FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): Reassembly

1. Install the following parts to the differential case.

   HINT:

   • Differential pinion gear [A]
   • Differential pinion thrust washer [B]
   • Differential pinion shaft [C]
   • Differential side gear [D]
   • Differential side gear thrust washer [E]
   Fig 1: Identifying Differential Case Parts

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   NOTE:

   • Make sure that there is no dirt or foreign matter on the thrust washer, side gear, etc. before installing them.
   • If replacing either the side gears or pinion gears, replace them as a set.
   • Apply gear oil API GL-5 to all sliding and rotating parts.
2. Install the 2 side gears and 2 side gear thrust washers to the differential case.
   Fig 2: Installing Side Gears & Side Gear Thrust Washers To Differential Case

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3. Install the 2 pinion gears and 2 differential pinion thrust washers to the differential case.
   Fig 3: Installing Pinion Gears & Differential Pinion Thrust Washers To Differential Case

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4. Insert the differential pinion shaft into the differential case.

HINT:

Align the holes of the differential case and differential pinion shaft.

Fig 4: Inserting Differential Pinion Shaft Into Differential Case

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1. Using a pin punch (3 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
   Fig 5: Installing Straight Pin Through Differential Case & Hole Of Pinion Shaft

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2. Using a chisel and a hammer, stake the outside of the differential case pin hole.
   Fig 6: Staking Outside Of Differential Case Pin Hole

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1. Clean the contact surfaces of the differential case and ring gear.
2. Hold the differential case in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
3. Heat the ring gear to approximately 100°C (212°F) in boiling water.
   CAUTION: Use thick gloves to protect hands as the ring gear is hot.
4. Carefully take the ring gear out of the boiling water.
   Fig 7: Heating Ring Gear In Boiling Water

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5. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
6. Align the matchmarks on the ring gear and differential case.
   Fig 8: Aligning Matchmarks On Ring Gear And Differential Case

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7. Temporarily install 4 new lock plates and the 8 bolts.
8. After the ring gear cools down, tighten the 8 bolts.

   Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf) 

9. Using a chisel and a hammer, stake the 4 lock plates.

1. Stake one claw so that it is flush against the flat surface of the bolt.
2. Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.

Fig 9: Staking Lock Plates

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1. Using SST and a press, install the case bearing inner races LH and RH to the differential case.

Fig 10: Installing Case Bearing Inner Races LH & RH To Differential Case

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SST 09950-60010 (09951-00510), 09636-20010 

1. Using SST, the bolt, nut (M12 X P1.25) and washer, install the outer race of the rear tapered roller bearing.

SST 09950-60020 (09951-00710, 09951-00720) 

HINT:

• Bolt: M12 X P1.25, bolt length: 186 mm (7.3 in.)
• Nut: M12 X P1.25

Fig 11: Installing Outer Race Of Rear Tapered Roller Bearing

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1. Install the front adjust shim to the differential carrier.
2. Using SST, the bolt, nut (M12 X P1.25) and washer, install the outer race of the front tapered roller bearing.

   SST 09950-60010 (09951-00640), 09950-60020 (09951-00810) 

   NOTE: Do not apply hypoid gear oil to a new bearing.

   HINT:

   • Bolt: M12 X P1.25, bolt length: 186 mm (7.3 in.)
   • Nut: M12 X P1.25
   Fig 12: Installing Outer Race Of Front Tapered Roller Bearing

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3. Using SST and a press, install the inner race of the front drive pinion front tapered roller bearing to the drive pinion.

SST 09506-30012 

Fig 13: Installing Race Of Front Drive Pinion

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1. Install the case plate washer to the differential carrier.

   HINT:

   • If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft plate washer and install it.
   • If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft plate washer with the same thickness as the removed one.
2. Using SST and a press, install the outer race of the front differential case bearing LH to the differential carrier.

SST 09950-60020 (09951-00600, 09951-00730, 09952-06010), 09950-70010 (09951-07100) 

Fig 14: Installing Outer Race Of Front Differential Case Bearing LH To Differential Carrier

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1. Install the case plate washer to the differential side bearing retainer.

   HINT:

   • If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft plate washer and install it.
   • If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft plate washer with the same thickness as the removed one.
2. Using SST and a press, install the outer race of the front differential case bearing RH to the differential side bearing retainer.

SST 09950-60020 (09951-00600, 09951-00730, 09952-06010), 09950-70010 (09951-07100) 

Fig 15: Installing Outer Race Of Front Differential Case Bearing RH To Differential Side Bearing Retainer

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1. Using SST and a press, install a new dust deflector.

   SST 09316-60011 (09316-00011) 

   NOTE:

   • Slowly press in the dust deflector but not press it excessively.
   • If any burrs remain after pressing in the deflector, remove them.

Fig 16: Installing Dust Deflector

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1. Install the drive pinion (with the inner race of the front drive pinion front tapered roller bearing already installed) to the differential carrier. While holding the drive pinion, install the inner race of the front drive pinion rear tapered roller bearing and the drive pinion oil slinger.
   NOTE:

   • Do not drop the drive pinion.
   • Install the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.
   Fig 17: Installing Drive Pinion (with Inner Race Of Front Drive Pinion Front Tapered Roller Bearing Installed)

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2. Using SST, install the companion flange.

   SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) 

   NOTE:

   • Hold the drive pinion until the SST is installed.
   • Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
   • Apply grease to the threads and tip of the SST center bolt before use.
   Fig 18: Installing Companion Flange Using SST

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3. Using SST to hold the flange, tighten the drive pinion nut.

   SST 09330-00021, 09950-30012 (09955-03030) 

   Torque: 235 N*m (2,400 kgf*cm, 173 ft.*lbf) or less 

   NOTE:

   • Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
   • As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.

   HINT:

   Tighten the nut approximately 108 N*m (1,100 kgf*cm, 80 ft.*lbf), and tighten it further while checking the preload.

   Fig 19: Tightening Drive Pinion Nut

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4. Turn the bearing clockwise and counterclockwise several times to stabilize it.
5. Using a torque wrench, measure the drive pinion preload.

Drive pinion preload (at starting): 

New bearing: 0.81 to 1.40 N*m (8.3 to 14.3 kgf*cm, 7.2 to 12.4 in.*lbf) 

Reused bearing: 0.32 to 0.61 N*m (3.3 to 6.2 kgf*cm, 2.8 to 5.4 in.*lbf) 

If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

Fig 20: Turning Bearing To Stabilize

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1. Install the differential case to the differential carrier.

Fig 21: Installing Front Differential Case

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

   Preload (at starting): 

   New bearing: 1.10 to 1.89 N*m (11.2 to 19.3 kgf*cm, 9.7 to 16.7 in.*lbf) 

   Reused bearing: 0.62 to 1.1 N*m (6.2 to 11.2 kgf*cm, 5.5 to 9.7 in.*lbf) 

   Fig 22: Measuring Preload With Teeth Of Drive Pinion & Ring Gear Using Torque Wrench

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   HINT:

   • If the measured preload is less than the specified value, replace the case plate washer of the ring gear tooth surface side with a thicker one.
   • If the preload is greater than the specified value, replace the case plate washer of the ring gear tooth surface side with a thinner one.
2. Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.
   Fig 23: Setting Lever Probe To Dial Indicator

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3. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.

SST 09564-32011 

Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) 

Fig 24: Measuring Ring Gear Backlash While Holding Companion Flange

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HINT:

• If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.
• Record the measured backlash to use as a reference for selecting a case washer.
• Inspect tooth contact to use the result as a reference for selecting a case washer.

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

SST 09330-00021, 09950-30012 (09955-03030) 

Fig 25: Removing Front Drive Pinion Companion Flange Front

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1. Install a new drive pinion bearing spacer to the drive pinion.

Fig 26: Installing New Drive Pinion Bearing Spacer To Drive Pinion

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1. While holding the drive pinion, install the inner race of the front drive pinion rear tapered roller bearing.
   NOTE: Do not drop the drive pinion.
   Fig 27: Installing Front Drive Pinion Rear Tapered Roller Bearing Inner Race

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2. Using the companion flange, install the inner race of the front drive pinion rear tapered roller bearing to the drive pinion.

   SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03020, 09955-03030) 

   NOTE:

   • Hold the drive pinion until the SST is installed.
   • Apply grease to the threads and tip of the SST center bolt before use.
   Fig 28: Installing Inner Race Of Front Drive Pinion Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the companion flange.

SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03020, 09955-03030) 

Fig 29: Removing Companion Flange Using SST

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1. Install the drive pinion oil slinger to the differential carrier.

Fig 30: Identifying Front Differential Drive Pinion Oil Slinger

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1. Join the 2 SST and secure them with vinyl tape.

   SST 09309-36010, 09502-12010 

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

   SST 09309-36010, 09502-12010 

   Oil seal installation depth: 0.7 to 1.3 mm (0.028 to 0.051 in.) 

3. Apply MP grease to the oil seal lip.

Fig 31: Applying MP Grease To Oil Seal Lip

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1. Install the differential side bearing retainer deflector with the bolt.

Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

Fig 32: Installing Differential Side Bearing Retainer Deflector Bolt

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

   SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) 

   NOTE: Apply grease to the threads and tip of the SST center bolt before use.
   Fig 33: Installing Companion Flange To Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the threads of a new drive pinion nut with hypoid gear oil LSD.
3. Using SST to hold the flange, tighten the drive pinion nut.

SST 09330-00021, 09950-30012 (09955-03030) 

Torque: 108 to 235 N*m (1,100 to 2,400 kgf*cm, 80 to 173 ft.*lbf) 

Fig 34: Tightening Drive Pinion Nut

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1. Using a torque wrench, measure the preload of the drive pinion.

   Preload (at starting): 

   New bearing: 0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf) 

   Reused bearing: 0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf) 

   Fig 35: Measuring Preload Of Drive Pinion Using Torque Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.
3. If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
4. If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

1. Install the differential case to the differential carrier.

Fig 36: Installing Differential Case To Differential Carrier

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1. Check that there are no foreign objects or damage to the installation surface of the side bearing retainer.
2. Apply FIPG to the side bearing retainer.

   FIPG: 

   08826-00090, THREE BOND 1281 or equivalent 

   Fig 37: Installing Front Differential Side Bearing Retainer

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   HINT:

   • Apply FIPG in a continuous bead, approximately 1 to 2 mm (0.04 to 0.08 in.) in diameter on the entire sealing surface.
   • Overlap FIPG at least 10 mm (0.39 in.) or more at the beginning and the end of application.
   • Install the carrier cover within 3 minutes after applying FIPG.
   • Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least at least 12 hours after installation of parts using FIPG sealant.
3. Install the differential side bearing retainer with the 8 bolts.

Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf) 

Fig 38: Installing Differential Side Bearing Retainer Bolts

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1. Install the differential breather plug to the differential carrier.

Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf) 

Fig 39: Installing Front Differential Breather Plug

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

SST 09930-00010 

Fig 40: Staking Drive Pinion Nut

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1. Using SST and a hammer, install 2 new oil seals.
   Fig 41: Installing Front Differential Case Oil Seal

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   SST 09613-22011, 09950-60010 (09951-00560) 

   Oil seal installation depth: 

   LH Side: 1.0 to 2.0 mm (0.039 to 0.079 in.) 

   RH Side: 7.5 to 8.5 mm (0.295 to 0.335 in.) 

2. Apply MP grease to the oil seal lips.

1. Install the differential drain plug and a new gasket.

Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

1. Remove the differential carrier from the overhaul stand, etc.

Fig 42: Removing Differential Carrier Assembly

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