Front Differential Carrier Assembly Reassembly

Using SST and a press, press in a new shaft bearing.

SST

09223-00010

Using a snap ring expander, install the snap ring.

HINT:

Install the snap ring securely.

Install the shaft into the differential tube.

Using a snap ring expander, install the snap ring.

HINT:

Install the snap ring securely.

Coat the lip of a new oil seal with MP grease.

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

SST

09223-15020

Standard oil seal depth:

5.3 +-0.5 mm (0.209 +-0.020 in.)

Install 2 thrust washers on 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	Thickness
1.48 to 1.52 mm (0.0583 to 0.0598 in.)	1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)	1.78 to 1.82 mm (0.0701 to 0.0717 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.)	1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)	1.88 to 1.92 mm (0.0740 to 0.0756 in.)
1.68 to 1.72 mm (0.0661 to 0.0677 in.)	-

Install the 2 side gears (with thrust washers), 2 pinion gears, 2 pinion thrust washers and pinion shaft in 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.
   

   Standard backlash:

   0.15 mm (0.0059 in.)
   

   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 with those of the differential case.

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

Adhesive:

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

Torque:

97 N*m{985 kgf*cm, 71 ft.*lbf}

Using SST and a press, press in the case bearing (inner) on 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 race) 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 on the drive pinion.

HINT:

First fit 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 roller bearing (inner) onto the drive pinion.

SST

09506-30012

Install the drive pinion and oil slinger, front drive pinion tapered roller bearing and front differential drive pinion oil slinger.

HINT:

Assemble 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)
09330-00021(09330-00030)

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{3,770 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.
   

1. Apply hypoid gear oil to the nut.
   

Using a torque wrench, measure the preload.

Standard preload (at start of torque):

Item	Specified Condition
New bearing	0.98 to 1.57 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)
Reused bearing	0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)

NOTICE:

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

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

09564-32011

Standard backlash:

0.11 to 0.21 mm (0.0043 to 0.0083 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 drive pinion washer and case. Make sure that the ring gear has backlash.

   
   

   Standard washer thickness:

   
   

   Thickness	Thickness	Thickness
   1.57 to 1.59 mm (0.0618 to 0.0626 in.)	1.75 to 1.77 mm (0.0689 to 0.0697 in.)	2.03 to 2.05 mm (0.0791 to 0.0807 in.)
   1.59 to 1.61 mm (0.0626 to 0.0634 in.)	1.77 to 1.79 mm (0.0697 to 0.0705 in.)	2.05 to 2.07 mm (0.0807 to 0.0815 in.)
   1.61 to 1.63 mm (0.0634 to 0.0642 in.)	1.79 to 1.81 mm (0.0705 to 0.0713 in.)	2.07 to 2.09 mm (0.0815 to 0.0822 in.)
   1.63 to 1.65 mm (0.0642 to 0.0650 in.)	1.81 to 1.83 mm (0.0713 to 0.0720 in.)	2.09 to 2.11 mm (0.0822 to 0.0830 in.)
   1.65 to 1.67 mm (0.0650 to 0.0657 in.)	1.83 to 1.85 mm (0.0720 to 0.0728 in.)	2.11 to 2.13 mm (0.0830 to 0.0839 in.)
   1.67 to 1.69 mm (0.0657 to 0.0665 in.)	1.85 to 1.87 mm (0.0728 to 0.0736 in.)	2.13 to 2.15 mm (0.0839 to 0.0846 in.)
   1.69 to 1.71 mm (0.0665 to 0.0673 in.)	1.87 to 1.89 mm (0.0736 to 0.0744 in.)	2.15 to 2.17 mm (0.0846 to 0.0854 in.)
   1.71 to 1.73 mm (0.0673 to 0.0681 in.)	1.89 to 2.01 mm (0.0744 to 0.0791 in.)	-
   1.73 to 1.75 mm (0.0681 to 0.0689 in.)	2.01 to 2.03 mm (0.0791 to 0.0799 in.)	-

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

Standard total preload (at start of torque):

0.22 to 0.88 N*m (2 to 9 kgf*cm, 1.9 to 7.7 in.*lbf) + drive pinion preload

1. If necessary, disassemble and inspect the differential.
   

Remove the differential case bearing (outer) retainer and differential case.

Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

Install the differential case and differential case bearing (outer).

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 (outer) 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	Thickness	Thickness
1.69 to 1.71 mm (0.0665 to 0.0673 in.)	1.93 to 1.95 mm (0.0760 to 0.0768 in.)	2.17 to 2.19 mm (0.0854 to 0.0862 in.)
1.72 to .,74 mm (0.0677 to 0.0685 in.)	1.96 to 1.98 mm (0.0772 to 0.0780 in.)	2.20 to 2.22 mm (0.0866 to 0.0874 in.)
1.75 to 1.77 mm (0.0689 to 0.0697 in.)	1.99 to 2.01 mm (0.0783 to 0.0791 in.)	2.23 to 2.25 mm (0.0878 to 0.0886 in.)
1.78 to 1.80 mm (0.0700 to 0.0709 in.)	2.02 to 2.04 mm (0.0795 to 0.0803 in.)	2.26 to 2.28 mm (0.0890 to 0.0898 in.)
1.81 to 1.83 mm (0.0713 to 0.0720 in.)	2.05 to 2.07 mm (0.0807 to 0.0815 in.)	2.29 to 2.31 mm (0.0902 to 0.0909 in.)
1.84 to 1.86 mm (0.0724 to 0.0732 in.)	2.08 to 2.10 mm (0.0819 to 0.0827 in.)	2.32 to 2.34 mm (0.0913 to 0.0921 in.)
1.87 to 1.89 mm (0.0736 to 0.0744 in.)	2.11 to 2.13 mm (0.0831 to 0.0839 in.)	-
1.90 to 1.92 mm (0.0748 to 0.0756 in.)	2.14 to 2.16 mm (0.0843 to 0.0850 in.)	-

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

Using SST, remove 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.

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

SST

09556-22010

Remove the bearing spacer.

Install a new bearing spacer 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

Standard oil seal depth:

4.35 +-0.45 mm (0.1713 +-0.0177 in.)

Using SST, a steel plate and press, press in a new dust deflector.

SST

09636-20010

NOTICE:

Do not damage the dust deflector.

Place the companion flange on the drive pinion.

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

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.

Using SST to hold the companion flange in place, torque the nut.

SST

09330-00021(09330-00030)

Torque:

370 N*m{3,770 kgf*cm, 273 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.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

HINT:

Install the side bearing retainer within 10 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 of the backlash between the drive pinion and ring gear.

Standard preload (at start of torque):

Item	Specified Condition
New bearing	0.98 to 1.75 N*m (10 to 16 kgf*cm, 8.7 to 14 in.*lbf)
Reused bearing	0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)

1. If the preload is greater than the maximum, replace the bearing spacer.
   

1. If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.
   

Torque:

370 N*m{3,770 kgf*cm, 273 ft.*lbf}or less

1. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.
   

   HINT:

   Do not loosen the pinion nut to reduce the preload.

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

Standard total preload (at start of torque):

0.22 to 0.88 N*m (2 to 9 kgf*cm, 1.9 to 7.7 in.*lbf) + drive pinion 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 (0.0043 to 0.0083 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:

Runout	Specified Condition
Vertical runout	0.10 mm (0.0039 in.)
Lateral runout	0.10 mm (0.0039 in.)

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

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

Coat the lip of a new oil seal with MP grease.

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

SST

09608-32010

Standard oil seal depth:

0 +-0.45 mm (0 +-0.018 in.)

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 shaft.

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

Check that there is 2 to 3 mm (0.08 to 0.12 in.) of axial play.

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

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.

Seal packing:

Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

HINT:

Install the differential tube within 10 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.

Apply adhesive to 2 or 3 threads of each bolt's end.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the 4 bolts.

Torque:

110 N*m{1,120 kgf*cm, 81 ft.*lbf}