RM36D0EC _52 Drivetrain _083071 AXLE AND DIFFERENTIAL _0402906 REAR DIFFERENTIAL CARRIER ASSEMBLY A

AXLE AND DIFFERENTIAL  REAR DIFFERENTIAL CARRIER ASSEMBLY  REASSEMBLY  


CAUTION / NOTICE / HINT

NOTICE:

Steps 10 to 17 are temporary reassembly procedures for adjustment purposes.


PROCEDURE

Hide 1.INSTALL STRAIGHT PIN

a.

Using a plastic-faced hammer, install the 4 straight pins to the rear differential carrier sub-assembly.

C279493C01
3,1.75 3.313,1.948 0.313,0.198 10 *a 6.906,1.75 7.125,2.135 0.219,0.385 10 *a
*a 8.0 to 9.0 mm (0.315 to 0.354 in.) - -



Hide 41183 2.INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

a.
C110156C01
1.188,1.031 1.188,0.115 false 1.188,0.115 0.969,0.115 false 0.802,0.021 1.167,0.385 0.365,0.365 10 *a
*a Arrow Mark


Using a 5 mm socket hexagon wrench, install the rear differential breather plug oil deflector with the 2 bolts.

Torque:
5.0 N*m (51 kgf*cm, 44 in.*lbf)

NOTICE:

Make sure that the arrow mark faces the front (transmission coupling side) of the vehicle.



Hide 3.INSTALL DIFFERENTIAL RING GEAR

a.

Clean the contact surfaces of the rear differential case sub-assembly and differential ring gear.


b.
C170428C03
1.464,0.28 1.639,0.449 0.174,0.168 10 *a 0.885,0.66 1.42,0.399 false
*a 100°C (212°F)


Clean the ring gear set bolt hole.


c.

Heat the differential ring gear to approximately 100°C (212°F) in boiling water.


d.
C326860

Carefully take the differential ring gear out of the boiling water.

CAUTION:

Use thick gloves to protect your hands as the differential ring gear is hot.



e.
C130563C06
0.885,1.781 1.542,1.302 false 0.896,1.771 1.531,1.406 false 0.74,1.76 1.052,2.063 0.313,0.302 10 *a
*a Matchmark


After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the rear differential case sub-assembly.


f.

Align the matchmarks of the rear differential case sub-assembly and differential ring gear, and then install the differential ring gear.


g.

Secure the rear differential case sub-assembly between aluminum plates in a vise.

NOTICE:

Do not overtighten the vise.



h.

Install 10 new rear differential case bolts.

Torque:
90 N*m (918 kgf*cm, 66 ft.*lbf)

NOTICE:
·

The new bolts are coated with heat resistant oil. Do not clean off this coating.

·

Install the bolts tightening diametrically opposite bolts uniformly in several passes.




Hide 41301A 4.INSTALL REAR DIFFERENTIAL CASE BEARING LH

a.
C130601E02
0.563,1.333 0.875,1.323 false 0.25,1.25 0.708,1.448 0.458,0.198 10 SST

Using SST and a press, press the rear differential case bearing LH (inner race) onto the rear differential case sub-assembly.

SST
09223-50010  

NOTICE:
·

If the rear differential case bearing LH (inner race) is damaged, replace the rear differential case bearing LH (inner race) and rear differential case bearing LH (outer race) with new ones as a set.

·

If reusing a bearing, coat it with Toyota Genuine Differential gear oil LX SAE 75W-85 API GL-5 or equivalent.




Hide 41301A 5.INSTALL REAR DIFFERENTIAL CASE BEARING RH

a.
C130600E02
0.635,1.313 1,1.313 false 0.323,1.24 0.781,1.438 0.458,0.198 10 SST

Using SST and a press, press the rear differential case bearing RH (inner race) onto the rear differential case sub-assembly.

SST
09223-50010  

NOTICE:
·

If the rear differential case bearing RH (inner race) is damaged, replace the rear differential case bearing RH (inner race) and outer race with new ones as a set.

·

If reusing a bearing, coat it with Toyota Genuine Differential gear oil LX SAE 75W-85 API GL-5 or equivalent.




Hide 41301A 6.INSTALL REAR DIFFERENTIAL CASE BEARING LH

a.
C110161C01
0.531,0.656 0.969,0.656 false 0.531,0.656 0.896,1.344 false 1.99,1.635 1.99,1.531 1.99,1.531 2.25,1.281 false 2.625,1.656 2.448,1.656 2.448,1.656 2.354,1.365 false 0.25,0.594 0.708,0.792 0.458,0.198 10 false SST 1.948,1.667 2.26,1.865 0.313,0.198 10 false *2 2.677,1.573 2.99,1.771 0.313,0.198 10 false *1
*1 Rear Differential Side Gear Shaft Washer
*2 Rear Differential Case Bearing LH (Outer Race)


Using SST and a press, press the rear differential side gear shaft washer and rear differential case bearing LH (outer race) into the differential side bearing retainer.

SST
09950-60011  (09951-00510, 09951-00620, 09952-06010)
09950-70010  (09951-07100)

NOTICE:
·

Use the removed rear differential side gear shaft washer or use one of the same thickness.

·

When replacing a bearing, replace the rear differential case bearing LH (inner race) and rear differential case bearing LH (outer race) races as a set.

·

Press in the bearing and washer until they are fit against the end.

·

Do not place any load on the rolling contact surface of the bearing.

·

Install the rear differential side gear shaft oil seal after performing the teeth contact check and backlash adjustment.




Hide 41301A 7.INSTALL REAR DIFFERENTIAL CASE BEARING RH

a.
C110162C01
2.156,1.635 2.156,1.5 2.156,1.5 2.375,1.26 false 2.458,1.354 2.583,1.646 2.583,1.646 2.719,1.646 false 2.115,1.677 2.427,1.875 0.313,0.198 10 *2 2.771,1.594 3.083,1.792 0.313,0.198 10 *1
*1 Rear Differential Side Gear Shaft Washer
*2 Rear Differential Case Bearing RH (Outer Race)


Using SST and a press, press the rear differential side gear shaft washer and rear differential case bearing RH (outer race) into the rear differential carrier sub-assembly.

SST
09950-60011  (09951-00510, 09951-00620, 09952-06010)
09950-70010  (09951-07150)

NOTICE:
·

Use the removed rear differential side gear shaft washer or use one of the same thickness.

·

When replacing a rear differential case bearing RH, replace the rear differential case bearing RH (inner race) and rear differential case bearing RH (outer race) races as a set.

·

Press in the bearing and washer until they are fit against the end.

·

Do not place any load on the rolling contact surface of the bearing.

·

Install the rear differential side gear shaft oil seal after performing the teeth contact check and backlash adjustment.




Hide 41201B 8.INSTALL REAR DRIVE PINION FRONT BEARING

a.
C110307C01
0.469,0.417 0.906,0.885 false 0.469,0.427 0.781,1.188 false 2.823,1.708 3.021,1.708 3.021,1.708 3.021,1.479 false 0.208,0.323 0.667,0.521 0.458,0.198 10 SST 2.677,1.635 2.99,1.833 0.313,0.198 10 *1
*1 Rear Drive Pinion Front Tapered Roller Bearing (Outer Race)


Using SST and a press, press the rear drive pinion front tapered roller bearing (outer race) into the rear differential carrier sub-assembly.

SST
09950-60011  (09951-00550)
09950-60021  (09951-00680, 09952-06010)
09950-70010  (09951-07100)

NOTICE:

When replacing a rear drive pinion front tapered roller bearing (outer race), replace the inner and outer races as a set.



Hide 41201A 9.INSTALL REAR DRIVE PINION REAR BEARING

a.
C274521C01
1.333,3.469 1.333,2.885 1.333,2.885 0.792,2.896 false 0.677,4.26 1.281,4.26 1.281,4.26 1.281,3.938 false 1.281,4.146 1.385,4.146 1.385,4.146 1.375,3.844 false 1.635,2.281 1.948,2.479 0.313,0.198 10 *a 0.333,0.865 0.646,1.063 0.313,0.198 10 *b 0.5,2.823 0.958,3.021 0.458,0.198 10 SST 0.365,4.167 0.823,4.365 0.458,0.198 10 SST
*a Turn
*b Hold


Using SST, bolts, nuts, and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier sub-assembly.

SST
09950-60011  (09951-00600)
09950-60021  (09951-00680, 09951-00750)

NOTICE:

When replacing the rear drive pinion rear tapered roller bearing (outer race), replace the inner and outer races as a set.


HINT:

Use M12 x P1.25 bolts with shaft lengths of 186 mm (part No. 90101-12159) and M12 x p1.25 nuts (part No. 90179-12051) for the installation.



Hide 41201A 10.INSTALL REAR DRIVE PINION REAR BEARING

a.

Install the rear differential drive pinion washer to the differential drive pinion.

NOTICE:

Use the removed rear differential drive pinion washer or use one of the same thickness.



b.
C130604E04
1.375,1.594 1.198,1.594 1.198,1.594 1.198,1.396 false 2.469,1.396 2.469,0.948 false 1.417,1.521 1.875,1.719 0.458,0.198 10 SST 2.344,1.427 2.802,1.625 0.458,0.198 10 SST

Using SST and a press, press the rear drive pinion rear tapered roller bearing (inner race) into the differential drive pinion.

SST
09506-30012  


Hide 41231 11.INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

a.
C110146

Install the rear differential drive pinion bearing spacer to the differential drive pinion.

NOTICE:

Install the removed rear differential drive pinion bearing spacer, as this is a temporary installation for adjustment.



Hide 12.ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

a.

Install the differential drive pinion (with rear drive pinion rear tapered roller bearing inner race) to the rear differential carrier sub-assembly.


b.

Install the rear drive pinion front tapered roller bearing (inner race) and a new rear drive pinion nut to the differential drive pinion.

NOTICE:
·

New bearings are coated with anti-rust oil. If using new bearings, do not clean off this coating.

·

If reusing a bearing, coat it with Toyota Genuine Differential gear oil LX SAE 75W-85 API GL-5 or equivalent.




c.
C316082C01
2.615,1.781 2.927,1.938 0.313,0.156 10 false *a 0.094,0.875 0.406,1.031 0.313,0.156 10 false *b 2.073,0.365 2.385,0.521 0.313,0.156 10 false *c
*a Turn
*b Hold
*c Torque Wrench Fulcrum Length


Using SST and torque wrench, gradually tighten a new drive pinion nut within the adjustment range of the differential drive pinion preload.

SST
09556-16011  09564-16020  

Torque:
Specified tightening torque:

245 N*m (2498 kgf*cm, 181 ft.*lbf) or less


HINT:
·

This torque value is effective when SST is straight to a torque wrench.

·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 600 mm (1.97 ft.)): 226 N*m (2305 kgf*cm, 167 ft.*lbf) or less.




d.
C110311E01
2.388,0.986 2.68,1.145 0.292,0.159 10 SST 2.334,1.077 1.491,1.077 false

Using SST and a torque wrench, measure the preload (starting torque) of the differential drive pinion.

SST
09556-52010  

Standard Drive Pinion Preload (starting torque):
Bearing Preload
New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12 to 19 in.*lbf)
Reused bearing 0.77 to 1.26 N*m (8 to 12 kgf*cm, 7 to 11 in.*lbf)


NOTICE:
·

Measure the preload after rotating the bearing several times in the forward and backward directions to make sure the bearing is operating correctly.

·

Record the preload measurement for use with the total preload inspection.




Hide 41301 13.INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY

a.
C110144

Install the rear differential case sub-assembly to the rear differential carrier sub-assembly.


Hide 14.INSTALL DIFFERENTIAL SIDE BEARING RETAINER

a.

Using a scraper, clean the seal packing from the rear differential carrier sub-assembly and differential side bearing retainer, and remove any oil using a cleaning solvent.

NOTICE:

Do not scratch the installation area.



b.
C285334

Install the differential side bearing retainer to the rear differential carrier sub-assembly with the 8 bolts.

Torque:
34.3 N*m (350 kgf*cm, 25 ft.*lbf)


Hide 15.ADJUST DIFFERENTIAL RING GEAR BACKLASH

a.
C110134C10
0.635,1.219 0.76,1.219 false 0.76,1.219 0.823,1.323 false 0.792,3.448 0.792,3.781 false 0.292,1.125 0.594,1.302 0.302,0.177 10 SST 0.625,3.792 0.927,3.969 0.302,0.177 10 SST 2.156,1.875 2.469,2.073 0.313,0.198 10 *a 0.427,3.073 0.74,3.271 0.313,0.198 10 *b
*a Turn
*b Hold


Insert a dial indicator through the rear differential side gear shaft oil seal hole, and set it perpendicular to the edge of a differential ring gear tooth.


b.

Using SST, secure the differential drive pinion.

SST
09556-52010  


c.

Using SST, measure the backlash while rotating the rear differential case sub-assembly forward and in reverse.

SST
09564-32011  

Standard:

0.088 to 0.208 mm (0.00347 to 0.00818 in.)


NOTICE:

Measure the ring gear at 3 or more locations.



d.

If the result is not within the specified range, select and install a rear differential side gear shaft washer from the table below.

HINT:
·

Adjust the thickness of the LH and RH differential side gear shaft washers by the same amount each time until the backlash is within the standard range. If the thickness on the LH side is increased, decrease the thickness on the RH side, and if the thickness on the LH side is decreased, increase the thickness on the RH side.

·

If the backlash is small, select a thick washer for the RH side and a thin washer for the LH side.

·

If the backlash is large, select a thin washer for the RH side and a thick washer for the LH side.



Rear Differential Side Gear Shaft Washer Type:
Part No. Thickness Identifying Mark Part No. Thickness Identifying Mark
90564-37022 1.59 to 1.61 mm (0.0625 to 0.0633 in.) A0 90564-37040 2.13 to 2.15 mm (0.0839 to 0.0846 in.) B8
90564-37023 1.62 to 1.64 mm (0.0637 to 0.0645 in.) A1 90564-37041 2.16 to 2.18 mm (0.0850 to 0.0858 in.) B9
90564-37024 1.65 to 1.67 mm (0.0650 to 0.0657 in.) A2 90564-37042 2.19 to 2.21 mm (0.0862 to 0.0870 in.) C0
90564-37025 1.68 to 1.70 mm (0.0661 to 0.0669 in.) A3 90564-37043 2.22 to 2.24 mm (0.0874 to 0.0882 in.) C1
90564-37026 1.71 to 1.73 mm (0.0673 to 0.0681 in.) A4 90564-37044 2.25 to 2.27 mm (0.0886 to 0.0894 in.) C2
90564-37027 1.74 to 1.76 mm (0.0685 to 0.0693 in.) A5 90564-37045 2.28 to 2.30 mm (0.0898 to 0.0906 in.) C3
90564-37028 1.77 to 1.79 mm (0.0697 to 0.0705 in.) A6 90564-37046 2.31 to 2.33 mm (0.0909 to 0.0917 in.) C4
90564-37029 1.80 to 1.82 mm (0.0709 to 0.0717 in.) A7 90564-37047 2.34 to 2.36 mm (0.0921 to 0.0929 in.) C5
90564-37030 1.83 to 1.85 mm (0.0720 to 0.0728 in.) A8 90564-37048 2.37 to 2.39 mm (0.0933 to 0.0941 in.) C6
90564-37031 1.86 to 1.88 mm (0.0732 to 0.0740 in.) A9 90564-37049 2.40 to 2.42 mm (0.0945 to 0.0953 in.) C7
90564-37032 1.89 to 1.91 mm (0.0744 to 0.0752 in.) B0 90564-37050 2.43 to 2.45 mm (0.0957 to 0.0965 in.) C8
90564-37033 1.92 to 1.94 mm (0.0756 to 0.0764 in.) B1 90564-37051 2.46 to 2.48 mm (0.0969 to 0.0976 in.) C9
90564-37034 1.95 to 1.97 mm (0.0768 to 0.0776 in.) B2 90564-37052 2.49 to 2.51 mm (0.0980 to 0.0988 in.) D0
90564-37035 1.98 to 2.00 mm (0.0780 to 0.0787 in.) B3 90564-37053 2.52 to 2.54 mm (0.0992 to 0.1000 in.) D1
90564-37036 2.01 to 2.03 mm (0.0792 to 0.0799 in.) B4 90564-37054 2.55 to 2.57 mm (0.1004 to 0.1012 in.) D2
90564-37037 2.04 to 2.06 mm (0.0803 to 0.0811 in.) B5 90564-37055 2.58 to 2.60 mm (0.1016 to 0.1024 in.) D3
90564-37038 2.07 to 2.09 mm (0.0815 to 0.0822 in.) B6 90564-37056 2.61 to 2.63 mm (0.1028 to 0.1035 in.) D4
90564-37039 2.10 to 2.12 mm (0.0827 to 0.0834 in.) B7 90564-37057 2.64 to 2.66 mm (0.1040 to 0.1047 in.) D5



Hide 16.ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

a.

Remove the 8 bolts and differential side bearing retainer from the rear differential carrier sub-assembly.


b.

Remove the rear differential case sub-assembly.


c.

Uniformly apply a light coat of Prussian Blue on both sides of the differential ring gear teeth.


d.

Install the rear differential case sub-assembly.


e.

Temporarily install the differential side bearing retainer to the differential carrier sub-assembly with the 8 bolts.


f.

Rotate the differential drive pinion several times.


g.

Remove the 8 bolts and differential side bearing retainer from the rear differential carrier sub-assembly.


h.

Check the tooth contact pattern of the differential drive pinion and differential ring gear.

C247128C02
0.313,0.927 0.625,1.125 0.313,0.198 10 *a 2.563,0.083 2.875,0.281 0.313,0.198 10 *b 4.844,0.063 5.156,0.26 0.313,0.198 10 *c 3.667,1.479 3.979,1.677 0.313,0.198 10 *d 2.656,1.99 2.969,2.188 0.313,0.198 10 *e 4.875,2.042 5.188,2.24 0.313,0.198 10 *f 3.708,3.281 4.021,3.479 0.313,0.198 10 *g
*a Proper Contact *b Heel Contact
*c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
*e Toe Contact *f Flank Contact
*g Select an adjusting washer that will shift the drive pinion away from the ring gear (*e, *f) - -


NOTICE:

Check the tooth contact pattern at 2 or more positions around circumference of the differential ring gear.



i.

In instances of face contact or flank contact, perform the following procedure.

i.

Move and adjust the differential ring gear using the rear differential side gear shaft washer.

HINT:

Adjust the thickness of the LH and RH rear differential side gear shaft washers by the same amount each time. If the thickness on the LH side is increased, decrease the thickness on the RH side, and if the thickness on the LH side is decreased, increase the thickness on the RH side.




j.

In instances of heel contact or toe contact, perform the following procedure.

i.

Select a rear differential drive pinion washer from the table below, and move and adjust the drive pinion.

Rear Differential Drive Pinion Washer:
Part No. Thickness Identifying Mark Part No. Thickness Identifying Mark
90564-35041 1.695 to 1.705 mm (0.0667 to 0.0671 in.) 41 90564-35071 1.955 to 1.965 mm (0.0770 to 0.0774 in.) 71
90564-35043 1.715 to 1.725 mm (0.0675 to 0.0679 in.) 43 90564-35073 1.975 to 1.985 mm (0.0778 to 0.0781 in.) 73
90564-35045 1.735 to 1.745 mm (0.0683 to 0.0687 in.) 45 90564-35075 1.995 to 2.005 mm (0.0785 to 0.0789 in.) 75
90564-35047 1.755 to 1.765 mm (0.0690 to 0.0695 in.) 47 90564-35077 2.015 to 2.025 mm (0.0793 to 0.0797 in.) 77
90564-35049 1.775 to 1.785 mm (0.0699 to 0.0703 in.) 49 90564-35079 2.035 to 2.045 mm (0.0801 to 0.0805 in.) 79
90564-35051 1.795 to 1.805 mm (0.0707 to 0.0711 in.) 51 90564-35081 2.055 to 2.065 mm (0.0809 to 0.0813 in.) 81
90564-35053 1.815 to 1.825 mm (0.0715 to 0.0719 in.) 53 90564-35083 2.075 to 2.085 mm (0.0817 to 0.0821 in.) 83
90564-35055 1.835 to 1.845 mm (0.0722 to 0.0726 in.) 55 90564-35085 2.095 to 2.105 mm (0.0825 to 0.0829 in.) 85
90564-35057 1.855 to 1.865 mm (0.0730 to 0.0734 in.) 57 90564-35087 2.115 to 2.125 mm (0.0833 to 0.0837 in.) 87
90564-35059 1.875 to 1.885 mm (0.0738 to 0.0742 in.) 59 90564-35089 2.135 to 2.145 mm (0.0841 to 0.0844 in.) 89
90564-35061 1.895 to 1.905 mm (0.0746 to 0.0750 in.) 61 90564-35091 2.155 to 2.165 mm (0.0848 to 0.0852 in.) 91
90564-35063 1.915 to 1.925 mm (0.0754 to 0.0758 in.) 63 90564-35093 2.175 to 2.185 mm (0.0856 to 0.0860 in.) 93
90564-35065 1.935 to 1.945 mm (0.0762 to 0.0766 in.) 65 90564-35095 2.195 to 2.205 mm (0.0864 to 0.0868 in.) 95




k.

If the tooth contact pattern has been adjusted, recheck the backlash, preload and tooth contact pattern.


Hide 17.INSPECT TOTAL PRELOAD

a.
C110135E01
0.46,0.414 0.757,0.573 0.297,0.159 10 SST 0.843,0.495 1.1,0.495 false 1.1,0.495 1.339,0.705 false

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

SST
09556-52010  

NOTICE:

Measure the preload after rotating the case bearing several times in the forward and backward directions to make sure the bearing is operating correctly.


Standard drive pinion preload:
Item Specified Condition
New bearing Drive pinion preload + 1.18 to 1.90 N*m (12 to 19 kgf*cm, 11 to 16 in.*lbf)
Reused bearing Drive pinion preload + 0.58 to 1.01 N*m (6 to 10 kgf*cm, 5 to 8 in.*lbf)



b.

If the result is not within the specified range, perform the following procedures.

i.

Select and install another side gear shaft washer RH.


ii.

Recheck the backlash, preload and tooth contact pattern.



Hide 18.REMOVE DIFFERENTIAL SIDE BEARING RETAINER

a.
C285334

Remove the 8 bolts and differential side bearing retainer from the rear differential carrier sub-assembly.


Hide 41301 19.REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

a.
C110144

Remove the rear differential case sub-assembly from the rear differential carrier sub-assembly.


Hide 20.REMOVE DIFFERENTIAL DRIVE PINION

a.

Remove the differential drive pinion from the rear differential carrier sub-assembly.


b.

Remove the rear differential drive pinion bearing spacer from the differential drive pinion.


Hide 41231 21.INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

a.
C110146

Install a new rear differential drive pinion bearing spacer to the differential drive pinion.


Hide 22.INSTALL DIFFERENTIAL DRIVE PINION

a.
C110145

Install the differential drive pinion to the rear differential carrier sub-assembly.


Hide 41204B 23.TEMPORARILY TIGHTEN REAR DRIVE PINION NUT

a.

Apply hypoid gear oil LSD to the threads of the rear drive pinion nut and its seating surface.


b.
C259901C03
1.438,1.146 0.719,1.615 0.719,1.615 1.5,0.667 true 0.313,1.042 0.625,1.24 0.313,0.198 10 *b 0.5,1.688 0.958,1.885 0.458,0.198 10 SST 2.417,1.625 2.729,1.823 0.313,0.198 10 *a
*a Turn
*b Hold


Using SST, temporarily tighten the rear drive pinion nut to the differential drive pinion.

SST
09556-16011  09564-16020  


Hide 24.ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

a.
C110311E01
2.388,0.986 2.68,1.145 0.292,0.159 10 SST 2.334,1.077 1.491,1.077 false

Using SST and a torque wrench, check the starting torque.

SST
09556-52010  

NOTICE:
·

Adjust the preload after rotating the case bearing several times in the forward and backward directions to make sure the bearing is operating correctly.

·

Adjust the preload so that it matches the drive pinion temporary adjustment starting torque.



Standard drive pinion preload:
Bearing Specified Condition
New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12 to 19 in.*lbf)
Reused bearing 0.77 to 1.26 N*m (8 to 12 kgf*cm, 7 to 11 in.*lbf)



b.
C316082C01
2.615,1.781 2.927,1.938 0.313,0.156 10 false *a 0.094,0.875 0.406,1.031 0.313,0.156 10 false *b 2.073,0.365 2.385,0.521 0.313,0.156 10 false *c
*a Turn
*b Hold
*c Torque Wrench Fulcrum Length


If the preload is insufficient, use SST to tighten the drive pinion nut 5 to 10° at a time. Measure the starting torque and repeat the adjustment as necessary until the preload matches the specified torque.

SST
09556-52010  09564-16020  


c.

If the tightening torque of the rear drive pinion nut exceeds 245 N*m but the preload is still insufficient, loosen the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.

HINT:
·

This torque value is effective when SST is straight to a torque wrench.

·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 600 mm (1.97 ft.)): 226 N*m (2305 kgf*cm, 167 ft.*lbf) or less.




d.

If there are no problems, replace the rear differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.


Hide 41301 25.INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY

a.
C110144

Install the rear differential case sub-assembly to the rear differential carrier sub-assembly.


Hide 26.INSTALL DIFFERENTIAL SIDE BEARING RETAINER

a.
C285334

Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

Torque:
34.3 N*m (350 kgf*cm, 25 ft.*lbf)


Hide 27.INSPECT DIFFERENTIAL RING GEAR BACKLASH

a.
C110134C11
0.615,1.375 0.823,1.375 false 0.844,3.469 0.781,3.677 false 0.323,1.292 0.75,1.573 0.427,0.281 10 SST 0.677,3.698 1.104,3.979 0.427,0.281 10 SST 0.396,2.99 0.563,3.156 0.167,0.167 10 *b 2.417,1.979 2.573,2.146 0.156,0.167 10 *a
*a Turn
*b Hold


Insert a dial indicator into the rear differential side gear shaft oil seal hole, and place it perpendicular to the edge of a ring gear tooth.


b.

Using SST, secure the drive pinion.

SST
09556-52010  


c.

Using SST, check the backlash while rotating the rear differential case sub-assembly forward and in reverse.

SST
09564-32011  

Standard:

0.088 to 0.208 mm (0.00347 to 0.00818 in.)


NOTICE:

Measure the ring gear at 3 or more locations.



Hide 28.INSPECT TOTAL PRELOAD

a.
C110135E04
0.708,0.469 0.948,0.458 0.948,0.458 1.333,0.698 false 0.406,0.385 0.865,0.583 0.458,0.198 10 false SST

Using SST and a torque wrench, measure the preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.

SST
09556-52010  

NOTICE:

Measure the preload after rotating the case bearing several times in the forward and backward directions to make sure the bearing is operating correctly.


Standard drive pinion preload:
Bearing Specified Condition
New bearing Drive pinion preload + 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10 to 16 in.*lbf)
Reused bearing Drive pinion preload + 0.58 to 1.01 N*m (6 to 11 kgf*cm, 5 to 8 in.*lbf)



b.

If the result is not within the specified range, perform the following procedures.

i.

Select and install another side gear shaft washer RH.


ii.

Recheck the backlash, preload and tooth contact pattern.



Hide 29.REMOVE DIFFERENTIAL SIDE BEARING RETAINER

a.
C285334

Remove the 8 bolts and differential side bearing retainer from the rear differential carrier sub-assembly.


Hide 30.INSTALL DIFFERENTIAL SIDE BEARING RETAINER

a.
C110312C01
2.552,0.458 2.865,0.656 0.313,0.198 10 *a 0.833,1.906 1.146,2.104 0.313,0.198 10 *a 3.042,1.281 3.354,1.479 0.313,0.198 10 *b 2.135,1.573 2.448,1.771 0.313,0.198 10 *a 2.677,1.885 2.99,2.083 0.313,0.198 10 *a
*a 6 mm (0.236 in.)
*b 3 mm (0.118 in.)


Apply seal packing 1281 to the areas of the differential side bearing retainer shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent


NOTICE:
·

Apply seal packing 1281 in a continuous line, approximately 2 to 3 mm (0.0788 to 0.118 in.) in diameter.

·

Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.

·

Install the differential side bearing retainer within 3 minutes of application.




b.
C285334

Install the differential side bearing retainer to the rear differential carrier sub-assembly with the 8 bolts.

Torque:
34.3 N*m (350 kgf*cm, 25 ft.*lbf)

NOTICE:

After installing the cover, leave the vehicle for at least 1 hour without driving or adding oil. After this, avoid any sudden acceleration or deceleration for the next 12 hours.



Hide 31.INSPECT TOTAL PRELOAD

a.
C110135E01
0.46,0.414 0.757,0.573 0.297,0.159 10 SST 0.843,0.495 1.1,0.495 false 1.1,0.495 1.339,0.705 false

Using SST and a torque wrench, check the starting torque with the teeth of the differential drive pinion and differential ring gear in contact.

SST
09556-52010  

NOTICE:

Measure the preload after rotating the case bearing several times in the forward and backward directions to make sure the bearing is operating correctly.


Standard drive pinion preload:
Bearing Specified Condition
New bearing Drive pinion preload + 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10 to 16 in.*lbf)
Reused bearing Drive pinion preload + 0.58 to 1.01 N*m (6 to 10 kgf*cm, 5 to 8 in.*lbf)



Hide 32.INSPECT DIFFERENTIAL RING GEAR BACKLASH

a.
C110134C11
0.615,1.375 0.823,1.375 false 0.844,3.469 0.781,3.677 false 0.323,1.292 0.75,1.573 0.427,0.281 10 SST 0.677,3.698 1.104,3.979 0.427,0.281 10 SST 0.396,2.99 0.563,3.156 0.167,0.167 10 *b 2.417,1.979 2.573,2.146 0.156,0.167 10 *a
*a Turn
*b Hold


Insert a dial indicator through the rear differential side gear shaft oil seal hole, and set it perpendicular to the edge of a ring gear tooth.


b.

Using SST, secure the drive pinion.

SST
09556-52010  


c.

Using SST, check the backlash while rotating the rear differential case sub-assembly forward and in reverse.

SST
09564-32011  

Standard backlash:

0.088 to 0.208 mm (0.000347 to 0.00818 in.)


NOTICE:

Measure the ring gear at 3 or more locations.



Hide 41204B 33.INSTALL REAR DRIVE PINION NUT

a.

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


Hide 34.INSTALL DIAPHRAGM OIL SEAL

a.
C293307C01
0.396,0.688 0.615,0.688 false 2.104,1.781 1.896,1.781 1.896,1.781 1.896,1.531 false 3.208,1.365 3.385,1.531 0.177,0.167 10 false *a 0.094,0.604 0.458,0.771 0.365,0.167 10 false SST 2.177,1.688 2.49,1.885 0.313,0.198 10 false *1
*1 Diaphragm Oil Seal
*a Distance


Using SST and a hammer, tap a new diaphragm oil seal into the rear differential carrier sub-assembly until it reaches the standard value.

SST
09710-30021  (09710-03121)
09950-60011  (09951-00570)
09950-70010  (09951-07100)

Standard distance:

6.5 to 7.5 mm (0.256 to 0.295 in.) (from the edge of the differential carrier sub-assembly)


NOTICE:
·

Tap the oil seal uniformly so that the oil seal is straight.

·

Do not tap the oil seal in too far.




Hide 42330G 35.INSTALL REAR DRIVE SHAFT OIL SEAL RH

a.
C293308C01
2.313,0.573 2.302,0.188 2.302,0.188 2.531,0.188 false 0.656,1.417 0.656,0.583 0.656,0.583 0.49,0.583 false 2.604,0.125 2.917,0.323 0.313,0.198 10 false *1 0.188,0.51 0.552,0.708 0.365,0.198 10 false SST 1.281,0.51 1.594,0.708 0.313,0.198 10 false *a
*1 Rear Differential Side Gear Shaft Oil Seal
*a Distance


Using SST and a hammer, tap a new rear drive shaft oil seal RH into the differential carrier until they reach the standard value.

SST
09223-00010  

Standard distance:

6.7 to 7.7 mm (0.264 to 0.303 in.) (from the protruding part of the carrier)


NOTICE:
·

Tap the oil seal uniformly so that the oil seal is straight.

·

Do not tap the oil seal in too far.




Hide 42340D 36.INSTALL REAR DRIVE SHAFT OIL SEAL LH

HINT:

Perform the same procedure as for the RH side.


Hide 41330J 37.INSTALL TRANSMISSION COUPLING SHIM

a.
C277169C01
1.448,0.146 1.76,0.344 0.313,0.198 10 *1 1.469,2.635 1.781,2.833 0.313,0.198 10 *2 1.5,2.292 1.813,2.49 0.313,0.198 10 B2 2.646,2.281 2.802,2.479 0.156,0.198 10 B 3.229,3.677 3.385,3.875 0.156,0.198 10 A 2.99,2.219 3.302,2.417 0.313,0.198 10 B1
*1 Transmission Coupling Assembly
*2 Differential Carrier Sub-assembly


Using a vernier caliper and precision straightedge, measure dimensions B1 and B2 of the transmission coupling assembly.


b.

Calculate dimension B by subtracting dimension B2 from B1.

HINT:
·

Dimension B = Dimension B1 - Dimension B2

·

Dimension B1 is the distance from the installation surface of the transmission coupling assembly to the edge of the bearing.




c.

Using a vernier caliper and precision straightedge, measure dimension A of the rear differential carrier sub-assembly.

HINT:

Dimension A is the distance from the installation surface of the rear differential carrier sub-assembly to the edge of the differential drive pinion.



d.

Select a transmission coupling shim based on the difference between dimensions A and B, and install the shim.

Transmission Coupling Shim:
Difference of dimension A and B Part No. Thickness Identifying Mark
3.96 to 4.01 mm (0.156 to 0.157 in.) 90564-25024 1.98 to 2.02 mm (0.078 to 0.079 in.) 1
4.26 to 4.31 mm (0.168 to 0.169 in.) 90564-25025 2.28 to 2.32 mm (0.090 to 0.091 in.) 2
4.56 to 4.61 mm (0.180 to 0.181 in.) 90564-25026 2.58 to 2.62 mm (0.102 to 0.103 in.) 3
3.81 to 3.86 mm (0.150 to 0.151 in.) 90564-25027 1.83 to 1.87 mm (0.072 to 0.073 in.) 4
4.11 to 4.16 mm (0.162 to 0.163 in.) 90564-25028 2.13 to 2.17 mm (0.084 to 0.085 in.) 5
4.41 to 4.46 mm (0.174 to 0.175 in.) 90564-25029 2.43 to 2.47 mm (0.096 to 0.097 in.) 6
3.71 to 3.76 mm (0.146 to 0.148 in.) 90564-25031 1.73 to 1.77 mm (0.068 to 0.069 in.) 8
3.76 to 3.81 mm (0.148 to 0.149 in.) 90564-25032 1.78 to 1.82 mm (0.070 to 0.071 in.) 9
3.86 to 3.91 mm (0.152 to 0.153 in.) 90564-25033 1.88 to 1.92 mm (0.074 to 0.075 in.) 10
3.91 to 3.96 mm (0.154 to 0.155 in.) 90564-25034 1.93 to 1.97 mm (0.076 to 0.077 in.) 11
4.01 to 4.06 mm (0.158 to 0.159 in.) 90564-25035 2.03 to 2.07 mm (0.080 to 0.081 in.) 12
4.06 to 4.11 mm (0.160 to 0.161 in.) 90564-25036 2.08 to 2.12 mm (0.082 to 0.083 in.) 13
4.16 to 4.21 mm (0.164 to 0.165 in.) 90564-25037 2.18 to 2.22 mm (0.086 to 0.087 in.) 14
4.21 to 4.26 mm (0.166 to 0.167 in.) 90564-25038 2.23 to 2.27 mm (0.088 to 0.089 in.) 15
4.31 to 4.36 mm (0.170 to 0.171 in.) 90564-25039 2.33 to 2.37 mm (0.092 to 0.093 in.) 16
4.36 to 4.41 mm (0.172 to 0.173 in.) 90564-25040 2.38 to 2.42 mm (0.094 to 0.095 in.) 17
4.46 to 4.51 mm (0.176 to 0.177 in.) 90564-25041 2.48 to 2.52 mm (0.098 to 0.099 in.) 18
4.51 to 4.56 mm (0.178 to 0.179 in.) 90564-25042 2.53 to 2.57 mm (0.100 to 0.101 in.) 19
4.61 to 4.66 mm (0.182 to 0.183 in.) 90564-25043 2.63 to 2.67 mm (0.104 to 0.105 in.) 20
4.66 to 4.71 mm (0.184 to 0.185 in.) 90564-25044 2.68 to 2.72 mm (0.106 to 0.107 in.) 21



Hide 41330E 38.INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER

a.
C289090C01
1.344,1.75 1.958,1.74 1.958,1.74 2.198,1.469 false 1.135,1.677 1.448,1.875 0.313,0.198 10 false *1
*1 Transmission Coupling Conical Spring Washer
V100135

Front of the vehicle (transmission coupling assembly side)


Install the transmission coupling conical spring washer to the rear differential carrier sub-assembly.

NOTICE:

Install the transmission coupling conical spring washer so that the protruding part is facing the front of the vehicle (transmission coupling assembly side).



Hide 41330D 39.INSTALL TRANSMISSION COUPLING ASSEMBLY

a.
C326199

Using a 5 mm socket hexagon wrench, install the yoke to the rear differential carrier sub-assembly with the 2 bolts.

Torque:
5.0 N*m (51 kgf*cm, 44 in.*lbf)


b.
C130359

Install a new O-ring to the 4WD linear solenoid.


c.
C130597

Install the 4WD linear solenoid to the yoke.


d.
C130575C01
0.781,0.875 0.792,0.313 0.792,0.313 0.563,0.313 false 0.406,0.229 0.719,0.427 0.313,0.198 10 *1
*1 Snap Ring


Using a snap ring expander, install a new snap ring.


e.

Using a scraper, clean the seal packing from the rear differential carrier sub-assembly and transmission coupling assembly, and remove any oil using a cleaning solvent.

NOTICE:

Do not scratch the installation area.



f.
C130565C07
1.938,0.552 2.073,0.177 2.073,0.177 2.26,0.177 false 2.292,0.094 2.667,0.375 0.375,0.281 10 *1 2.771,1.146 3.115,1.417 0.344,0.271 10 *a
*1 Seal Packing
*a 2 to 3 mm (0.0788 to 0.1181 in.)


Apply seal packing 1281 to the areas of the transmission coupling assembly shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent


NOTICE:
·

Apply seal packing 1281 in a continuous line, approximately 2 to 3 mm (0.0788 to 0.118 in.) in diameter.

·

Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.

·

Install the transmission coupling assembly within 3 minutes of application.




g.
C277170

Install the transmission coupling assembly to the rear differential carrier sub-assembly with the 4 bolts.

Torque:
19.6 N*m (200 kgf*cm, 14 ft.*lbf)


Hide 41108C 40.INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

a.
C110319E01
2.549,0.93 2.852,1.091 0.304,0.161 10 SST 2.522,1.012 2.042,1.012 false

Using SST, install a new rear differential carrier cover breather plug to the rear differential carrier sub-assembly.

SST
09612-07010  (09612-10061)

NOTICE:

Tap the plug in until the flange meets the edge of the rear differential carrier sub-assembly.



Hide 41108A 41.INSTALL REAR DIFFERENTIAL CARRIER COVER PLUG

a.
C110129

Using an 8 mm socket hexagon wrench, install a new rear differential carrier cover plug to the rear differential carrier sub-assembly.

Torque:
30 N*m (306 kgf*cm, 22 ft.*lbf)


Hide 41110H 42.INSTALL REAR DIFFERENTIAL FILLER PLUG

a.
C288367

Using a 10 mm socket hexagon wrench, install a new gasket and the rear differential filler plug.

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)


Hide 41110D 43.INSTALL REAR DIFFERENTIAL DRAIN PLUG

a.
C285350

Using a 10 mm socket hexagon wrench, install a new gasket and the rear differential drain plug.

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)


Hide 44.INSPECT RUNOUT OF TRANSMISSION COUPLING ASSEMBLY

a.
C277165C01
2.677,3.719 2.354,3.719 2.354,3.719 2.344,3.042 false 0.177,0.167 0.49,0.365 0.313,0.198 10 *a 2.042,0.167 2.354,0.365 0.313,0.198 10 *b 2.719,3.646 3.177,3.844 0.458,0.198 10 SST
*a Vertical Runout
*b Lateral Runout


Attach a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the transmission coupling assembly.


b.

Using SST, rotate the transmission coupling assembly forward and in reverse and measure the vertical runout.

SST
09564-32011  

Maximum:

0.06 mm (0.00236 in.)



c.

Set the dial indicator at a right angle to the transmission coupling assembly in the position shown in the illustration.


d.

Using SST, rotate the transmission coupling assembly forward and in reverse and measure the lateral runout.

SST
09564-32011  

Maximum:

0.07 mm (0.00276 in.)



Hide 45.INSTALL STUD BOLT

a.
C110326C01
0.938,1.854 0.938,1.552 false 2.167,1.875 2.167,1.542 false 0.813,0.271 1.083,0.458 0.271,0.188 10 *a 2.156,0.25 2.479,0.438 0.323,0.188 10 *b 0.896,1.885 1.208,2.083 0.313,0.198 10 *c 2.115,1.906 2.427,2.104 0.313,0.198 10 *d
*a 12.2 mm (0.480 in.)
*b 26.3 mm (1.04 in.)
*c Propeller Shaft Side
*d Transmission Coupling Assembly Side


Using 2 nuts, install the 4 stud bolts to the transmission coupling assembly.

Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)

NOTICE:

Install the longer threaded part of each bolt to the transmission coupling assembly side.