Rear Differential Carrier Assembly (For Lsd) 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

  2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

  3. INSPECT DIFFERENTIAL RING GEAR BACKLASH

  4. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT

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

  6. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

  7. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  8. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  9. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

  10. REMOVE DIFFERENTIAL CASE ASSEMBLY

  11. REMOVE DIFFERENTIAL DRIVE PINION

  12. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  13. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

  14. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

  17. REMOVE DIFFERENTIAL RING GEAR

  18. INSPECT RUNOUT OF DIFFERENTIAL CASE

  19. REMOVE REAR DIFFERENTIAL CASE BEARING

  20. DISASSEMBLE DIFFERENTIAL CASE

  21. INSPECT REAR DIFFERENTIAL SIDE GEAR THRUST WASHER

  22. INSPECT CLUTCH PLATE

  23. INSPECT COMPRESSION SPRING

Rear Differential Carrier Assembly (For Lsd) -- Disassembly



1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

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

    Maximum Runout:
    Runout
    		Specified Condition
    Vertical runout
    		0.10 mm (0.00394 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 ring gear runout.

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


3. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

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

    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 DRIVE PINION COMPANION FLANGE REAR NUT


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) 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 (For Lsd) Disassembly

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

    SST
    09330-00021(09330-00030)


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


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Using SST, remove the companion flange.

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


6. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Using SST, remove the oil seal from the differential carrier.

    SST
    09308-10010


7. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


8. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Using SST, remove the front bearing (inner race) from the drive pinion.

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


9. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Remove the 2 bolts and 2 adjusting nut locks.



10. REMOVE DIFFERENTIAL CASE ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

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

  1. Remove the 4 bolts, 2 bearing caps, 2 adjusting nuts and 2 bearings (outer race).



    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Remove the differential case from the differential carrier.

    HINT:
    Tag the 2 case bearing outer races to show the location for reassembly.


11. REMOVE DIFFERENTIAL DRIVE PINION

  1. Remove the differential drive pinion from the differential carrier.



12. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


13. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Using SST and a press, press out the bearing (inner race).

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


14. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER


15. 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).



16. 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).



17. REMOVE DIFFERENTIAL RING GEAR


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) 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.



18. INSPECT RUNOUT OF DIFFERENTIAL CASE
HINT:
If the ring gear runout is at the maximum or less (refer to the "Inspect Runout of Differential Ring Gear" procedure), this inspection is not necessary.

  1. Install the differential case to the differential carrier.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

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

    Maximum 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 from the differential carrier.



19. REMOVE REAR DIFFERENTIAL CASE BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Using SST, remove the 2 side bearings (inner race) from the differential case.

    SST
    09950-00020
    09950-00030
    09950-40011(09957-04010)
    09950-60010(09951-00480)


20. DISASSEMBLE DIFFERENTIAL CASE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Rear Differential Carrier Assembly (For Lsd) Disassembly

  1. Place matchmarks on the differential case LH and RH.

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

  1. Using a plastic-faced hammer, separate the differential case LH and RH.

  1. Remove the 2 side gears, 6 side gear thrust washers, 4 clutch plates, 2 spring retainers, compression spring, 4 pinion gears, 4 pinion gear thrust washers and spider from the differential case.

    HINT:
    1. Keep the disassembled parts in order.
    2. If the side gear backlash has been adjusted by a TOYOTA dealer, adjusting shims are installed between the side gear thrust washer and the differential case.
    If replacing a side gear, also replace the thrust washer that contacts it.


21. INSPECT REAR DIFFERENTIAL SIDE GEAR THRUST WASHER
HINT:
If replacing the thrust washer, also replace the clutch plate that contacts it.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a micrometer, check that the thickness of the thrust washer is even.

    Thickness (Reference):
    1.97 to 2.06 mm (0.0776 to 0.0811 in.)
    If necessary, replace the thrust washer.

  1. Visually check the thrust washer.
    If bare metal is showing, replace the thrust washer.



22. INSPECT CLUTCH PLATE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a micrometer, check that the thickness of the clutch plate is even.

    Thickness (Reference):
    1.97 to 2.03 mm (0.0776 to 0.0799 in.)
    If necessary, replace the clutch plate.


23. INSPECT COMPRESSION SPRING


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using vernier caliper, measure the free length of the spring.

    Length (Reference):
    32.8 mm (1.29134 in.)
    If necessary, replace the compression spring.