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Home >> Lexus >> 2006 >> IS 250 RWD, Automatic >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Differential >> REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE) >> Reassembly

REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): Reassembly

  1. INSTALL DIFFERENTIAL PINION AND SIDE GEAR (for 4WD) 
    1. Install the following parts to the differential case.

      HINT:

      • Differential pinion: [A]
      • Differential pinion thrust washer: [B]
      • Differential pinion shaft: [C]
      • Differential side gear: [D]
      • Differential side gear thrust washer: [E]
      Fig 1: Identifying Differential Pinion And Side Gear Parts (For 4WD)
      G04047141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 hypoid 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
      G04047142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 pinion gears and 2 differential pinion thrust washers to the differential case.
      Fig 3: Installing Pinion Gears And Differential Pinion Thrust Washers
      G04047143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
    G04047144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT AND ADJUST DIFFERENTIAL SIDE GEAR BACKLASH (for 4WD) (See step 2 in  INSPECTION   ) 
  3. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN (for 4WD) 
    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 Rear Differential Pinion Shaft Pin
      G04047145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
    G04047146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2WD) (See step 3 in  INSPECTION   ) 
  5. INSTALL DIFFERENTIAL RING GEAR 
    1. Clean the contact surfaces of the differential case and ring gear.
    2. Clean the differential ring gear set bolt hole.
    3. Heat the ring gear to approx. 100°C (212°F) in boiling water.
      CAUTION: Use thick gloves to protect hands as the ring gear is hot.
      Fig 7: Heating Ring Gear In Boiling Water
      G04047147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Carefully take the ring gear out of the boiling water.
    5. Hold the differential case in a vise between aluminum plates.
      NOTE: Do not overtighten the vise.
    6. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
    7. Align the matchmarks on the ring gear and differential case.
      Fig 8: Aligning Matchmarks On Ring Gear & Differential Case
      G04047148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Temporarily install 5 new lock plates and 10 bolts.
    9. After the ring gear cools down, tighten the 10 bolts uniformly.

      Torque: 97 N*m (985 kgf*cm, 72 ft.*lbf) 

    10. Using a chisel and a hammer, stake the 5 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 Using Chisel And Hammer
    G04047149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR DIFFERENTIAL CASE BEARING 
    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
    G04047150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09950-60010 (09951-00430, 09951-00580, 09951-00590, 09952-06010), 09950-70010 (09951-07100), 09710-04081 

    NOTE:
    • Do not apply hypoid gear oil to a new bearing.
    • Do not deform the bearing cage.
    • Place the SST carefully on the inner races of the bearings or on the center of the differential case (as applicable).
    • If the bearing is replaced, replace it and the outer race as a set.
  7. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR (See step 14 in  INSPECTION   ) 
  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Install the drive pinion plate washer to the drive pinion.

      HINT:

      • Temporarily install the inner race of the rear drive pinion rear tapered roller bearing to prevent the drive pinion washer from being dropped.
      • The drive pinion washer can be installed in either direction.
      Fig 11: Identifying Plate Washer
      G04047151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the inner race of the rear drive pinion rear tapered roller bearing to the drive pinion.

    SST 09506-30012 

    Fig 12: Installing Inner Race Of Rear Drive Pinion Rear Tapered Roller Bearing To Drive Pinion
    G04047152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (for 2WD) 
    1. Using SST and a press, install the outer race of the rear drive pinion rear tapered roller bearing to the differential carrier.

    SST 09950-60020 (09951-00890), 09950-70010 (09951-07200) 

    Fig 13: Installing Outer Race Of Rear Drive Pinion Rear Tapered Roller Bearing To Differential Carrier (2WD)
    G04047153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (for 4WD) 
    1. Using SST and a press, install the outer race of the rear drive pinion rear tapered roller bearing to the differential carrier.

    SST 09950-60020 (09951-00790), 09950-70010 (09951-07200) 

    Fig 14: Installing Outer Race Of Rear Drive Pinion Rear Tapered Roller Bearing To Differential Carrier (4WD)
    G04047154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the outer race of the rear drive pinion front tapered roller bearing to the differential carrier.

    SST 09950-60020 (09951-00720), 09950-70010 (09951-07100) 

    Fig 15: Installing Outer Race Of Rear Drive Pinion Front Tapered Roller Bearing To Differential Carrier
    G04047155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR 
    1. Using SST and a press, install a new dust deflector.
    Fig 16: Identifying New Dust Deflector
    G04047156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09636-20010 

    NOTE:
    • Slowly press in the dust deflector.
    • If any burrs remain after pressing in the deflector, remove them.
  13. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (for 2WD) 
    1. Install the drive pinion and the inner race of the rear drive pinion front tapered roller bearing to the differential carrier.
      Fig 17: Installing Drive Pinion & Inner Race Of Rear Drive Pinion Front Tapered Roller Bearing To Differential Carrier
      G04047157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not drop the drive pinion.
      • Install the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.
    2. Install the drive pinion oil slinger to the drive pinion.
      Fig 18: Installing Drive Pinion Oil Slinger To Drive Pinion
      G04047158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the companion flange.

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

      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 19: Installing Companion Flange Using SST
      G04047159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST to hold the flange, tighten the drive pinion nut.

      SST 09330-00021 

      Torque: 338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less 

      NOTE:
      • Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
      • 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.
      Fig 20: Tightening Drive Pinion Nut
      G04047160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turn the bearing clockwise and counterclockwise several times to stabilize it.
    6. Using a torque wrench, measure the drive pinion preload.

    Drive pinion preload (at starting) 

    PRELOAD SPECIFICATION

    Specifications Preload
    New bearing  1.39 to 2.49 N*m (14.2 to 25.4 kgf*cm, 12.3 to 22.0 in.*lbf) 
    Reused bearing  1.01 to 1.81 N*m (10.3 to 18.5 kgf*cm, 8.9 to 16.0 in.*lbf) 
    NOTE:
    • Record the preload for total preload measurement.
    • Do not apply hypoid gear oil to a new bearing.

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

    Fig 21: Adjusting Differential Drive Pinion Preload
    G04047161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (for 4WD) 
    1. Install the drive pinion and the inner race of the rear drive pinion front tapered roller bearing to the differential carrier.
      NOTE:
      • Do not drop the drive pinion.
      • Install the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.
      Fig 22: Installing Drive Pinion And Inner Race
      G04047162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the drive pinion oil slinger to the drive pinion.
      Fig 23: Installing Drive Pinion Oil Slinger To Drive Pinion
      G04047163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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 24: Installing Companion Flange
      G04047164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST to hold the flange, tighten the drive pinion nut.

      SST 09330-00021 

      Torque: 223 N*m (2,280 kgf*cm, 164 ft.*lbf) or less 

      NOTE:
      • Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
      • Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
      Fig 25: Tightening Drive Pinion Nut
      G04047165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.
    5. Turn the bearing clockwise and counterclockwise several times to stabilize it.
      Fig 26: Turning Bearing To Stabilizer
      G04047166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a torque wrench, measure the drive pinion preload.

    Drive pinion preload (at starting) 

    PRELOAD SPECIFICATION

    Specifications Preload
    New bearing  1.39 to 2.49 N*m (14.2 to 25.4 kgf*cm, 12.3 to 22.0 in.*lbf) 
    Reused bearing  1.01 to 1.81 N*m (10.3 to 18.5 kgf*cm, 8.9 to 16.0 in.*lbf) 
    NOTE:
    • Record the preload for total preload measurement.
    • Do not apply hypoid gear oil to a new bearing.

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

  15. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.
      NOTE: Be sure to install the bearing outer races in each correct position.
      2. Fig 27: Installing Case Bearing Outer Races LH And RH To Case Bearing Inner Races LH And RH
      G04047167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the differential case to the differential carrier.
    3. Install the right and left (on the back and tooth sides) side gear shaft washers so that the case bearing is not loose.
    Fig 28: Installing Right And Left (On Back And Tooth Sides)
    G04047168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    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.
  16. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH (See step 2 in  INSPECTION   ) 
  17. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. After adjusting the backlash of the differential ring gear, remove the teeth side gear shaft plate washer.
      Fig 29: Removing Teeth Side Gear Shaft Plate Washer
      G04047169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the thickness of the removed side gear shaft plate washer.
    3. Select a new side gear shaft plate washer which is 0.06 to 0.09 mm (0.0024 to 0.0035 in.) thicker than the removed one.

      HINT:

      Select a side gear shaft plate washer which can be pressed in 2/3 of the way with a finger.

    4. Using SST and a plastic hammer, drive in the side gear shaft plate washer.

      SST 09504-22011 

    5. Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.
      Fig 30: Aligning Matchmarks On Bearing Cap & Differential Carrier
      G04047170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure the right and left bearing caps are not interchanged.
    6. Tighten both bearing caps with the 4 bolts.

      Torque: 85 N*m (870 kgf*cm, 63 ft.*lbf) 

      Fig 31: Tightening Both Bearing Caps Bolts
      G04047171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Set the dial indicator to the end of the differential ring gear face.
    8. While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.

    Backlash: 

    2WD: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) 

    4WD: 0.10 to 0.15 mm (0.0039 to 0.0059 in.) 

    If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft plate washers equally.

    Fig 32: Measuring Value Out Of Specified Range
    G04047172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    • Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
    • Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
  18. INSPECT TOTAL PRELOAD 
    1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
      Fig 33: Measuring Preload With Teeth Of Drive Pinion & Ring Gear In Contact Using Torque Wrench
      G04047173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload (at starting) New differential case bearing: 

      PRELOAD (AT STARTING) NEW DIFFERENTIAL CASE BEARING

      Specifications New drive pinion tapered roller bearing Reused drive pinion tapered roller bearing
      2WD  2.47 to 4.16 N*m (25.2 to 42.4 kgf*cm, 21.9 to 36.8 in.*lbf)  2.09 to 3.48 N*m (21.3 to 35.5 kgf*cm, 18.5 to 30.8 in.*lbf) 
      4WD  1.53 to 2.30 N*m (15.6 to 23.5 kgf*cm, 13.5 to 20.4 in.*lbf)  0.64 to 1.06 N*m (6.5 to 1.08 kgf*cm, 5.7 to 9.4 in.*lbf) 

      Reused differential case bearing 

      REUSED DIFFERENTIAL CASE BEARING

      Specification New drive pinion tapered roller bearing Reused drive pinion tapered roller bearing
      2WD  1.88 to 3.27 N*m (20.2 to 33.3 kgf*cm, 16.6 to 28.9 in.*lbf)  1.50 to 2.59 N*m (15.3 to 26.4 kgf*cm, 13.3 to 22.9 in.*lbf) 
      4WD  1.46 to 2.21 N*m (14.9 to 22.5 kgf*cm, 12.9 to 19.6 in.*lbf)  0.67 to 1.06 N*m (6.8 to 10.8 kgf*cm, 5.9 to 9.4 in.*lbf) 

      HINT:

      • If the measured preload is less than the specified value, replace the side gear shaft plate washer of the ring gear tooth surface side with a thicker one.
      • If the preload is greater than the specified value, replace the side gear shaft plate washer of the ring gear tooth surface side with a thinner one.
    2. Set the dial indicator perpendicular to the end of the ring gear face.
    3. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
    Fig 34: Measuring Backlash
    G04047174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Backlash: 

    BACKLASH SPECIFICATION

    Specifications Backlash
    2WD  0.13 to 0.18 mm (0.0051 to 0.0071 in.) 
    4WD  0.10 to 0.15 mm (0.0039 to 0.0059 in.) 

    HINT:

    • If the backlash is not within the specified range, change the thickness of the right and left side gear shaft plate washers by equal amounts to adjust it.
    • Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
    • Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
  19. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 11 in  INSPECTION   ) 
  20. REMOVE REAR DRIVE PINION NUT 
    1. Using SST to hold the flange, remove the drive pinion nut.
    Fig 35: Removing Drive Pinion Nut Using SST
    G04047175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 2WD) (See step 14 in  DISASSEMBLY   ) 
  22. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 4WD) (See step 15 in  DISASSEMBLY   ) 
  23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER (See step 18 in  DISASSEMBLY   ) 
  24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (See step 19 in  DISASSEMBLY   ) 
  25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER 
    1. Install a new drive pinion bearing spacer to the drive pinion.
    NOTE: Be sure to face the larger inner diameter side rearward.
    Fig 36: Installing New Drive Pinion Bearing Spacer To Drive Pinion
    G04047176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Install the rear drive pinion front tapered roller bearing to the drive pinion.
    Fig 37: Installing Rear Drive Pinion Front Tapered Roller Bearing To Drive Pinion
    G04047177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Install the drive pinion oil slinger to the drive pinion.
    Fig 38: Installing Drive Pinion Oil Slinger To Drive Pinion
    G04047178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 2WD) 
    1. Using SST and a companion flange, install the rear drive pinion front tapered roller bearing.

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

    NOTE: Apply grease to the threads and tip of the SST center bolt before use.
    Fig 39: Installing Rear Drive Pinion Companion Flange (For 2WD)
    G04047179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 4WD) 
    1. Using SST and a companion flange, install the rear drive pinion front tapered roller bearing.
    Fig 40: Installing Rear Drive Pinion Companion Flange (For 4WD)
    G04047180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    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.
  30. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 2WD) (See step 14 in  DISASSEMBLY   ) 
  31. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 4WD) (See step 15 in  DISASSEMBLY   ) 
  32. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.

      SST 09554-22010 

      Oil seal installation depth: 1.55 to 2.45 mm (0.061 to 0.096 in.) 

    2. Apply MP grease to the oil seal lip.
    Fig 41: Installing Rear Differential Carrier Oil Seal
    G04047181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 2WD) 
    1. Using SST, install the companion flange.

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

      NOTE: Apply grease to the threads and tip of the SST center bolt before use.
      Fig 42: Identifying Rear Drive Pinion Companion Flange
      G04047182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the flange, tighten the drive pinion nut.

    SST 09330-00021 

    Torque: 338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less 

    NOTE:
    • Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
    • Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
    Fig 43: Tightening Drive Pinion Nut
    G04047183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL REAR DRIVE PINION COMPANION FLANGE (for 4WD) 
    1. Using SST, install the companion flange.

      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 44: Installing Rear Drive Pinion Companion Flange (For 4WD)
      G04047184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the flange, tighten the drive pinion nut.

    SST 09330-00021 

    Torque: 223 N*m (2,280 kgf*cm, 164 ft.*lbf) or less 

    NOTE:
    • Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
    • Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
    Fig 45: Tightening Drive Pinion Nut
    G04047185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using a torque wrench, measure the preload of the drive pinion.

    Drive Pinion Preload (at starting) 

    New bearing: 

    DRIVE PINION PRELOAD (AT STARTING) (NEW BEARING)

    Specifications Preload
    2WD  1.49 to 2.59 N*m (15.2 to 26.4 kgf*cm, 13.2 to 22.9 in.*lbf) 
    4WD  1.40 to 2.00 N*m (14.3 to 20.4 kgf*cm, 12.4 to 17.7 in.*lbf) 

    Reused bearing 

    DRIVE PINION PRELOAD (AT STARTING) (REUSED BEARING)

    Specifications Preload
    2WD  1.11 to 1.91 N*m (11.3 to 19.5 kgf*cm, 9.8 to 16.9 in.*lbf) 
    4WD  0.51 to 0.76 N*m (5.2 to 7.7 kgf*cm, 4.5 to 6.7 in.*lbf) 
    Fig 46: Adjusting Differential Drive Pinion Preload
    G04047186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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.

      Torque: 

      2WD: 338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less 

      4WD: 223 N*m (2,280 kgf*cm, 164 ft.*lbf) or less 

    • 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.
    • 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.
  36. INSPECT TOTAL PRELOAD (See step 9 in  INSPECTION   ) 
  37. INSPECT DIFFERENTIAL RING GEAR BACKLASH (See step 2 in  INSPECTION   ) 
  38. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE (See step 7 in  INSPECTION   ) 
  39. INSTALL REAR DRIVE PINION NUT 
    1. Using a SST and a hammer, stake the drive pinion nut.

    SST 09930-00010 

    Fig 47: Staking Drive Pinion Nut
    G04047187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 2WD) 
    1. Using SST and a hammer, install 2 new oil seals.

      SST 09213-70011, 09950-60010 (09951-00410, 09951-00620, 09952-06010), 09950-70010 (09951-07100) 

      Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) 

    2. Apply MP grease to the oil seal lip.
    Fig 48: Installing Rear Differential Side Gear Shaft Oil Seal (For 2WD)
    G04047188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD) 
    1. Using SST and a hammer, install 2 new oil seals.

      SST 09710-04101, 09950-60010 (09951-00580, 09951-00620, 09952-06010), 09950-70010 (09951-07100) 

      Oil seal installation depth: 0 to 1.0 mm (0 to 0.039 in.) 

    2. Apply MP grease to the oil seal lip.
    Fig 49: Installing Rear Differential Side Gear Shaft Oil Seal (For 4WD)
    G04047189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL REAR DIFFERENTIAL DRAIN PLUG 
    1. Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.

    Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

  43. REMOVE REAR DIFFERENTIAL CARRIER 
    1. Remove the differential carrier from the overhaul stand, etc.
    Fig 50: Removing Rear Differential Carrier From Overhaul Stand
    G04047190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR 
    1. Install the oil deflector and bolt to the carrier cover.

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

  45. INSTALL REAR DIFFERENTIAL CARRIER COVER 
    1. Clean any residual FIPG material on the contact surfaces using gasoline or alcohol.
      Fig 51: Identifying Rear Differential Carrier Cover
      G04047191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply FIPG to the carrier cover.

      FIPG: 

      08826-00090, THREE BOND 1281 or equivalent 

      HINT:

      • Apply FIPG in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 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
      Fig 52: Applying FIPG To Carrier Cover
      G04047192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the carrier cover with the 8 bolts.

    Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf) 

    Fig 53: Identifying Carrier Cover Bolts
    G04047193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL REAR DIFFERENTIAL BREATHER PLUG 
    1. Install the breather plug to the carrier cover.

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

    Fig 54: Installing Rear Differential Breathing Plug
    G04047194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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