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FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): Inspection: Inspection

  1. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH 
    1. 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 1: Setting Lever Probe To Dial Indicator
      GTY122652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange by hand.
      Fig 2: Measuring Ring Gear Backlash
      GTY136815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-32011 

      Backlash

      0.08 to 0.13 mm (0.0031 to 0.0051 in.)

      HINT: 

      • 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.
      • Select the case washer from the table below so that the backlash is within the specified range, and install the selected washer.
    3. If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.
      WASHER THICKNESS

      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      2.21 to 2.23 (0.0870 to 0.0878) 2.55 to 2.57 (0.1004 to 0.1012) 2.89 to 2.91 (0.1138 to 0.1146)
      2.23 to 2.25 (0.0878 to 0.0886) 2.57 to 2.59 (0.1012 to 0.1020) 2.91 to 2.93 (0.1146 to 0.1154)
      2.25 to 2.27 (0.0886 to 0.0894) 2.59 to 2.61 (0.1020 to 0.1028) 2.93 to 2.95 (0.1154 to 0.1161)
      2.27 to 2.29 (0.0894 to 0.0902) 2.61 to 2.63 (0.1028 to 0.1035) 2.95 to 2.97 (0.1161 to 0.1169)
      2.29 to 2.31 (0.0902 to 0.0909) 2.63 to 2.65 (0.1035 to 0.1043) 2.97 to 2.99 (0.1169 to 0.1177)
      2.31 to 2.33 (0.0909 to 0.0917) 2.65 to 2.67 (0.1043 to 0.1051) 2.99 to 3.01 (0.1177 to 0.1185)
      2.33 to 2.35 (0.0917 to 0.0925) 2.67 to 2.69 (0.1051 to 0.1059) 3.01 to 3.03 (0.1185 to 0.1193)
      2.35 to 2.37 (0.0925 to 0.0933) 2.69 to 2.71 (0.1059 to 0.1067) 3.03 to 3.05 (0.1193 to 0.1201)
      2.37 to 2.39 (0.0933 to 0.0941) 2.71 to 2.73 (0.1067 to 0.1075) 3.05 to 3.07 (0.1201 to 0.1209)
      2.39 to 2.41 (0.0941 to 0.0949) 2.73 to 2.75 (0.1075 to 0.1083) 3.07 to 3.09 (0.1209 to 0.1217)
      2.41 to 2.43 (0.0949 to 0.0957) 2.75 to 2.77 (0.1083 to 0.1091) 3.09 to 3.11 (0.1217 to 0.1224)
      2.43 to 2.45 (0.0957 to 0.0965) 2.77 to 2.79 (0.1091 to 0.1098) 3.11 to 3.13 (0.1224 to 0.1232)
      2.45 to 2.47 (0.0965 to 0.0972) 2.79 to 2.81 (0.1098 to 0.1106) 3.13 to 3.15 (0.1232 to 0.1240)
      2.47 to 2.49 (0.0972 to 0.0980) 2.81 to 2.83 (0.1106 to 0.1114) 3.15 to 3.17 (0.1240 to 0.1248)
      2.49 to 2.51 (0.0980 to 0.0988) 2.83 to 2.85 (0.1114 to 0.1122) 3.17 to 3.19 (0.1248 to 0.1256)
      2.51 to 2.53 (0.0988 to 0.0996) 2.85 to 2.87 (0.1122 to 0.1130) 3.19 to 3.21 (0.1256 to 0.1264)
      2.53 to 2.55 (0.0996 to 0.1004) 2.87 to 2.89 (0.1130 to 0.1138) 3.21 to 3.23 (0.1264 to 0.1272)
  2. INSPECT FRONT DRIVE PINION COMPANION FLANGE 
    1. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
      Fig 3: Measuring Runout Of Companion Flange Vertically & Horizontally Using Dial Indicator
      GTY113096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum runout

      0.05 mm (0.0020 in.)

      If the runout is greater than the maximum value, replace the companion flange.

  3. INSPECT DRIVEN PINION PRELOAD 
    1. Using a torque wrench, measure the preload using the backlash of the drive pinion and ring gear.
      Fig 4: Measuring Drive Pinion Preload
      GTY122371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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)

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

  4. INSPECT TOTAL PRELOAD 
    1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
      Fig 5: Measuring Drive Pinion Preload
      GTY122371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Total preload (at starting)

      New bearing 

      1.27 to 2.06 N*m (13.0 to 21.0 kgf*cm, 11.2 to 18.2 in.*lbf)

      Reused bearing 

      0.78 to 1.27 N*m (8.0 to 13.0 kgf*cm, 6.9 to 11.2 in.*lbf)

      If the total preload is not within the specified range, adjust the total preload or repair as necessary.

  5. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Remove the 8 bolts and side bearing retainer.
      Fig 6: Identifying Differential Side Bearing Retainer Bolts
      GTY113100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the differential case from the differential carrier.
      Fig 7: Removing/Installing Differential Case
      GTY129052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.
      Fig 8: Applying Red Lead Primer To Ring Gear Teeth
      GTY130818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the differential case to the differential carrier.
    5. Install the differential side bearing retainer with the 8 bolts.
      Fig 9: Identifying Differential Side Bearing Retainer Bolts
      GTY113100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. Rotate the ring gear in both directions.
    7. Remove the 8 bolts and side bearing retainer.
    8. Remove the differential case from the differential carrier.
    9. Inspect the tooth contact pattern.
      Fig 10: Identifying Tooth Contact Pattern
      GTY113173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. If the teeth are not contacting properly, use the following table to select a proper adjust shim for correction.
      Fig 11: Identifying Adjust Shim
      GTY126256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the contact pattern is either face contact or flank contact, the tooth contact may be adjustable while keeping the backlash within the specified range.
      • If the thickness of the front adjust shim has been changed, adjust the backlash and measure the total preload.
      WASHER THICKNESS:

      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      2.345 to 2.355 (0.0923 to 0.0927) 2.465 to 2.475 (0.0970 to 0.0974) 2.585 to 2.595 (0.1018 to 0.1022)
      2.355 to 2.365 (0.0927 to 0.0931) 2.475 to 2.485 (0.0974 to 0.0978) 2.595 to 2.605 (0.1022 to 0.1026)
      2.365 to 2.375 (0.0931 to 0.0935) 2.485 to 2.495 (0.0978 to 0.0982) 2.605 to 2.615 (0.1026 to 0.1030)
      2.375 to 2.385 (0.0935 to 0.0939) 2.495 to 2.505 (0.0982 to 0.0986) 2.615 to 2.625 (0.1030 to 0.1033)
      2.385 to 2.395 (0.0939 to 0.0943) 2.505 to 2.515 (0.0986 to 0.0990) 2.625 to 2.635 (0.1033 to 0.1037)
      2.395 to 2.405 (0.0943 to 0.0947) 2.515 to 2.525 (0.0990 to 0.0994) 2.635 to 2.645 (0.1037 to 0.1041)
      2.405 to 2.415 (0.0947 to 0.0951) 2.525 to 2.535 (0.0994 to 0.0998) 2.645 to 2.655 (0.1041 to 0.1045)
      2.415 to 2.425 (0.0951 to 0.0955) 2.535 to 2.545 (0.0998 to 0.1002) 2.655 to 2.665 (0.1045 to 0.1049)
      2.425 to 2.435 (0.0955 to 0.0959) 2.545 to 2.555 (0.1002 to 0.1006) 2.665 to 2.675 (0.1049 to 0.1053)
      2.435 to 2.445 (0.0959 to 0.0963) 2.555 to 2.565 (0.1006 to 0.1010) 2.675 to 2.685 (0.1053 to 0.1057)
      2.445 to 2.455 (0.0963 to 0.0967) 2.565 to 2.575 (0.1010 to 0.1014) 2.685 to 2.695 (0.1057 to 0.1061)
      2.455 to 2.465 (0.0967 to 0.0970) 2.575 to 2.585 (0.1014 to 0.1018) 2.695 to 2.705 (0.1061 to 0.1065)
  6. INSPECT AND ADJUST DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Hold the differential case in a vise between aluminum plates.
      Fig 12: Holding Differential Case In Vise
      GTY112935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not overtighten the vise.

    2. Measure the side gear backlash while holding 1 pinion gear toward the differential case.

      Backlash

      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specified range, install the 2 side gear thrust washers of different thicknesses.

      HINT: 

      Refer to the following table to select the 2 side gear thrust washers.

      WASHER THICKNESS:

      Mark Thickness mm (in.)
      14 0.93 to 0.97 (0.0366 to 0.0382)
      02 0.98 to 1.02 (0.0386 to 0.0402)
      15 1.03 to 1.07 (0.0406 to 0.0421)
      03 1.08 to 1.12 (0.0425 to 0.0441)
      16 1.13 to 1.17 (0.0445 to 0.0461)
      04 1.18 to 1.22 (0.0465 to 0.0480)
  7. INSPECT DIFFERENTIAL PINION AND SIDE GEAR 
    1. Check that there is no damage to the differential pinion gears and side gears.

      If a differential pinion gear and/or side gear is damaged, replace them with new ones.

  8. INSPECT DIFFERENTIAL CASE 
    1. Check that there is no damage to the differential case.

      If the differential case is damaged, replace it.

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