install the rear differential side gear shaft oil seal after performing the teeth contact inspection and backlash adjustment.
   

Using SST and a press, press-fit the rear differential side gear shaft washer and rear differential case bearing RH (outer race) to the rear differential carrier.

SST

09950-60010(09951-00510,09951-00620,09952-06010)
09950-70010(09951-07150)

NOTICE:

1. Install each rear differential side gear shaft washer to the place it was removed from.
   
2. When replacing a bearing, replace the inner and outer races as a set.
   
3. Install the rear differential side gear shaft oil seal after performing the teeth contact inspection and backlash adjustment.
   

Using SST and a press, press-fit the rear drive pinion tapered roller bearing front (outer race) to the rear differential carrier.

SST

09950-60010(09951-00550)
09950-60020(09951-00680)
09950-70010(09951-07100)

Using SST, bolts, nuts and washers, install the rear drive pinion tapered roller bearing rear (outer race) to the rear differential carrier.

SST

09950-60010(09951-00600)
09950-60020(09951-00680,09951-00750)

HINT:

Use M12 x P1.25 bolts with shaft lengths of 186 mm (part No. 90101-12159) and M12 x p1.25 nuts for the installation.

Install the rear differential drive pinion washer to the differential drive pinion.

NOTICE:

Install each rear differential drive pinion washer to the place it was removed from.

Using SST and a press, press-fit the tapered roller rear (inner race) to the differential drive pinion.

SST

09506-30012

Install the differential drive pinion (with rear drive pinion tapered roller bearing rear inner race) to the rear differential carrier.

Install the rear drive pinion tapered roller bearing front inner race and a new rear drive pinion nut to the differential drive pinion.

NOTICE:

1. New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.
   
2. If reusing a bearing, coat it with hypoid gear oil.
   

Using SST, tighten a new rear drive pinion nut a little at a time until the specified preload is reached. Do not exceed the torque limit shown below.

SST

09556-16011
09564-16020

Torque:

without SST:

245 N*m{2500 kgf*cm, 181 ft.*lbf}or less

with SST:

226 N*m{2305 kgf*cm, 167 ft.*lbf}or less

HINT:

The torque value for use with SST is calculated using the length of a torque wrench (600 mm (23.6 in.)) (RAV4_ACA30 RM0000018UO018X.html).

Using SST and a torque wrench, measure the starting torque of the differential drive pinion.

SST

09556-16011

Standard Drive Pinion Preload (start torque):

Bearing	Preload
New bearing	1.31 to 2.18 N*m (13 to 22 kgf*cm, 12 to 19 in.*lbf)
Reused bearing	0.24 to 0.37 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 before inspecting.
   
2. Record the preload measurement for use with the total preload inspection.
   

Install the rear differential case to the rear differential carrier.

Using a scraper and wire brush, clean the seal packing from the rear differential carrier and differential side bearing retainer.

NOTICE:

Do not scratch the installation area.

Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

Torque:

34 N*m{350 kgf*cm, 25 ft.*lbf}

Insert a dial gauge through the rear differential carrier cover plug hole, and set it perpendicular to the ring gear tooth surface's tip.

Using SST, fix the drive pinion in place.

SST

09556-16011

Using SST, rotate the rear differential case forward and backward, and measure the backlash.

SST

09564-16020

NOTICE:

Measure at 3 or more areas around the circumstance of the ring gear.

If the result is not within the specified range, select washers that are thicker or thinner ad necessary, where the thickness for the left and right side is the same. Then perform the rear differential case bearing outer race installation.

HINT:

1. If the backlash is small, select a thick washer for the RH side and a thin washer for the LH side.
   
2. If the backlash is large, select a thin washer for the RH side and a thick washer for the LH side.
   

Rear Differential Side Gear Shaft Washer Type:

Thickness mm (in.)	Identifying Mark	Thickness mm (in.)	Identifying Mark
1.59 to 1.61 (0.0625 to 0.0633)	A0	2.13 to 2.15 (0.0839 to 0.0846)	B8
1.62 to 1.64 (0.0637 to 0.0649)	A1	2.16 to 2.18 (0.0850 to 0.0858)	B9
1.65 to 1.67 (0.0650 to 0.0657)	A2	2.19 to 2.21 (0.0862 to 0.0870)	C0
1.68 to 1.70 (0.0661 to 0.0669)	A3	2.22 to 2.24 (0.0874 to 0.0882)	C1
1.71 to 1.73 (0.0673 to 0.0681)	A4	2.25 to 2.27 (0.0886 to 0.0894)	C2
1.74 to 1.76 (0.0685 to 0.0693)	A5	2.28 to 2.30 (0.0898 to 0.0906)	C3
1.77 to 1.79 (0.0697 to 0.0705)	A6	2.31 to 2.33 (0.0909 to 0.0917)	C4
1.80 to 1.82 (0.0709 to 0.0717)	A7	2.34 to 2.36 (0.0921 to 0.0929)	C5
1.83 to 1.85 (0.0720 to 0.0728)	A8	2.37 to 2.39 (0.0930 to 0.0941)	C6
1.86 to 1.88 (0.0732 to 0.0740)	A9	2.40 to 2.42 (0.0945 to 0.0953)	C7
1.89 to 1.91 (0.0744 to 0.0752)	B0	2.43 to 2.45 (0.0957 to 0.0965)	C8
1.92 to 1.94 (0.0756 to 0.0764)	B1	2.46 to 2.48 (0.0969 to 0.0976)	C9
1.95 to 1.97 (0.0768 to 0.0776)	B2	2.49 to 2.51 (0.0980 to 0.0988)	D0
1.98 to 2.00 (0.0780 to 0.0787)	B3	2.52 to 2.54 (0.0992 to 0.1000)	D1
2.02 to 2.04 (0.0795 to 0.0803)	B4	2.55 to 2.57 (0.1004 to 0.1012)	D2
2.04 to 2.06 (0.0803 to 0.0811)	B5	2.58 to 2.60 (0.1016 to 0.1024)	D3
2.07 to 2.09 (0.0815 to 0.0823)	B6	2.61 to 2.63 (0.1028 to 0.1035)	D4
2.10 to 2.12 (0.0827 to 0.0835)	B7	2.64 to 2.66 (0.1039 to 0.1047)	D5

Remove the 8 bolts an differential side bearing retainer from the rear differential carrier.

Remove the rear differential carrier case.

Uniformly apply a light coat of prussian blue on both sides of the differential ring gear teeth.

Install the rear differential case.

Temporarily install the differential side bearing retainer to the differential carrier with the 8 bolts.

Rotate the differential side pinion several times.

Remove the 8 bolts and rear differential side bearing retainer from the differential carrier.

Check the tooth contact pattern of the differential drive pinion and differential ring gear.

NOTICE:

Check the tooth contact pattern at 2 or more positions around circumference of the differential ring gear.

Perform the following procedures for face or flank contact.

1. Select washers that are thicker or thinner as necessary, where the thickness for the left and right side is the same. Then install the rear differential case bearing outer race. (*1)
   

2. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.
   

   HINT:

   If the tooth contact pattern is not correct, repeat*1.

3. Repeat the differential ring gear and differential drive pinion backlash inspection.
   

   HINT:

   If the differential ring gear and differential drive pinion backlash is not as specified, replace the differential ring gear and differential drive pinion with new ones.

Perform the following procedures for heel or toe contact.

1. Select a drive pinion washer again and perform the rear drive pinion tapered roller bearing rear installation.
   
   

   Rear Differential Drive Pinion Washer:

   
   

   Thickness mm (in.)	Identifying Mark	Thickness mm (in.)	Identifying Mark
   1.695 to 1.705 (0.0667 to 0.0671)	41	1.955 to 1.965 (0.0770 to 0.0774)	71
   1.705 to 1.715 (0.0671 to 0.0675)	42	1.965 to 1.975 (0.0774 to 0.0778)	72
   1.715 to 1.725 (0.0675 to 0.0679)	43	1.975 to 1.985 (0.0778 to 0.0781)	73
   1.725 to 1.735 (0.0679 to 0.0683)	44	1.985 to 1.995 (0.0781 to 0.0785)	74
   1.735 to 1.745 (0.0683 to 0.0687)	45	1.995 to 2.005 (0.0785 to 0.0789)	75
   1.745 to 1.755 (0.0687 to 0.0690)	46	2.005 to 2.015 (0.0789 to 0.0793)	76
   1.755 to 1.765 (0.0690 to 0.0695)	47	2.015 to 2.025 (0.0793 to 0.0797)	77
   1.765 to 1.775 (0.0695 to 0.0699)	48	2.025 to 2.035 (0.0797 to 0.0801)	78
   1.775 to 1.785 (0.0699 to 0.0703)	49	2.035 to 2.045 (0.0801 to 0.0805)	79
   1.785 to 1.795 (0.0703 to 0.0707)	50	2.045 to 2.055 (0.0805 to 0.0809)	80
   1.795 to 1.805 (0.0707 to 0.0711)	51	2.055 to 2.065 (0.0809 to 0.0813)	81
   1.805 to 1.815 (0.0711 to 0.0715)	52	2.065 to 2.075 (0.0813 to 0.0817)	82
   1.815 to 1.825 (0.0715 to 0.0719)	53	2.075 to 2.085 (0.0817 to 0.0821)	83
   1.825 to 1.835 (0.0719 to 0.0720)	54	2.085 to 2.095 (0.0821 to 0.0825)	84
   1.835 to 1.845 (0.0720 to 0.0726)	55	2.095 to 2.105 (0.0825 to 0.0829)	85
   1.845 to 1.855 (0.0726 to 0.0730)	56	2.105 to 2.115 (0.0829 to 0.0833)	86
   1.855 to 1.865 (0.0730 to 0.0734)	57	2.115 to 2.125 (0.0833 to 0.0837)	87
   1.865 to 1.875 (0.0734 to 0.0738)	58	2.125 to 2.135 (0.0837 to 0.0841)	88
   1.875 to 1.885 (0.0738 to 0.0742)	59	2.135 to 2.145 (0.0841 to 0.0844)	89
   1.885 to 1.895 (0.0742 to 0.0746)	60	2.145 to 2.155 (0.0844 to 0.0848)	90
   1.895 to 1.905 (0.0746 to 0.0750)	61	2.155 to 2.165 (0.0848 to 0.0852)	91
   1.905 to 1.915 (0.0750 to 0.0754)	62	2.165 to 2.175 (0.0852 to 0.0856)	92
   1.915 to 1.925 (0.0754 to 0.0758)	63	2.175 to 2.185 (0.0856 to 0.0860)	93
   1.925 to 1.935 (0.0758 to 0.0762)	64	2.185 to 2.195 (0.0860 to 0.0864)	94
   1.935 to 1.945 (0.0762 to 0.0766)	65	2.195 to 2.205 (0.0864 to 0.0868)	95
   1.945 to 1.955 (0.0766 to 0.0770)	70	-	-

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

SST

09556-16011

Standard Total Preload:

Bearing	Preload
New bearing	Standard drive pinion preload plus 1.18 to 1.63 N*m (12 to 17 kgf*cm, 10 to 14 in.*lbf)
Reused bearing	Standard drive pinion preload plus 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)

NOTICE:

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

If the results are not within the specification, perform the procedures below.

1. Select a side gear shaft washer for the RH side again, and then perform the rear differential case bearing outer race installation (RH side only).
   

2. Repeat the total preload inspection.
   

3. Repeat the ring gear backlash inspection.
   

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

Remove the 8 bolts and differential side bearing retainer from the rear differential carrier.

Remove the rear differential case from the rear differential carrier.

Install a new rear differential drive pinion bearing spacer to the differential drive pinion.

Install the differential drive pinion to the rear differential carrier.

Apply hypoid gear oil LSD to the threads of the rear drive pinion nut.

Install a new rear drive pinion nut to the differential drive pinion. Using SST, tighten the nut while confirming the preload.

SST

09556-16011
09564-16020

Torque:

without SST:

245 N*m{2500 kgf*cm, 181 ft.*lbf}or less

with SST:

226 N*m{2305 kgf*cm, 167 ft.*lbf}or less

HINT:

The torque value for use with SST is calculated using the length of a torque wrench (600 mm (23.6 in.)).

Using SST and a torque wrench, inspect the starting torque.

SST

09556-16011

Standard Drive Pinion Preload (start torque):

Bearing	Preload
New bearing	1.31 to 2.18 N*m (13 to 22 kgf*cm, 12 to 19 in.*lbf)
Reused bearing	0.24 to 0.37 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 before adjusting.
   
2. Adjust it so that it matches the drive pinion temporary adjustment starting torque.
   

If the preload is insufficient, use SST to tighten the drive pinion nut 5 to 10° at a time. Measure the starting torque and repeat the adjustment as necessary until the preload matches the specified torque.

SST

09556-16011
09564-16020

If the tightening torque of the rear drive pinion nut exceeds 245 N*m {2500 kgf*cm} but the preload is still insufficient, loosen the rear drive pinion nut.
Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.

If there is no defect, replace the rear drive differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

Torque:

34 N*m{350 kgf*cm, 25 ft.*lbf}

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

SST

09556-16011

Standard Total Preload:

Bearing	Preload
New bearing	Standard drive pinion preload plus 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10 to 17 in.*lbf)
Reused bearing	Standard drive pinion preload plus 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)

NOTICE:

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

If the results are not within the specified range, select a rear differential side gear shaft washer for the RH side again, and then perform the rear differential case bearing outer race installation (RH side only).

NOTICE:

If using a different rear differential side gear shaft washer, adjust the ring gear backlash. Then adjust the total preload.

Remove the 8 bolts and side bearing retainer from the rear differential carrier.

Using white gasoline, remove grease and oil from the alignment surfaces of the rear differential carrier and differential side bearing retainer.

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:

1. Apply seal packing in a continuous line 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
   
2. Perform the installation with 3 minutes of applying seal packing 1281.
   

Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

Torque:

34 N*m{350 kgf*cm, 25 ft.*lbf}

NOTICE:

After installing the cover, do not add oil or drive the vehicle, and leave it alone for 1 hour or more. Also, avoid sudden acceleration and deceleration for 12 hours or more.

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

SST

09556-16011

Standard Total Preload:

Bearing	Preload
New bearing	Standard drive pinion preload plus 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10 to 17 in.*lbf)
Reused bearing	Standard drive pinion preload plus 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)

NOTICE:

For a more accurate measurement, rotate the case bearing forward and backward before inspecting.

Insert a dial gauge through the rear differential carrier cover plug hole, and set it perpendicular to the ring gear tooth surface's tip.

Using SST, fix the drive pinion in place.

SST

09556-16011

Using SST, rotate the rear differential case forward and backward, and inspect the backlash.

SST

09564-16020

Standard backlash:

0.09 to 0.16 mm (0.000354 to 0.00630 in.)

NOTICE:

Inspect at 3 or more areas around the circumference of the ring gear.

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

Apply a light coat of MP grease No. 2 to the lip of a new diaphragm oil seal.

Using SST and a hammer, tap the diaphragm oil seal into the rear differential carrier according to the specification.

SST

09710-30021(09710-03121)
09950-60010(09951-00570)
09950-70010(09951-07100)

Standard distance:

7.0 +/-0.5 mm (0.276 +/-0.0197 in.)

Apply a light coat of MP grease No. 2 to the lip of a new rear differential side gear shaft oil seal.

Using SST and a hammer, tap the 2 rear differential side gear shaft oil seals into the rear differential carrier and differential side bearing retainer according to the specification.

SST

09223-00010

Standard distance:

7.2 +/-0.5 mm (0.283 +/-0.0197 in.)

Using a vernier caliper and precision straightedge, measure dimensions B1 and B2 of the transmission coupling.

Calculate dimension B by subtracting dimension B2 from B1.

HINT:

1. Dimension B = Dimension B1 - Dimension B2
   
2. Dimension B1 is the distance from the installation surface of the transmission coupling to the edge of the bearing.
   

Using a vernier caliper and precision straightedge, measure dimension A of the differential carrier.

HINT:

Dimension A is the distance from the installation surface of the differential carrier to the edge of the drive pinion.

Select a transmission coupling shim based on the difference between dimensions A and B, and install the shim.

Transmission Coupling Shim Type:

Difference of dimension A and B mm (in.)	Thickness mm (in.)	Identifying Mark
3.96 to 4.01 (0.148 to 0.154)	1.98 to 2.02 (0.078 to 0.080)	1
4.26 to 4.31 (0.161 to 0.168)	2.28 to 2.32 (0.090 to 0.091)	2
4.56 to 4.61 (0.174 to 0.181)	2.58 to 2.62 (0.102 to 0.103)	3
3.81 to 3.86 (0.141 to 0.148)	1.83 to 1.87 (0.072 to 0.074)	4
4.11 to 4.16 (0.154 to 0.161)	2.13 to 2.17 (0.084 to 0.085)	5
4.41 to 4.46 (0.168 to 0.174)	2.43 to 2.47 (0.096 to 0.097)	6
3.71 to 3.76 (0.146 to 0.148)	1.73 to 1.77 (0.068 to 0.070)	8
3.76 to 3.81 (0.148 to 0.150)	1.78 to 1.82 (0.070 to 0.072)	9
3.86 to 3.91 (0.151 to 0.154)	1.88 to 1.92 (0.074 to 0.076)	10
3.91 to 3.96 (0.154 to 0.156)	1.93 to 1.97 (0.076 to 0.078)	11
4.01 to 4.06 (0.158 to 0.160)	2.03 to 2.07 (0.080 to 0.081)	12
4.06 to 4.11 (0.160 to 0.162)	2.08 to 2.12 (0.082 to 0.083)	13
4.16 to 4.21 (0.164 to 0.166)	2.18 to 2.22 (0.086 to 0.087)	14
4.21 to 4.26 (0.166 to 0.168)	2.23 to 2.27 (0.088 to 0.089)	15
4.31 to 4.36 (0.170 to 0.172)	2.33 to 2.37 (0.092 to 0.093)	16
4.36 to 4.41 (0.172 to 0.174)	2.38 to 2.42 (0.094 to 0.095)	17
4.46 to 4.51 (0.176 to 0.178)	2.48 to 2.52 (0.098 to 0.099)	18
4.51 to 4.56 (0.178 to 0.180)	2.53 to 2.57 (0.100 to 0.101)	19
4.61 to 4.66 (0.181 to 0.183)	2.63 to 2.67 (0.104 to 0.105)	20
4.66 to 4.71 (0.183 to 0.185)	2.68 to 2.72 (0.106 to 0.107)	21

Install the transmission coupling conical spring washer to the rear differential carrier.

NOTICE:

Install the transmission coupling conical spring washer so that the green marking (protruding part) is facing the front of the vehicle (coupling side).

Using a 5 mm socket hexagon wrench, install the yoke with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install a new O-ring to the solenoid.

NOTICE:

Do not damage or twist the O-ring .

Install the solenoid to the yoke.

Install the snap ring.

Using white gasoline, remove grease and oil from the alignment surfaces of the rear differential carrier and transmission coupling.

Apply seal packing to the areas indicated in the illustration of the transmission coupling.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

1. Apply seal packing in a continuous line 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
   
2. Perform the installation with 3 minutes of applying seal packing 1281.
   

Install the rear differential carrier cover to the rear differential carrier assembly with the 4 bolts.

Torque:

20 N*m{200 kgf*cm, 14 ft.*lbf}

Using a plastic-faced hammer, tap in the breather plug.

SST

09612-07010(09612-10061)

Using an 8 mm socket hexagon wrench, install a new rear differential carrier cover plug.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Install a new gasket to the rear differential filler plug.

Using a 10 mm socket hexagon wrench, install the rear differential filler plug.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

Install a new gasket to the rear differential drain plug.

Using a 10 mm socket hexagon wrench, install the rear differential drain plug.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

Install a dial gauge so that it is perpendicular to the inner side of the transmission coupling.

Using SST, rotate the transmission coupling forward and backward and measure the vertical runout.

SST

09564-16020

Maximum vertical runout:

0.06 mm (0.00236 in.)

Install a dial gauge perpendicularly onto the transmission coupling, as shown in the illustration.

Using SST, rotate the transmission coupling forward and backward and measure the lateral runout.

SST

09564-16020

Maximum lateral runout:

0.07 mm (0.00276 in.)

Install the differential support assembly rear with the 4 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}