Rear Differential Carrier Assembly (W/ Differential Lock) Reassembly

Install the side gear thrust washer to the side gear.

Install the 4 rear differential pinion thrust washers to the 4 rear drive pinion gears.

Install the 4 rear differential pinion thrust washers and 4 rear drive pinion gears to the spider.

Fix the differential case RH.

Install the rear differential side gear and rear differential spider to the differential case RH.

Using a dial indicator, measure the differential case RH side backlash while holding the pinion toward the case.

Standard backlash:

0.05 to 0.20 mm (0.002 to 0.008 in.)

Remove the rear differential spider from the differential case RH.

Install the rear differential side gear and rear differential spider to the differential case LH.

Using a dial indicator, measure the differential case LH side backlash while holding the pinion toward the case.

Standard backlash:

0.05 to 0.20 mm (0.002 to 0.008 in.)

HINT:

Using the table below, select 2 thrust washers which will ensure that the backlash is within the specifications.

Standard washer thickness:

Thickness	Thickness
0.90 mm (0.035 in.)	1.20 mm (0.047 in.)
1.00 mm (0.039 in.)	1.30 mm (0.051 in.)
1.10 mm (0.043 in.)	-

Align the matchmarks and assemble the RH and LH cases.

Using a plastic-faced hammer, install the differential case.

Install the 8 bolts.

Torque:

47 N*m{480 kgf*cm, 35 ft.*lbf}

Clean the contact surfaces 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.

Temporarily install 5 new lock plates and 10 bolts.

After the ring gear cools down, install the 8 bolts by diametrically tightening the bolts uniformly in several passes.

Torque:

84 N*m{857 kgf*cm, 62 ft.*lbf}

Using a chisel and hammer, stake the 5 lock plates.

HINT:

Strike the tab labeled A so that it is flush with the flat surface of the bolt. Strike the tab labeled B so that half of the tab contacts the bolt as shown in the illustration.

Using SST and a press, press the bearing onto the differential case.

SST

09950-60010(09951-00430,09951-00480,09951-00470,09951-00550)
09950-70010(09951-07150,09951-00560,09951-00570)

Install the differential case on the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.

Install the 2 bearing caps with the 4 bolts.

Torque:

85 N*m{870 kgf*cm, 63 ft.*lbf}

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

Maximum runout:

0.07 mm (0.0028 in.)

Remove the 2 bearing caps, 2 adjusting nuts and differential case.

Using SST, a plate and press, press in the dust deflector.

SST

09636-20010

NOTICE:

Be careful not to damage the dust deflector.

Using SST and a press, press the roller bearing (outer) to the carrier.

SST

09316-60011(09316-00011,09316-00021)

Using SST and a press, press the roller bearing (outer) into the carrier.

SST

09316-60011(09316-00041,09316-00011)

Install the plate washer on the drive pinion.

HINT:

First fit a washer with the same thickness as the removed washer, and then check 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, rear drive pinion front tapered roller bearing and rear 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(09951-03010,09953-03010,09954-03010,09955-03030,09956-03040)

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 companion flange in place, torque the nut.

SST

09330-00021(09330-00030)

Torque:

370 N*m{3770 kgf*cm, 273 ft.*lbf}

NOTICE:

1. As there is no spacer, torque a little at a time. Be careful not to overtighten the nut.
   

1. Apply hypoid gear oil LSD to the nut.
   

Using a torque wrench, measure the preload.

Standard drive pinion preload (at start of torque):

Bearing	Preload
New bearing	1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf)
Reused bearing	0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 4.9 to 7.5 in.*lbf)

NOTICE:

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

Apply MP grease on the rack of the shift fork and connecting part of the indicator switch.

Insert the shift fork into the differential carrier, as shown in the illustration.

Place the outer race and adjusting nut on the left side of the sleeve.

HINT:

Check that the sleeve moves smoothly.

Install the shift fork in the groove of the sleeve holding it by hand, and install the case in the carrier.

HINT:

Make sure that there is backlash between the ring gear and drive pinion.

Install the 2 adjusting nuts on the carrier, making sure the nuts are threaded properly.

Align the matchmarks on the cap and carrier.

Install the right and left bearing caps with the 4 bolts.

Torque:

85 N*m{870 kgf*cm, 63 ft.*lbf}

1. If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly.
   

   HINT:

   Reinstall the adjusting nuts if necessary.

Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned by SST.

Using SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.).

SST

09504-00011
09960-10010(09962-01000,09963-00700)

While turning the ring gear, use SST to fully tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side.

SST

09504-00011
09960-10010(09962-01000,09963-00700)

Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

Using a dial indicator, adjust the ring gear backlash until it is within the specification.

Standard backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

1. The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.
   

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

Torque the bearing cap bolts.

Torque:

85 N*m{870 kgf*cm, 63 ft.*lbf}

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):

0.39 to 0.59 N*m (4 to 6 kgf*cm, 3.4 to 5.2 in.*lbf) + drive pinion preload

1. If necessary, disassemble and inspect the differential.
   

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

Hold the companion flange firmly in place and rotate the ring gear in both directions.

Inspect the tooth contact pattern.

1. 
   
   
   


2. If the teeth are not contacting properly, use the following chart to select a proper washer.
   

   Standard plate washer thickness:

   Thickness mm (in.)	Thickness mm (in.)
   1.69 to 1.71 (0.0665 to 0.0673)	2.02 to 2.04 (0.0795 to 0.0803)
   1.72 to 1.74 (0.0677 to 0.0685)	2.05 to 2.07 (0.0807 to 0.0815)
   1.75 to 1.77 (0.0689 to 0.0697)	2.08 to 2.10 (0.0819 to 0.0827)
   1.78 to 1.80 (0.0701 to 0.0709)	2.11 to 2.13 (0.0831 to 0.0839)
   1.81 to 1.83 (0.0713 to 0.0720)	2.14 to 2.16(0.0843 to 0.0850)
   1.84 to 1.86 (0.0724 to 0.0732)	2.17 to 2.19 (0.0854 to 0.0862)
   1.87 to 1.89 (0.0736 to 0.0744)	2.20to 2.22 (0.0866 to 0.0874)
   1.90 to 1.92 (0.0748 to 0.0756)	2.23 to 2.25 (0.0878 to 0.0886)
   1.93 to 1.95 (0.0760 to 0.0768)	2.26 to 2.28 (0.0890 to 0.0898)
   1.96 to 1.98 (0.0772 to 0.0780)	2.29 to 2.31 (0.0902 to 0.0909)
   1.99 to 2.01 (0.0783 to 0.0791)	2.32 to 2.34 (0.0913 to 0.0921)

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.

HINT:

If the bearing is damaged during removal, replace it.

Install a new bearing spacer to the drive pinion.

Using a brass bar and hammer, tap in a new oil storage ring.

NOTICE:

Be careful not to damage the oil storage ring.

for TMC Made:

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

   SST

   09554-30011
   

   Standard oil seal depth:

   0 +/-0.3 mm (0 +/-0.0118 in.)
   

2. Apply MP grease to the lip of the oil seal.
   

for DANA Made:

1. Using a brass bar and hammer, tap in a new oil seal until its surface is flush with the differential carrier end.
   

   NOTICE:

   Do not damage the oil seal.

2. Apply MP grease to the lip of the oil seal.
   

Using SST, install the companion flange on the drive pinion.

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.

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

Using SST to hold the flange, torque the nut.

SST

09330-00021(09330-00030)

Torque:

370 N*m{3770 kgf*cm, 273 ft.*lbf}or less

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

Standard drive pinion preload (at start of torque):

Bearing	Preload
New bearing	1.05 to 1.64 N*m (11 to 17 kgf*cm, 9.3 to 15 in.*lbf)
Reused bearing	0.56 to 0.85 N*m (6 to 9 kgf*cm, 4.9 to 7.5 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{3770 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.

Standard total preload (at start of torque):

0.39 to 0.59 N*m (4 to 6 kgf*cm, 3.4 to 5.2 in.*lbf) + drive pinion preload

1. If necessary, disassemble and inspect the differential.
   

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

Standard backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

1. If the backlash is not as specified, adjust the side bearing preload or repair as necessary.
   

   HINT:

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

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

Maximum runout:

Runout	Maximum
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 nut.

Install 2 new adjusting locks on the bearing caps with the 2 bolts.

Torque:

13 N*m{130 kgf*cm, 96 ft.*lbf}

Bend the nut locks.

HINT:

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

Apply MP grease onto the outer surface of the fork shaft.

Align the holes of the shift fork and shift fork shaft, and install the fork shaft.

Remove any seal packing material and be careful not to drop oil on the contacting surface of the differential carrier and shaft retainer.

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

Seal packing:

Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent

HINT:

Install the shaft retainer within 10 minutes after applying seal packing.

Clean the threads of the bolts and retainer bolts holes with toluene or trichloroethylene.

Apply adhesive to 2 or 3 threads of the mounting bolt end.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Tighten the shaft retainer with the 2 bolts.

Torque:

24 N*m{240 kgf*cm, 17 ft.*lbf}

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

Shift the fork to the lock side.

Install the steel ball, spring and spring seat.

Clean the threads of the 2 plug holes with toluene or trichloroethylene.

Apply adhesive to the plug threads.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a 6 mm hexagon wrench, install and tighten the screw plugs.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Measure the distance between the sleeve and tip of the differential case when the differential is free and locked.

Standard distance:

Position	Specified Condition
Lock	17.44 to 18.86 mm (0.6866 to 0.7425 in.)
Free	32.40 to 33.90 mm (1.2756 to 1.3346 in.)

Install the indicator switch and a new gasket.

Torque:

40 N*m{410 kgf*cm, 30 ft.*lbf}

Install a new O-ring to the actuator.

Install the actuator with the bolt.

Torque:

26 N*m{270 kgf*cm, 20 ft.*lbf}

Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole.

Ensure that the matchmarks on the pinion of the actuator are in the range between 0 and 5° clockwise above the center line of the actuator.

NOTICE:

1. If the matchmarks are not within this range, use dry cell batteries to rotate the pinion until the matchmarks are within the range.
   
2. Do not apply positive (+) battery voltage directly between the terminals.
   
3. If the matchmarks come to the limit of the rotation range, do not apply any more voltage.
   

Install a new O-ring to the actuator.

Apply a light coat of gear oil to the O-ring.

Apply MP grease to the gear parts.

Ensure that the outermost rack tooth of the shift fork fits the matchmarks on the pinion of the actuator.

Install the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side.

HINT:

Do not damage the O-ring of the actuator.

Align the actuator with the long hole and rotate the actuator counterclockwise when the knock pin is set to the right-hand side.

Install and tighten the bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}