Rear Differential Carrier Assembly (W/ Differential Lock) Reassembly

Install the rear differential side gear thrust washer to the rear differential side gear.

Install the rear differential pinion thrust washer and rear differential pinion to the rear differential spider.

Fix the differential case RH in place.

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 pushing the pinion toward the case.

Standard backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 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 pushing the pinion toward the case.

Standard Backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

Standard Thrust Washer:

Thickness	Thickness
0.88 to 0.92 mm (0.0346 to 0.0362 in.)	1.18 to 1.22 mm (0.0465 to 0.0480 in.)
0.98 to 1.02 mm (0.0386 to 0.0402 in.)	1.28 to 1.32 mm (0.0504 to 0.0520 in.)
1.08 to 1.12 mm (0.0425 to 0.0441 in.)	-

Align the matchmarks and assemble the differential case from the RH and LH cases.

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

Install the 8 bolts.

Torque:

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

Clean the contact surfaces of the differential case and ring gear.

Heat the ring gear to approximately 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 install the ring gear to the differential case.

Align the matchmarks on the ring gear and differential case.

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

Adhesive:

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

Torque:

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

Using SST and a press, install the bearing to the differential case.

SST

09308-14010
09950-60010(09951-00490)

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

Install the 2 bearing caps with the 4 bolts.

Torque:

102.9 N*m{1049 kgf*cm, 76 ft.*lbf}

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

Maximum runout:

0.07 mm (0.00276 in.)

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

Using SST and a press, install the tapered roller bearing to the carrier.

SST

09308-14010
09309-14040

Install the plate washer to the carrier.

HINT:

First, install 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, install the tapered roller bearing to the carrier.

SST

09950-70010(09951-07200)
09255-10012

Using SST and a press, install the tapered roller bearing to the drive pinion.

SST

09506-30012

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

HINT:

Install the spacer and oil seal after adjusting the gear contact pattern.

Using SST, install the drive pinion 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.

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

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

Limit Torque Value:

457 N*m (4660 kgf*cm, 337ft.*lbf) or less

NOTICE:

1. As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
   
2. Apply hypoid gear oil LSD to drive pinion thread and seat face.
   

Using a torque wrench, measure the preload.

Standard Preload (at Starting):

Item	Specified Condition
New bearing	0.68 to 2.03 N*m (7 to 20 kgf*cm, 7 to 17 in.*lbf)
Used bearing	0.73 to 1.83 N*m (8 to 18 kgf*cm, 7 to 16 in.*lbf)

NOTICE:

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

Place the 2 bearing outer races on their respective bearings.

HINT:

Do not interchange the right and left races.

Install the 2 adjusting nuts to 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:

102.9 N*m{1049 kgf*cm, 76 ft.*lbf}

HINT:

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

Reinstall the adjusting nuts if necessary.

Tighten the 4 bearing cap bolts to the specified torque, and then loosen them to the point where the adjusting nuts can be turned by SST.

Torque:

102.9 N*m{1049 kgf*cm, 76 ft.*lbf}

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

SST

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

While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side.

HINT:

After the bearings have settled, loosen the adjusting nut on the drive pinion side.

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

SST

09504-00011

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

Standard backlash (reference):

0.10 to 0.20 mm (0.00394 to 0.00787 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.
   
2. Perform the measurement at 3 or more positions around the circumference of the ring gear.
   

Tighten the bearing cap bolts.

Torque:

102.9 N*m{1049 kgf*cm, 76 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 starting):

Item	Specified Condition
New bearing	0.88 to 2.43 N*m (9 to 24 kgf*cm, 8 to 21 in.*lbf)
Used bearing	0.93 to 2.23 N*m (10 to 22 kgf*cm, 9 to 19 in.*lbf)

NOTICE:

Record the differential ring gear preload.

Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

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

Inspect the tooth contact pattern.

1. 
   
   
   
2. 
   

   Text in Illustration

   *A	Drive Side	*B	Coast Side
   *a	Proper Contact	*b	Toe Contact
   *c	Face Contact	*d	Select an adjusting washer that will shift the drive pinion closer to the ring gear.
   *e	Heel Contact	*f	Flank Contact
   *g	Select an adjusting washer that will shift the drive pinion away from the ring gear.	*h	Heel Contact
   *i	Flank Contact	*j	Toe Contact
   *k	Face Contact	-	-

If the teeth are not engaged properly, use the following chart to select an appropriate washer for correction.

Standard Plate Washer:

Mark	Thickness	Mark	Thickness
29	1.84 to 1.86 mm (0.0725 to 0.0732 in.)	53	2.08 to 2.10 mm (0.0819 to 0.0826 in.)
31	1.86 to 1.88 mm (0.0733 to 0.0740 in.)	55	2.10 to 2.12 mm (0.0827 to 0.0834 in.)
33	1.88 to 1.90 mm (0.0741 to 0.0748 in.)	57	2.12 to 2.14 mm (0.0835 to 0.0842 in.)
35	1.90 to 1.92 mm (0.0749 to 0.0755 in.)	59	2.14 to 2.16 mm (0.0843 to 0.0850 in.)
37	1.92 to 1.94 mm (0.0756 to 0.0763 in.)	61	2.14 to 2.16 mm (0.0843 to 0.0850 in.)
39	1.94 to 1.96 mm (0.0764 to 0.0771 in.)	63	2.18 to 2.20 mm (0.0859 to 0.0866 in.)
41	1.96 to 1.98 mm (0.0772 to 0.0779 in.)	65	2.20 to 2.22 mm (0.0867 to 0.0874 in.)
43	1.98 to 2.00 mm (0.0780 to 0.0787 in.)	67	2.22 to 2.24 mm (0.0875 to 0.0881 in.)
45	2.00 to 2.02 mm (0.0788 to 0.0795 in.)	69	2.24 to 2.26 mm (0.0882 to 0.0889 in.)
47	2.02 to 2.04 mm (0.0796 to 0.0803 in.)	71	2.26 to 2.28 mm (0.0890 to 0.0897 in.)
49	2.04 to 2.06 mm (0.0804 to 0.0811 in.)	73	2.28 to 2.30 mm (0.0898 to 0.0905 in.)
51	2.06 to 2.08 mm (0.0812 to 0.0818 in.)	75	2.30 to 2.32 mm (0.0906 to 0.0913 in.)

Using SST to hold the drive pinion companion flange, remove the nut.

SST

09330-00021

Using SST, remove the drive pinion companion flange.

SST

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

Install a new bearing spacer to the drive pinion.

Using SST, tap in a new oil storage ring.

SST

09308-14010

Apply MP grease to the oil seal lip.

Using SST and a hammer, install a new carrier oil seal.

SST

09214-76011

Standard oil seal drive in depth:

-0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

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

SST

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

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

Limit Torque Value:

457 N*m (4660 kgf*cm, 337ft.*lbf) or less

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

Standard Preload (at Starting):

Item	Specified Condition
New bearing	0.83 to 2.18 N*m (9 to 22 kgf*cm, 8 to 19 in.*lbf)
Reused bearing	0.88 to 1.98 N*m (9 to 20 kgf*cm, 8 to 17 in.*lbf)

Limit Torque Value:

457 N*m (4660 kgf*cm, 337ft.*lbf) or less

HINT:

Do not loosen the pinion nut to reduce the preload.

Using a torque wrench, measure the preload.

Standard total preload (at starting):

Item	Specified Condition
New bearing	1.03 to 2.58 N*m (11 to 26 kgf*cm, 10 to 22 in.*lbf)
Reused bearing	1.08 to 2.38 N*m (12 to 24 kgf*cm, 10 to 21 in.*lbf)

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

Standard Backlash:

0.10 to 0.20 mm (0.00394 to 0.00787 in.)

HINT:

Perform the measurement 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.

Distance from center to runout measurement point:

30 mm (1.18 in.)

Maximum Runout:

Item	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 drive pinion nut.

Install 2 new adjusting nut locks to the bearing caps with the 2 bolts.

Torque:

12.7 N*m{130 kgf*cm, 9 ft.*lbf}

After tightening the bolts, bend the nut locks.

Apply MP grease to shaft.

Install the fork shaft so that the hole of the shift fork shaft aligns with that of the shift fork.

Remove any FIPG material and be careful not to drop the oil 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

FIPG Width:

Approx. 1 to 2 mm (0.0394 to 0.0787 in.)

HINT:

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

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

Apply adhesive to 2 or 3 threads at the tip of each mount bolt.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the shaft retainer with the 2 bolts.

Torque:

23.2 N*m{237 kgf*cm, 17 ft.*lbf}

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

Using a 6 mm hexagon wrench, install the screw plug.

Torque:

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

Push the differential lock sleeve in deeply and hold it in position.

Install the ball, spring and spring seat.

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

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a 6 mm hexagon wrench, install the screw plug.

Torque:

23.2 N*m{237 kgf*cm, 17 ft.*lbf}

Install the indicator switch together with a new gasket.

Torque:

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

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

Standard distance:

Locked: 17.45 to 18.85 mm (0.687 to 0.742 in.)

Free: 32.40 to 33.90 mm (1.276 to 1.334 in.)

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

Make sure that the matchmarks on the pinion of the actuator are in the range of 0 to 5 degrees clockwise from the center line of the actuator.

NOTICE:

1. If the matchmarks are not within this range, rotate the pinion.
   
2. Do not apply positive battery voltage directly to the terminals.
   
3. If the matchmarks move to the limit of rotation, stop applying electric current.
   

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.

Mack sure that the outermost rack tooth of the shift fork aligns with the matchmarks on the pinion of the actuator.

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

HINT:

Do not damage the O-ring of the actuator.

Rotate the actuator counterclockwise so that the knock pin slides to the end of the hole as shown in the illustration.

Install the bolts.

Torque:

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