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Rear Differential Carrier Assembly: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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 approximately 100°C (212°F) in boiling water.
      Fig 1: Heating Ring Gear To Boiling Water
      G05318957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Use thick gloves to protect your hands as the ring gear is hot.
    4. Carefully take the ring gear out of the boiling water
    5. Secure the differential case between aluminum plates in a vise
      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
      Fig 2: Aligning Matchmarks On Ring Gear And Differential Case
      G05752140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the matchmarks on the ring gear and the differential case
    8. After the ring gear has cooled sufficiently, install 10 new ring gear set bolts to which thread lock has been applied

      Adhesive: 

      Toyota Genuine Adhesive 1360K, Three Bond 

      1360K or equivalent. 

      NOTE:
      • New ring gear set bolts should be used every time the ring gear is installed.
      • Do not allow oil to adhere to the ring gear set bolt during installation.
    9. Tighten the 10 set bolts uniformly, a little at a time

      Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 

      Fig 3: Identifying Ring Gear Bolts Tightening Sequence
      G04949202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Tighten the bolts further 60° to 90°.
      NOTE: Tighten diagonally opposite bolts in pairs.
      Fig 4: Tightening Ring Gear Bolts
      G05319054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 5: Pressing Case Bearing Inner Races
      G05752143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60010 (09951-00560, 09951 -00570), 09950-70010 (09951-07100) 

      NOTE:
      • Do not apply hypoid gear oil to a new bearing.
      • Do not deform the bearing cage. Set SST to the center of the differential case.
      • If the bearing is replaced, replace it and its outer race as a set.
  3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the rear drive pinion rear tapered roller bearing inner race to the drive pinion

      SST 09316-60011 (09316-00031), 09612-24014 (09613-22011) 

      Fig 6: Pressing Rear Drive Pinion Rear Tapered Roller Bearing Inner Race To Drive Pinion
      G05319056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race and plate washer.

      SST 09255-10012, 09950-70010 (09951-07200) 

      HINT:

      Select a plate washer of the same thickness as the removed one.

      Fig 7: Pressing Rear Drive Pinion Rear Tapered Roller Bearing Outer Race And Plate Washer
      G05319057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the rear drive pinion front tapered roller bearing outer race.

      SST 09950-60020 (09951 -00710), 09950-70010 (09951-07100) 

      Fig 8: Pressing Rear Drive Pinion Front Tapered Roller Bearing Outer Race
      G05319058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear drive pinion front tapered roller bearing to the differential carrier.
    Fig 9: Identifying Rear Drive Pinion Front Tapered Roller Bearing To Differential Carrier
    G04949180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR 

    HINT.

    Perform this procedure only when replacing the dust deflector.

    1. Using SST and a press, insert a new dust deflector to the companion flange.

      SST 09316-60011 (09316-00011) 

      Fig 10: Pressing Dust Deflector To Companion Flange
      G05319059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Slowly press in the dust deflector but not press it excessively.
      • If any burrs remain after pressing in the deflector, remove them.
  6. INSTALL DIFFERENTIAL DRIVE PINION 
    1. Using SST and a press, install the differential drive pinion

      SST 09316-60011 (09316-00011, 09316-00041), 09608-04031 

      HINT.

      Install the rear differential drive pinion bearing spacer and oil seal after adjusting the tooth contact pattern.

      Fig 11: Pressing Differential Drive Pinion
      G05319060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Install the drive pinion oil slinger
      Fig 12: Identifying Drive Pinion Oil Slinger
      G04949177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using SST, install the companion flange.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060) 

      NOTE:
      • Install the companion flange so that there is a slight looseness on the drive pinion because the bearing spacer is not yet installed.
      • Apply grease to the threads and tip of the SST center bolt before use.
        Fig 13: Adjusting Differential Drive Pinion Preload
        G05319062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the threads of the drive pinion nut with hypoid gear oil LSD
    3. Using SST to hold the flange, tighten the drive pinion nut
      Fig 14: Holding Flange Tightening Drive Pinion Nut
      G04949213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09229-55010, 09330-00021, 09950-30012 (09955-03040) 

      HINT 

      Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft *lbf), and tighten it further while checking the preload

      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.
    4. Turn the bearing clockwise and counterclockwise several times to stabilize it
    5. Using SST and a torque wrench, measure the preload.
      Fig 15: Measuring Preload
      G04949159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09229-55010 

      Drive pinion preload (at starting): 

      New bearing: 

      1.2 to 1.8 N*m (13 to 18 kgf*cm, 11 to 15 in.*lbf) 

      Reused bearing: 

      0.5 to 0.8 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf) 

      NOTE: Record the preload for total preload measurement.

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

  9. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Insert the differential case from the ring gear tooth side to install the differential case.
      NOTE: Do not damage the case bearing and ring gear.
      Fig 16: Inserting Differential Case From Ring Gear Tooth Side To Differential Case
      G04949215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE RH 
    1. Using SST and a hammer, install the ring gear tooth side differential side bearing outer race RH.

      SST 09608-32010, 09950-70010 (09951-07200) 

      HINT

      Tap in the differential side bearing outer race RH until half of the side gear shaft snap ring groove of the differential carrier can be seen

      Fig 17: Tapping Differential Side Bearing Outer Race
      G05319066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE LH 
    1. Install SST to the differential carrier with the 2 bolts.

      SST 09571-50010 

    2. Tighten the SST bolt (A) until the SST disc lightly touches the differential side bearing outer race LH.
      Fig 18: Identifying SST To Differential Carrier
      G05319006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, install the ring gear back surface side differential side bearing outer race LH.

      SST 09608-32010, 09950-70010 (09951 -07200) 

      HINT.

      Tap in the differential side bearing outer race LH until it touches the case bearing inner race roller.

      Fig 19: Tapping Differential Side Bearing Outer Race
      G05319043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING 
    1. Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.
      Fig 20: Identifying Side Gear Shaft Snap Ring
      G04949167Courtesy 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 snap ring and install it
      • If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft snap ring with the same thickness as the removed one.
    2. Install a dial indicator to the differential carrier.
    3. Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0 00394 in.).

      SST 09571-50010 

      Fig 21: Tightening SST Bolt
      G05319007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.00787 in.).

      HINT:

      • Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
      • Tighten the SST bolt to apply the preload to the case bearing.
    4. Turn the ring gear clockwise and counterclockwise several times
      Fig 22: Measuring Backlash Of Ring Gear
      G05319071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a dial indicator, measure the backlash of the ring gear at 3 positions

      Backlash: 

      0.08 to 0.13 mm (0.00315 to 0.00512 in.) 

      NOTE: The difference between the maximum and minimum values must be within 0.05 mm (0.00197 in.).

      HINT:

      • Record the measured backlash to use as a reference for selecting a side gear shaft snap ring
      • If the backlash is not within the specified range, replace the rear differential side gear shaft snap ring on the ring gear tooth side with a snap ring of different thickness as described in the following procedure
      • Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
    6. Loosen the SST bolt and separate the SST disc from the differential side bearing outer race RH on the ring gear tooth side
    7. Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear back surface side and differential side bearing outer race LH.

      SST 09608-32010, 09950-70010 (09951 -07200) 

      Fig 23: Tapping Differential Side Bearing Outer Race
      G05296188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
      Fig 24: Identifying Side Gear Shaft Snap Ring
      G04949167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using snap ring pliers, install a side gear shaft snap ring with a different thickness.

      HINT.

      When the side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash also changes by 0 02 mm (0.000787 in)

      Fig 25: Identifying Side Gear Shaft Snap Ring
      G04949167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap Ring Thickness 

      SNAP RING THICKNESS SPECIFICATION

      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      3 66 (0 14409) 3 92 (0 15433) 4 18 (0 16457)
      3 68 (0 14488) 3 94 (0 15512) 4 20 (0 16535)
      3 70 (0 14567) 3 96 (0 15591) 4 22 (0 16614)
      3 72 (0 14646) 3 98 (0 15669) 4 24 (0 16693)
      3 74 (0 14724) 4 00 (0 15748) 4 26 (0 16772)
      3 76 (0 14803) 4 02 (0 15827) 4 28 (0 16850)
      3 78 (0 14882) 4 04 (0 15905) 4 30 (0 16929)
      3 80 (0 14961) 4 06 (0 15984) 4 32 (0 17008)
      3 82 (0 15039) 4 08 (0 16063) 4 34 (0 17087)
      3 84 (0 15118) 4 10 (0 16142) 4 36 (0 17165)
      3 86 (0 15197) 4 12 (0 16220) 4 38 (0 17244)
      3 88 (0 15276) 4 14 (0 16299) 4 40 (0 17323)
      3 90 (0 15354) 4 16 (0 16378) 4 42 (0 17402)
    10. Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.
      Fig 26: Tapping Ring Gear Tooth Side Of Differential Carrier
      G04949226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Install a dial indicator to the differential carrier.
      12. Fig 27: Tightening SST Bolt
      G05319007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Tighten the SST bolt to alter the shape of the differential carrier approximately 0.1 mm (0.00394 in)

      SST 09571-50010 

      HINT.

      Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in

    13. Using a dial indicator, measure the backlash of the ring gear at 3 positions

      Backlash: 

      0.08 to 0.13 mm (0.00315 to 0.00512 in.) 

      Fig 28: Measuring Backlash Of Ring Gear
      G05752166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness

      HINT

      • Record the measured backlash to use as a reference for selecting a side gear shaft snap ring
      • Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring
  13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    Fig 29: Tightening SST Bolt
    G05319007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a dial indicator to the differential carrier.
    2. Tighten the SST bolt to alter the shape of the differential carrier by approximately 0 1 mm (0.00394 in).

      SST 09571-50010 

      NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.00787 in.).

      HINT.

      Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.

    3. Using snap ring pliers, install the thinnest side gear shaft snap ring on the ring gear tooth side
      Fig 30: Identifying Side Gear Shaft Snap Ring
      G04949164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the dial indicator and loosen the bolt (A) until the SST disc is separated from the differential side bearing outer race RH.
      Fig 31: Separating Differential Side Bearing Outer Race
      G05319080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.
      Fig 32: Tapping Ring Gear Tooth Side Of Differential Carrier
      G04949226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a dial indicator, measure the backlash of the ring gear at 3 positions If even one backlash reading is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft snap ring on the ring gear tooth side with a thicker one

      Backlash: 

      0.08 to 0.13 mm (0.00315 to 0.00512 in.) 

      HINT.

      If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

      Fig 33: Measuring Backlash Of Ring Gear
      G05319071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Loosen the 2 SST bolts and separate the SST disc from the differential side bearing outer race RH on the ring gear tooth side.
      Fig 34: Separating SST Disc From Differential Side Bearing Outer Race
      G05319012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. ADJUST TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact

      SST 09229-55010 

      Total preload (at starting): 

      New bearing: 

      1.8 to 3.6 N*m (19 to 36 kgf*cm, 16 to 31 in.*lbf) 

      Reused bearing: 

      1.1 to 2.6 N*m (12 to 26 kgf*cm, 10 to 23 in.*lbf) 

      Fig 35: Measuring Preload
      G04949159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the measured preload is less than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thicker one.
      • If the preload is greater than the specified value, replace the rear differential side gear shaft snap ring of the ring gear tooth surface side with a thinner one.

      HINT

      When the rear differential side gear shaft snap ring thickness changes by 0 02 mm (0.000787 in), the total preload will change by approximately 0 1 N*m (1 kgf*cm, 1 in.*lbf)

    2. Set a dial indicator to the end of the differential ring gear face
    3. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash
      Fig 36: Measuring Ring Gear Backlash
      G05752174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Backlash: 

      0.08 to 0.13 mm (0.00315 to 0.00512 in.) 

      NOTE:
      • 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 snap rings equally.
      • When the side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash will also change by approximately 0.02 mm (0.000787 in.).
    4. Recheck the total preload.
  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION  (See INSPECTION  )
  16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING 
    Fig 37: Identifying SST To Differential Carrier
    G05319006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install SST to the rear differential carrier with the 2 bolts

      SST 09571-50010 

    2. Install a dial indicator to the rear differential carrier
    3. Tighten the SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0 00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring
      Fig 38: Tightening SST Bolt
      G05319007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.00787 in.).

      HINT.

      • Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in
      • Approximately 0 1 mm (0.00394 in) clearance between the differential side bearing outer race RH and the side gear shaft snap ring is sufficient for the washer to move slightly
    4. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side
    5. Remove the dial indicator and loosen the SST bolt.
      NOTE: Do not remove SST.
      Fig 39: Identifying Side Gear Shaft Snap Ring
      G04949164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING 
    1. Using SST and a hammer, create a clearance between the differential side bearing outer race LH on the ring gear and side gear shaft snap ring

      SST 09608-32010, 09950-70010 (09951-07200) 

      HINT

      The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

      Fig 40: Tapping SST With Hammer
      G05319009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
      Fig 41: Identifying Side Gear Shaft Snap Ring
      G04949167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH 
    1. Tighten the SST bolt and push out the differential side bearing outer race LH on the ring gear back surface side

      SST 09571-50010 

      NOTE: Do not drop the side bearing outer race.
      Fig 42: Pushing Out Differential Side Bearing Outer Race
      G05319011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT.

      • To use as a reference for installation, clearly write the installation positions (back side or teeth side) of the differential side bearing outer race and the rear differential side gear shaft snap ring
      • Put identification marks on the differential side bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished
    2. Remove the 2 bolts and SST
      Fig 43: Separating SST Disc From Differential Side Bearing Outer Race
      G05319012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH 
    1. Raise the ring gear side of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH

      HINT:

      Fig 44: Removing Differential Side Bearing Outer Race
      G04949170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • For reassembly, check the installation position of the differential side bearing outer race and the side gear shaft snap ring before removing the differential side bearing outer race. Write down the result
      • Put identification marks on the differential side bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished
  20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Remove the rear differential case assembly.
      NOTE: Do not damage the case bearing.
      Fig 45: Removing Rear Differential Case Sub-Assembly
      G04949171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR DRIVE PINION NUT 
    1. Using SST to hold the flange, remove the drive pinion nut.

      SST 09229-55010, 09330-00021, 09950-30012 (09955-03040) 

      Fig 46: Holding Flange Removing Drive Pinion Nut
      G05319016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR DRIVE PINION COMPANION FLANGE 
    1. Using SST, remove the companion flange.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060) 

      NOTE: Apply grease to the threads and tip of the SST center bolt before use.
      Fig 47: Identifying Rear Drive Pinion Companion Flange With SST
      G05319096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Remove the differential drive pinion oil slinger.
      Fig 48: Identifying Drive Pinion Oil Slinger
      G04949177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE DIFFERENTIAL DRIVE PINION 
    1. Using a press, remove the drive pinion from the differential carrier
      NOTE: Do not drop the drive pinion.
      Fig 49: Pressing Drive Pinion From Differential Carrier
      G05752187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Remove the rear drive pinion front tapered roller bearing from the differential carrier
      Fig 50: Identifying Rear Drive Pinion Front Tapered Roller Bearing
      G05752188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER 
    1. Install a new drive pinion bearing spacer to the drive pinion.

      HINT:

      The bearing spacer can be installed in either direction

      Fig 51: Identifying Drive Pinion Bearing Spacer
      G05752189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Install the rear drive pinion front tapered roller bearing to the differential carrier.
      Fig 52: Identifying Rear Drive Pinion Front Tapered Roller Bearing
      G04949180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL DIFFERENTIAL DRIVE PINION 
    1. Using SST and a press, install the differential drive pinion to the differential carrier.

      SST 09316-60011 (09316-00011, 09316-00041), 09608-04031 

      Fig 53: Pressing Differential Drive Pinion
      G05319060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Install the differential drive pinion oil slinger to the differential drive pinion
      2. Fig 54: Identifying Drive Pinion Oil Slinger
      G04949177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL  (See REPLACEMENT  )
    Fig 55: Adjusting Differential Drive Pinion Preload
    G05319062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL REAR DRIVE PINION COMPANION FLANGE 
    1. Using SST, install the companion flange to the drive pinion

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040) 

      NOTE: Apply grease to the threads and tip of the SST center bolt before use.
    2. Coat the threads of a new drive pinion nut with hypoid gear oil LSD
    3. Using SST and a torque wrench, hold the flange and tighten the drive pinion nut
      Fig 56: Holding Flange Tightening Drive Pinion Nut
      G04949213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09229-55010, 09330-00021, 09950-30012 (09955-03040) 

      Torque: 

      490 N*m (5000 kgf*cm, 361 ft.*lbf) or less 

      NOTE:
      • Do not tighten excessively, otherwise the threads will be stripped.
      • Apply hypoid gear oil LSD to the threads of the nut and drive pinion.

      HINT.

      Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.

  32. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Insert the differential case from the ring gear tooth side
      NOTE: Do not damage the case bearing inner race or ring gear.
      Fig 57: Inserting Differential Case From Ring Gear Tooth Side To Differential Case
      G04949215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE RH 
    1. Using SST and a hammer, install the ring gear tooth side differential side bearing outer race RH.

      SST 09608-32010, 09950-70010 (09951 -07200) 

      Fig 58: Tapping Differential Side Bearing Outer Race
      G05319066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Tap in the differential side bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen

  34. INSTALL DIFFERENTIAL SIDE BEARING OUTER RACE LH 
    1. Install SST to the differential carrier with the 2 bolts.

      SST 09571-50010 

      Fig 59: Identifying SST To Differential Carrier
      G05319006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the SST bolt (A) until the SST disc lightly touches the differential side bearing outer race RH.
      Fig 60: Tapping Differential Side Bearing Outer Race
      G05296188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, install the ring gear back surface side differential side bearing outer race LH

      SST 09608-32010, 09950-70010 (09951-07200) 

      HINT

      Tap in the differential side bearing outer race until it touches the case bearing inner race roller

      Fig 61: Identifying Side Gear Shaft Snap Ring
      G04949167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING 
    1. Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

      HINT.

      Use the side gear shaft snap ring installed when performing tooth contact adjustment.

      Fig 62: Tightening SST Bolt
      G05319007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set a dial indicator on the differential carrier
    3. Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.00394 in).
      NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more that 0.2 mm (0.00787 in.).
      Fig 63: Identifying Side Gear Shaft Snap Ring
      G04949164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side

      HINT.

      Use the side gear shaft snap ring installed when performing tooth contact adjustment.

      Fig 64: Tapping Ring Gear Tooth Side Of Differential Carrier
      G04949226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the dial indicator and tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.
    6. Remove the 2 bolts and SST
      Fig 65: Separating SST Disc From Differential Side Bearing Outer Race
      G05319012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using SST and a torque wrench, measure the preload

      SST 09229-55010 

      Drive pinion preload (at starting): 

      New bearing: 

      1.2 to 1.8 N*m (13 to 18 kgf*cm, 11 to 15 in.*lbf) 

      Reused bearing: 

      0.5 to 0.8 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf) 

      Fig 66: Measuring Preload
      G04949159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut 5 to 10°

        Torque: 

        490 N*m (5000 kgf*cm, 361 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.
  37. INSPECT TOTAL PRELOAD  (See INSPECTION  )
  38. INSPECT DIFFERENTIAL RING GEAR BACKLASH  (See INSPECTION  )
  39. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION  (See INSPECTION  )
  40. STAKE REAR DRIVE PINION NUT 
    1. Using SST and a hammer, stake the drive pinion nut

      SST 09930-00010 

      Fig 67: Staking Drive Pinion Nut
      G05319116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Using SST and a hammer, install 2 new oil seals.

      SST 09223-15030, 09950-70010 (09951-07200) 

      Oil seal installation depth: 

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 

      Fig 68: Tapping Rear Differential Side Gear Shaft Oil Seal
      G05752206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT.

      • Make sure to check the identification marks on the oil seals before installation because the parts numbers differ between the left and right sides
      • To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seals
      • After installing both oil seals, tap them in until both surfaces are flush with the rear differential carrier
    2. Apply MP grease to the oil seal lips
  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. TEMPORARILY TIGHTEN REAR DIFFERENTIAL FILLER PLUG 
    1. Using a hexagon wrench (10 mm), temporarily install the differential filler plug

      HINT.

      Add differential oil before installing the gasket and fully tightening the rear differential filler plug.

  44. REMOVE REAR DIFFERENTIAL CARRIER 
    1. Remove the 4 bolts and differential carrier from the overhaul attachment
      NOTE: Clean the fitting surface between the differential carrier and carrier cover.
      Fig 69: Setting Differential Carrier To Overhaul Stand
      G04949151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR 
    1. Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush Then remove the oil with non-residue solvent or equivalent.
      NOTE: Do not scratch the sealing surface.
      Fig 70: Identifying Rear Differential Breather Plug Oil Deflector
      G04949150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear differential breather plug oil deflector to the rear differential carrier cover

      Torque: 7.0 N*m (70 kgf*cm, 62 in.*lbf) 

  46. INSTALL REAR DIFFERENTIAL CARRIER STRAIGHT PIN 
    1. Install the 2 rear differential carrier straight pins to the differential carrier.
  47. INSTALL REAR DIFFERENTIAL CARRIER COVER 
    1. Apply seal packing to the differential carrier as shown in the illustration

      Seal packing: 

      Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent 

      Fig 71: Applying Seal Packing To Differential Carrier
      G05752209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 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 carrier cover within 3 minutes of application.
        Fig 72: Locating Differential Carrier Cover With Bolts
        G05752210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the differential carrier cover with the 8 bolts and 2 pins

      Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf) 

      NOTE: Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.
  48. INSTALL REAR DIFFERENTIAL BREATHER PLUG 
    1. Install the breather plug to the differential carrier cover

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

      Fig 73: Locating Rear Differential Breather Plug
      G05752089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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