Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

Drivetrain. Land Cruiser. Urj200, 202 Grj200 Vdj200
Axle And Differential. Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY

  2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

  3. INSPECT DIFFERENTIAL RING GEAR BACKLASH

  4. REMOVE NO. 1 TRANSFER INDICATOR SWITCH

  5. REMOVE REAR DIFFERENTIAL LOCK COVER

  6. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR

  7. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT

  8. REMOVE REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY

  9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

  10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  11. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  12. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

  13. REMOVE DIFFERENTIAL DRIVE PINION

  14. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  15. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

  19. REMOVE DIFFERENTIAL RING GEAR

  20. INSPECT RUNOUT OF DIFFERENTIAL CASE

  21. DISASSEMBLE DIFFERENTIAL CASE

  22. REMOVE REAR DIFFERENTIAL CASE BEARING

  23. REMOVE REAR DIFFERENTIAL CASE BEARING

Rear Differential Carrier Assembly (W/ Differential Lock) -- Disassembly



1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using a dial indicator, measure the vertical and lateral runout of the companion flange.

    Maximum Runout:
    Runout
    		Specified Condition
    Vertical runout
    		0.10 mm (0.00394 in.)
    Lateral runout
    		0.10 mm (0.00394 in.)
    If the runout is more than the maximum, replace the companion flange.


2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a dial indicator, measure the runout of the ring gear.

    Maximum runout:
    0.05 mm (0.00197 in.)
    If the runout is more than the maximum, replace the ring gear with a new one.


3. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a dial indicator, measure the backlash of the ring gear.

    Standard backlash:
    0.10 to 0.20 mm (0.00394 to 0.00787 in.)
    HINT:
    Measure at 3 or more positions around the circumference of the ring gear.
    If the backlash is not as specified, adjust the side bearing preload or repair as necessary.


4. REMOVE NO. 1 TRANSFER INDICATOR SWITCH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the switch and gasket.



5. REMOVE REAR DIFFERENTIAL LOCK COVER


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts.

  1. Using a brass bar and hammer, tap on the cover to remove it.



6. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the shift fork shaft bolt.

  1. Using a screwdriver, pull out the actuator and remove the sleeve and shift fork.



7. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST and a hammer, unstake the nut.

    SST
    09930-00010


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

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

    SST
    09330-00021(09330-00030)


8. REMOVE REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST, remove the companion flange.

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


9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST, remove the oil seal.

    SST
    09308-10010


10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


11. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST, remove the bearing (inner race).

    SST
    09556-22010
    If the front bearing is damaged or worn, replace the bearing.


12. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Place matchmarks on the bearing caps and differential carrier.

  1. Remove the 4 bolts and 2 bearing caps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST and a hammer, remove the plate washers.

    SST
    09504-22011
    HINT:
    Measure the thickness of each plate washer and note it down.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Remove the differential case with the side bearing (outer race) from the differential carrier.

    HINT:
    Tag the bearing outer races to show the location for reassembly.


13. REMOVE DIFFERENTIAL DRIVE PINION


14. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


15. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST and a press, press out the rear bearing (inner race) from the drive pinion.

    SST
    09950-00020
    If the drive pinion or ring gear is damaged, replaced them as a set.


16. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER


17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a brass bar and hammer, tap out the bearing (outer race).



18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a brass bar and hammer, tap out the bearing (outer race).



19. REMOVE DIFFERENTIAL RING GEAR


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Place matchmarks on the ring gear and differential case.

  1. Remove the 12 ring gear set bolts.

  1. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.



20. INSPECT RUNOUT OF DIFFERENTIAL CASE

  1. Place the bearing outer races on their respective bearings.

    HINT:
    Do not interchange the left and right outer races.

  1. Install the assembled plate washers to the side bearing.

  1. Install the differential case to the differential carrier.

    HINT:
    If it is difficult to install the differential case to the carrier, replace the plate washer with a thinner one.
    However, select a plate washer that allows no clearance between it and the carrier.

  1. Align the matchmarks on the bearing caps and differential carrier.

  1. Install and uniformly tighten the 4 bolts a little at a time.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a dial indicator, measure the differential case runout.

    Maximum case runout:
    0.04 mm (0.00157 in.)
    If the runout is more than the maximum, replace the differential case and side bearings as a set.

  1. Remove the differential case.



21. DISASSEMBLE DIFFERENTIAL CASE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Place matchmarks on the differential case and differential cover.

  1. Using a T10 "TORX" socket, remove the 5 set bolts and 3 pinion shaft pins.

  1. Separate the cover and case.

  1. Remove the 2 side gears, 2 side gear thrust washers, 4 pinion gears, 4 pinion gear thrust washers, 3 pinion shafts and holder from the differential case.



22. REMOVE REAR DIFFERENTIAL CASE BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST, remove the side bearing.

    SST
    09950-40011(09952-04010,09953-04020,09954-04010,09955-04061)
    HINT:
    Fix the claws of SST to the notches in the differential case.


23. REMOVE REAR DIFFERENTIAL CASE BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

  1. Using SST, 4 bolts and a press, remove the bearing.

    SST
    09950-60010(09951-00580)
    09950-70010(09951-07150)