Reassembly

AXLE AND DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH

(a) Using SST and a press, press in the shaft bearing.

SST : 09223-00010

(b) Using a snap ring expander, install the snap ring.

HINT
Install the snap ring securely.

2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

(a) Install the shaft to the differential tube.

(b) Using snap ring expander, install the snap ring.

HINT
Install the snap ring securely.

3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Coat the lip of a new oil seal with MP grease.

Using SST and a plastic-faced hammer, tap in the oil seal.

SST : 09223-15020

Standard oil seal depth:

4.8 to 5.8 mm (0.189 to 0.229 in.)

Text in Illustration

4. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Install the 2 thrust washers to the 2 side gears.

Standard Thrust Washer:

Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion thrust washers and pinion shaft to the differential case.

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

Measure the side gear backlash.

(1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.

Standard backlash:

0.15 mm (0.00591 in.) or less

If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.

Using a 5 mm pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

(b) Stake the differential case.

5. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and ring gear.

(b) Heat the ring gear in water that is approximately 100°C (212°F).

(c) Carefully remove the ring gear from the boiling water.

(d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

Align the matchmarks on the ring gear with those of the differential case.

Text in Illustration

(e) After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.

Adhesive:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

Torque : 115 Nm (1173 kgf-cm, 85 ft-lbf)

6. INSTALL FRONT DIFFERENTIAL CASE BEARING

(a) Using SST and a press, press the 2 bearings (inner) into the differential case.

SST : 09950-60010

09951-00520

09951-00610

SST : 09950-70010

09951-07150

7. INSTALL FRONT DIFFERENTIAL CASE BEARING

HINT
When replacing the 3 differential case bearings, install the 2 thinnest new washers onto each bearing. When reusing the bearings, install the new case washers to the same places they were removed from.

Using SST and a press, press the case bearing (outer race) into the differential case bearing retainer.

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07150

Text in Illustration

Using SST and a press, press the case bearing (outer) into the differential carrier.

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07150

Text in Illustration

8. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

(a) Using SST, install the front drive pinion rear tapered roller bearing (outer race).

SST : 09950-60020

09951-00720

09951-00890

9. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using a brass bar and hammer, tap in the oil storage ring.

(b) Using SST, install the front drive pinion front tapered roller bearing (outer race).

SST : 09950-60020

09951-00720

09951-00890

Text in Illustration

10. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Install the washer to the drive pinion.

HINT
First, install a washer that has the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

(b) Using SST and a press, press the front bearing onto the drive pinion.

SST : 09506-30012

11. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Install the drive pinion, roller bearing and oil slinger to the differential case.

HINT
Install the spacer, oil storage ring and oil seal after adjusting the gear contact pattern.

Using SST, install the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

NOTICE:
Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

Text in Illustration

(b) Adjust the drive pinion preload by tightening the companion flange nut.

Using SST to hold the flange in place, tighten the nut.

SST : 09330-00021

Torque : 370 Nm (3770 kgf-cm, 273 ft-lbf) or less

NOTICE:
* As there is no spacer, tighten the nut a little at a time. Be careful not to overtighten it.
* Apply LSD gear oil to the nut.

Using a torque wrench, measure the preload.

Standard Preload (at Starting):

NOTICE:
For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

12. INSTALL DIFFERENTIAL CASE ASSEMBLY

13. ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Install the side bearing retainer with the 10 bolts.

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

Using SST and a dial indicator, measure the ring gear backlash.

SST : 09564-32011

Standard backlash:

0.11 to 0.21 mm (0.00433 to 0.00826 in.)

If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.

HINT
There should be no clearance between the plate washer and case. Make sure that the ring gear has backlash.

Standard Washer:

14. INSPECT TOTAL PRELOAD

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

Standard Total Preload (at Starting):

If necessary, disassemble and inspect the differential.

15. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Remove the differential case bearing retainer and differential case.

(b) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

(c) Install the differential case and differential case bearing retainer.

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

(d) Hold the companion flange firmly in place and rotate the ring gear in both directions.

(e) Remove the differential case bearing retainer and differential case.

(f) Inspect the tooth contact pattern.

If the teeth are not contacting properly, use the following chart to select an appropriate washer.

Text in Illustration

Standard Washer:

16. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT Disassembly

17. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Disassembly

18. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

19. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER) Disassembly

20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER) Disassembly

21. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER Replacement

22. INSTALL FRONT DIFFERENTIAL OIL STORAGE RING Replacement

23. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

(a) Using SST and a hammer, install the roller bearing (outer).

SST : 09316-60011

09316-00011

09316-00021

24. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

(a) Install the roller bearing (inner).

25. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

26. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.

Using SST and a hammer, tap in the oil seal.

SST : 09554-22010

Standard oil seal depth:

3.9 to 4.8 mm (0.154 to 0.188 in.)

Text in Illustration

27. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR

(a) Using a steel plate and press, press in a new dust deflector.

Text in Illustration

NOTICE:
Do not damage the dust deflector.

28. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Place the companion flange on the drive pinion.

(b) Using SST, install the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

NOTICE:
Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

(c) Coat the threads of a new nut with LSD oil.

(d) Using SST to hold the companion flange in place, tighten the nut to the correct torque.

SST : 09330-00021

09330-00030

Torque : 370 Nm (3773 kgf-cm, 273 ft-lbf) or less

29. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

(a) Remove any old FIPG material from the side bearing retainer.

NOTICE:
Do not drop oil on the contact surfaces of the differential carrier and side bearing retainer.

(b) Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

Apply seal packing to the side bearing retainer as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Text in Illustration

HINT
Install the side bearing retainer within 10 minutes of applying seal packing.

(c) Install the side bearing retainer with the 10 bolts.

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

(d) Using a brass bar and hammer, install the union.

30. INSPECT DRIVE PINION PRELOAD

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

Standard Preload (at Starting):

If the result not as specified, replace the bearing spacer.

If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

Torque : 370 Nm (3773 kgf-cm, 273 ft-lbf) or less

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.

HINT
Do not loosen the pinion nut to reduce the preload.

31. INSPECT TOTAL PRELOAD

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

Standard Total Preload (at Starting):

If necessary, disassemble and inspect the differential.

32. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Using SST and a dial indicator, measure the ring gear backlash.

SST : 09564-32011

Standard backlash:

0.11 to 0.21 mm (0.0043 to 0.00826 in.)

If the backlash is not within the specification, adjust the side bearing preload.

33. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Distance from center to runout measurement point:

30 mm (1.18 in.)

Maximum Runout:

Text in Illustration

If the runout is more than the maximum, replace the companion flange.

34. STAKE FRONT DRIVE PINION COMPANION FLANGE NUT

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

35. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Coat the lip of a new oil seal with MP grease.

(b) Using SST and a plastic-faced hammer, tap in the oil seal until its surface is flush with the differential carrier end.

SST : 09608-32010

Standard oil seal depth:

-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

36. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

(a) Using a brass bar and hammer, tap in the side bearing retainer deflector.

NOTICE:
Install the side bearing retainer deflector so that it is facing in the correct direction.

37. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY

(a) Remove any old FIPG material from the contact surfaces of the differential and clutch case.

NOTICE:
Do not drop oil on the contact surfaces of the differential and clutch case.

(b) Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

Apply seal packing to the differential as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Text in Illustration

HINT
Install the differential tube within 10 minutes of applying seal packing.

(c) Install the differential tube to the differential.

(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

(e) Apply adhesive to 2 or 3 threads at the tip of each bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Using an E14 "TORX" socket wrench, install the 4 bolts.

Torque : 110 Nm (1120 kgf-cm, 81 ft-lbf)