Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

Secure the differential carrier.

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 dial indicator, measure the runout of the ring gear.

Maximum runout:

0.07 mm (0.00276 in.)

1. If the runout is more than the maximum, replace the ring gear with a new one.
   

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

Standard backlash:

0.13 to 0.18 mm (0.00512 to 0.00708 in.)

1. If the backlash is not within the specification, adjust the side bearing preload or perform repairs as necessary.
   

   HINT:

   Perform the measurement at 3 or more positions around the circumference of the ring gear.

Using a torque wrench, measure the preload.

Standard Preload (Starting Torque):

Bearing	Specified Condition
New	1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf)
Reused	0.6 to 0.8 N*m (7 to 8 kgf*cm, 6 to 7 in.*lbf)

1. If the result is not as specified, adjust the preload (Toyota Fortuner RM0000010MS03BX_01_0010.html).
   

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

Standard Total Preload:

Bearing	Specified Condition
New	0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
Reused	0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload

1. If the result is not as specified, adjust the preload.
   

Remove the 4 bolts and actuator from the differential carrier.

Remove the O-ring.

Remove the switch and gasket.

Using a 6 mm hexagon wrench, remove the 2 screw plugs.

Remove the spring seat, spring and steel ball.

Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the shift fork shaft.

Remove the 2 bolts from the shaft retainer.

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

Remove the shift fork shaft.

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 in place, remove the nut.

SST

09330-00021(09330-00030)

Using SST, remove the companion flange with dust deflector.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03040)

NOTICE:

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

Using SST, remove the oil seal.

SST

09308-10010

Remove the oil slinger from the drive pinion.

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

SST

09556-22010

Remove the 2 bolts and 2 adjusting nut locks.

Place matchmarks on the bearing cap and differential carrier.

Remove the 4 bolts and 2 differential bearing caps.

Remove the 2 adjusting nuts.

Remove the rear differential case assembly from the differential carrier.

HINT:

Tag the 2 rear differential case bearings (outer) so that they can be reinstalled in the correct locations.

Remove the drive pinion and bearing spacer from the differential carrier.

Using SST, remove the roller bearing (outer) from the carrier.

SST

09308-00010

Using a brass bar and hammer, tap out the oil storage ring from the carrier.

Remove the bearing spacer from the drive pinion.

Using a brass bar and hammer, tap out the rear tapered roller bearing (outer) from the carrier.
If the bearing is damaged during removal, replace it.

Place matchmarks on the ring gear and differential case.

Using a screwdriver and hammer, pry out the staked portions of the lock plates.

Remove the 10 ring gear set bolts and 5 lock plates.

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

Install the rear differential case bearings (outer) to the differential case.

Install the differential case to the differential carrier.

Install the 2 adjusting nuts.

Install the 2 bearing caps to the differential carrier with the 4 bolts.

Torque:

85 N*m{867 kgf*cm, 63 ft.*lbf}

Inspect the differential case runout.

Maximum runout:

0.07 mm (0.00276 in.)

Remove the 4 bolts and 2 bearing caps.

Remove the 2 adjusting nuts.

Remove the differential case.

Remove the rear differential case bearings (outer).

Using SST, remove the 2 rear differential case bearings (inner) from the differential case.

SST

09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04061,09957-04010,09958-04011)
09950-60010(09951-00360)

HINT:

Do not remove the case bearings when not replacing the differential case.

Place matchmarks on the LH and RH cases.

Remove the 8 bolts uniformly, a little at a time.

Using a plastic-faced hammer, tap out the LH case from the RH case.

Remove the rear differential lock sleeve from the differential case LH.

Remove the following parts from the differential cases.

1. (1) Side gear (2 pieces)
   
2. (2) Side gear thrust washer (2 pieces)
   
3. (3) Spider
   
4. (4) Pinion gear (4 pieces)
   
5. (5) Pinion gear thrust washer (4 pieces)
   

Install the sleeve to the differential case LH and check that it moves smoothly.

Install the sleeve to the side gear and check that it moves smoothly.

Using a feeler gauge, measure the clearance between the shift fork and sleeve.

Standard clearance (reference):

0.15 to 0.35 mm (0.00591 to 0.0137 in.)

Check that the differential pinion and differential side gear are not damaged.

1. If the differential pinion or differential side gear is damaged, replace the differential gear kit.
   

Check that the differential case is not damaged.

1. If the differential case is damaged, replace it.