Front Differential Carrier Assembly Reassembly

Using a plastic-faced hammer, tap in the straight pins until the protrusion height shown in the illustration is within the specification.

Standard height (a):

9.5 to 10.0 mm (0.374 to 0.393 in.)

Using a plastic-faced hammer, tap in the straight pins until the protrusion height shown in the illustration is within the specification.

Standard height (a):

9.5 to 10.0 mm (0.374 to 0.393 in.)

Using SST and a press, press in the bearing.

SST

09223-00010

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

Install the side gear shaft into the differential tube.

Using snap ring pliers, install a new snap ring.

Using SST and a plastic-faced hammer, tap in a new oil seal.

SST

09608-32010

Standard oil seal depth:

4.8 to 5.8 mm (0.189 to 0.228 in.)

Coat the lip of the oil seal with MP grease.

Install the 2 side gear thrust washers onto the 2 side gears.

Install the 2 side gears (with thrust washers), 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly.

HINT:

1. Align the holes of the differential case assembly and pinion shaft.
   
2. Apply hypoid gear oil to each sliding surface and rotating part.
   

Measure the side gear backlash.

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

   Standard backlash:

   0.10 to 0.25 mm (0.00394 to 0.00984 in.)
   

   If the backlash is not within the specification, replace the 2 side gear thrust washers. Use the table below to select 2 thrust washers of the same thickness which will ensure that the backlash is within the specification.
   
   

   Standard Washer Thickness:

   
   

   Part No.	Specified Condition	Part No.	Specified Condition
   41361-34100	1.43 to 1.47 mm (0.0563 to 0.0578 in.)	41361-34150	1.68 to 1.72 mm (0.0662 to 0.0677 in.)
   41361-34110	1.48 to 1.52 mm (0.0583 to 0.0598 in.)	41361-34160	1.73 to 1.77 mm (0.0682 to 0.0696 in.)
   41361-34120	1.53 to 1.57 mm (0.0603 to 0.0618 in.)	41361-34170	1.78 to 1.82 mm (0.0701 to 0.0716 in.)
   41361-34130	1.58 to 1.62 mm (0.0622 to 0.0637 in.)	41361-34180	1.83 to 1.87 mm (0.0721 to 0.0736 in.)
   41361-34140	1.63 to 1.67 mm (0.0642 to 0.0657 in.)	-	-

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 surfaces of the differential case and ring gear.

Heat the ring gear to about 100°C (212°F) in boiling water.

Carefully take the ring gear out of the boiling water.

After the moisture on the ring gear has completely evaporated, quickly align the matchmarks on the ring gear and differential case and set the ring gear onto the differential case. Then temporarily install the 12 bolts so that the bolt holes in the ring gear and differential case are aligned.

After the ring gear cools down sufficiently, remove the 12 bolts. Then apply adhesive to the 12 bolts and install them.

Torque:

137 N*m{1397 kgf*cm, 101 ft.*lbf}

Adhesive:

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

Using SST and a press, press in the 2 bearings (inner race).

SST

09316-20011
09316-60011(09316-00041)

Install a new plate washer to the shaft bearing retainer.

Using SST and a press, press the bearing (outer race) into the differential cross shaft bearing retainer.

SST

09950-60020(09951-00890)
09950-70010(09951-07150)

Install a new plate washer to the differential carrier.

Using SST and a press, press the bearing (outer race) into the differential carrier assembly.

SST

09950-60020(09951-00890)
09950-70010(09951-07150)

Using SST, install the bearing (outer race).

SST

09950-60020(09951-00810,09951-00890)

Using SST, install the washer and bearing (outer race).

SST

09950-60020(09951-00890,09951-01030)

HINT:

First use an washer that is the same thickness as the removed washer. If it is necessary to change the washer when adjusting the tooth contact, change to an washer of a different thickness.

Using SST and a press, press in the bearing (inner race).

SST

09506-35010

Install the front differential union to the differential carrier.

Install the 2 bolts and oil deflector.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Install the differential cross shaft bearing retainer and differential support with the 14 bolts.

Torque:

for bolt A:

65 N*m{663 kgf*cm, 48 ft.*lbf}

for bolt B:

155 N*m{1581 kgf*cm, 114 ft.*lbf}

Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

SST

09316-60011(09316-00041)

Using SST, install the companion flange.

SST

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

Coat the threads of the nut with hypoid gear oil.

Using SST to hold the companion flange in place, then slowly tighten the nut within the drive pinion preload adjustment range so that it reaches the specified drive pinion preload (at Starting).

SST

09330-00021(09330-00030)

Limit Torque Value:

451 N*m (4599 kgf*cm, 333 ft.*lbf) or less

NOTICE:

As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.

Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Starting):

Bearing	Specified Condition
New	2.69 to 3.19 N*m (28 to 32 kgf*cm, 24 to 28 in.*lbf)
Reused	1.86 to 2.17 N*m (19 to 22 kgf*cm, 17 to 19 in.*lbf)

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

SST

09564-33010

Standard backlash:

0.17 to 0.27 mm (0.00670 to 0.0106 in.)

HINT:

1. There should be no clearance between the plate washer and differential case.
   
2. Make sure that there is ring gear backlash.
   

Standard Washer Thickness:

Part No.	Specified Condition	Part No.	Specified Condition
90564-50238	1.49 to 1.51 mm (0.0587 to 0.0594 in.)	90564-50260	1.93 to 1.95 mm (0.0760 to 0.0767 in.)
90564-50239	1.51 to 1.53 mm (0.0595 to 0.0602 in.)	90564-50261	1.95 to 1.97 mm (0.0768 to 0.0775 in.)
90564-50240	1.53 to 1.55 mm (0.0603 to 0.0610 in.)	90564-50262	1.97 to 1.99 mm (0.0776 to 0.0783 in.)
90564-50241	1.55 to 1.57 mm (0.0611 to 0.0618 in.)	90564-50263	1.99 to 2.01 mm (0.0784 to 0.0791 in.)
90564-50242	1.57 to 1.59 mm (0.0619 to 0.0625 in.)	90564-50264	2.01 to 2.03 mm (0.0792 to 0.0799 in.)
90564-50243	1.59 to 1.61 mm (0.0626 to 0.0633 in.)	90564-50265	2.03 to 2.05 mm (0.0800 to 0.0807 in.)
90564-50244	1.61 to 1.63 mm (0.0634 to 0.0641 in.)	90564-50266	2.05 to 2.07 mm (0.0808 to 0.0814 in.)
90564-50245	1.63 to 1.65 mm (0.0642 to 0.0649 in.)	90564-50267	2.07 to 2.09 mm (0.0815 to 0.0822 in.)
90564-50246	1.65 to 1.67 mm (0.0650 to 0.0657 in.)	90564-50268	2.09 to 2.11 mm (0.0823 to 0.0830 in.)
90564-50247	1.67 to 1.69 mm (0.0658 to 0.0665 in.)	90564-50269	2.11 to 2.13 mm (0.0831 to 0.0838 in.)
90564-50248	1.69 to 1.71 mm (0.0666 to 0.0673 in.)	90564-50270	2.13 to 2.15 mm (0.0839 to 0.0846 in.)
90564-50249	1.71 to 1.73 mm (0.0674 to 0.0681 in.)	90564-50271	2.15 to 2.17 mm (0.0847 to 0.0854 in.)
90564-50250	1.73 to 1.75 mm (0.0682 to 0.0688 in.)	90564-50272	2.17 to 2.19 mm (0.0855 to 0.0862 in.)
90564-50251	1.75 to 1.77 mm (0.0689 to 0.0696 in.)	90564-50273	2.19 to 2.21 mm (0.0863 to 0.0870 in.)
90564-50252	1.77 to 1.79 mm (0.0697 to 0.0704 in.)	90564-50274	2.21 to 2.23 mm (0.0871 to 0.0877 in.)
90564-50253	1.79 to 1.81 mm (0.0705 to 0.0712 in.)	90564-50275	2.23 to 2.25 mm (0.0878 to 0.0885 in.)
90564-50254	1.81 to 1.83 mm (0.0713 to 0.0720 in.)	90564-50276	2.25 to 2.27 mm (0.0886 to 0.0893 in.)
90564-50255	1.83 to 1.85 mm (0.0721 to 0.0728 in.)	90564-50277	2.27 to 2.29 mm (0.0894 to 0.0901 in.)
90564-50256	1.85 to 1.87 mm (0.0729 to 0.0736 in.)	90564-50278	2.29 to 2.31 mm (0.0902 to 0.0909 in.)
90564-50257	1.87 to 1.89 mm (0.0737 to 0.0744 in.)	90564-50279	2.31 to 2.33 mm (0.0910 to 0.0917 in.)
90564-50258	1.89 to 1.91 mm (0.0745 to 0.0751 in.)	90564-50280	2.33 to 2.35 mm (0.0918 to 0.0925 in.)
90564-50259	1.91 to 1.93 mm (0.0752 to 0.0759 in.)	-	-

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

Standard Total Preload (at Starting):

Bearing	Specified Condition
New	4.30 to 5.60 N*m (44 to 57 kgf*cm, 39 to 49 in.*lbf)
Reused	3.19 to 4.30 N*m (33 to 43 kgf*cm, 29 to 38 in.*lbf)

Remove the 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 to the differential carrier.

Install the differential cross shaft bearing retainer and front differential front support assembly LH with the 14 bolts.

Torque:

for bolt A:

65 N*m{663 kgf*cm, 48 ft.*lbf}

for bolt B:

155 N*m{1581 kgf*cm, 114 ft.*lbf}

Hold the companion flange firmly and rotate it in both directions.

Remove the 14 bolts, differential case, cross shaft bearing retainer and front support.

Inspect the tooth contact pattern.

Standard Washer Thickness:

Part No.	Specified Condition	Part No.	Specified Condition
90564-63065	1.815 to 1.835 mm (0.0715 to 0.0722 in.)	90564-63076	2.065 to 2.085 mm (0.0813 to 0.0820 in.)
90564-63066	1.840 to 1.860 mm (0.0725 to 0.0732 in.)	90564-63077	2.090 to 2.110 mm (0.0823 to 0.0830 in.)
90564-63067	1.865 to 1.885 mm (0.0735 to 0.0742 in.)	90564-63078	2.115 to 2.135 mm (0.0833 to 0.0840 in.)
90564-63068	1.890 to 1.910 mm (0.0744 to 0.0751 in.)	90564-63079	2.140 to 2.160 mm (0.0843 to 0.0850 in.)
90564-63069	1.915 to 1.935 mm (0.0754 to 0.0761 in.)	90564-63080	2.165 to 2.185 mm (0.0853 to 0.0860 in.)
90564-63070	1.940 to 1.960 mm (0.0764 to 0.0771 in.)	90564-63081	2.190 to 2.210 mm (0.0863 to 0.0870 in.)
90564-63071	1.965 to 1.985 mm (0.0774 to 0.0781 in.)	90564-63082	2.215 to 2.235 mm (0.0872 to 0.0879 in.)
90564-63072	1.990 to 2.010 mm (0.0784 to 0.0791 in.)	90564-63083	2.240 to 2.260 mm (0.0882 to 0.0889 in.)
90564-63074	2.015 to 2.035 mm (0.0794 to 0.0801 in.)	90564-63084	2.265 to 2.285 mm (0.0892 to 0.0899 in.)
90564-63075	2.040 to 2.060 mm (0.0804 to 0.0811 in.)	-	-

Using SST, remove the companion flange from the differential carrier.

SST

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

Remove the bolts labeled B and front differential front support assembly LH.

Remove the bolts labeled A.

Using a plastic-faced hammer, tap out the bearing retainer.

Remove the differential case from the differential carrier.

Set the differential carrier to an overhaul stand as shown in the illustration.

Using a press, press out the drive pinion.

NOTICE:

Do not drop the drive pinion.

Install a new bearing spacer.

Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and shaft bearing retainer.

Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal Diameter (A):

2.0 to 3.0 mm (0.0788 to 0.118 in.)

HINT:

Install the cross shaft bearing retainer within 10 minutes of applying seal packing.

Install the front differential cross shaft bearing retainer and front differential front support assembly LH with the 11 bolts (A) and 3 new bolts (B).

Torque:

for bolt A:

65 N*m{663 kgf*cm, 48 ft.*lbf}

for bolt B:

155 N*m{1581 kgf*cm, 114 ft.*lbf}

NOTICE:

Do not add oil or drive the vehicle immediately after installing the retainer, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.

Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

SST

09316-60011(09316-00041)

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

SST

09502-12010
09316-60011(09316-00041)

Standard oil seal depth:

5.6 to 6.6 mm (0.221 to 0.259 in.)

Coat the lip of the oil seal with MP grease.

Using SST, install the companion flange.

SST

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

Coat the threads of a new nut with hypoid gear oil.

Using SST to hold the companion flange in place, then slowly tighten the nut within the drive pinion preload adjustment range so that it reaches the specified drive pinion preload (at Starting).

SST

09330-00021(09330-00030)

Limit Torque Value:

451 N*m (4599 kgf*cm, 333 ft.*lbf) or less

Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Starting):

Bearing	Specified Condition
New	3.05 to 3.55 N*m (32 to 36 kgf*cm, 27 to 31 in.*lbf)
Reused	2.22 to 2.53 N*m (23 to 25 kgf*cm, 20 to 22 in.*lbf)

Torque:

451 N*m{4599 kgf*cm, 333 ft.*lbf}or less

HINT:

Do not loosen the nut to reduce the preload.

With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure the total preload.

Standard Total Preload (at Starting):

Bearing	Specified Condition
New	4.66 to 5.96 N*m (48 to 60 kgf*cm, 42 to 52 in.*lbf)
Reused	3.55 to 4.66 N*m (37 to 47 kgf*cm, 32 to 41 in.*lbf)

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

SST

09564-33010

Standard backlash:

0.17 to 0.27 mm (0.00670 to 0.0106 in.)

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

Maximum Runout:

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

Using a chisel and hammer, stake the nut.

Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end.

SST

09608-32010

Coat the lip of the oil seal with MP grease.

Standard oil seal depth:

-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and bearing retainer.

Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal Diameter (A):

2.0 to 3.0 mm (0.0788 to 0.118 in.)

HINT:

Install the differential tube within 10 minutes of applying seal packing.

Install the differential tube to the bearing retainer.

Install 4 new bolts.

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}or less

NOTICE:

Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.