Rear Differential Carrier Assembly: Disassembly

1. Fix the rear differential carrier in place with the overhaul attachment.

1. Remove the 4 stud bolts from the transmission coupling.

1. Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.
   Fig 1: Identifying Rear Differential Drain Plug And Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.
   Fig 2: Identifying Rear Differential Filler Plug And Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using an 8 mm socket hexagon wrench, remove rear differential carrier cover plug.

Fig 3: Identifying Differential Carrier Cover Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a chisel and hammer, slightly lift up the rear differential carrier cover breather plug.
2. Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.
   Fig 4: Identifying Differential Carrier Cover Breather Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a dial gauge so that it is perpendicular to the inner side of the transmission coupling, as shown in Fig 5.
2. Using SST, rotate the transmission coupling assembly forward and backward and measure the vertical runout.

   SST 09564-32011 

   Maximum vertical runout: 0.06 mm (0.0024 in.) 

3. Install a dial gauge perpendicularly onto the transmission coupling assembly, as shown in Fig 5.
4. Using SST, rotate the transmission coupling assembly forward and backward and measure the lateral runout.

   SST 09564-32011 

   Maximum lateral runout: 0.07 mm (0.0028) 

   Fig 5: Inspecting Transmission Coupling Assembly Vertical/Lateral Runout

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts and, using a plastic-faced hammer, lightly tap the rear differential carrier cover to remove it from the rear differential carrier.
   NOTE: Set the brass bar on the ribbed part of the rear differential carrier cover.
   Fig 6: Removing Electromagnetic Coupling

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, remove the snap ring.
   Fig 7: Removing Snap Ring Using Snap Ring Expander

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the solenoid from the yoke.
3. Remove the O-ring from the solenoid.
   Fig 8: Removing O-Ring From Solenoid

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 5 mm socket hexagon wrench, remove the 3 bolts and yoke from the differential carrier.
   Fig 9: Removing Bolts And Yoke From Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the spring washer from the differential carrier.
   Fig 10: Removing Conical Spring Washer From Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the shim from the differential carrier.
   Fig 11: Removing Shim From Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Insert a dial gauge through the rear differential carrier cover plug hole, and set it perpendicular to the ring gear tooth surface's tip.
2. Using SST, fix the drive pinion in place.

   SST 09556-16011 

3. Using SST, rotate the rear differential case forward and backward, and measure the backlash.

   SST 09564-32011 

   Standard backlash: 0.09 to 0.16 mm (0.0034 to 0.0063 in.) 

   NOTE: Measure at 3 or more areas around the circumference of the ring gear.
   Fig 12: Inspecting Differential Ring Gear Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a torque wrench, inspect the preload (starting torque) within the differential drive pinion and differential ring gear backlash area.

   SST 09556-16011 

   Standard drive pinion preload: 0.24 to 0.37 Nm (2 to 4 kgf.cm, 2 to 3 in.lbf) 

   NOTE: For a more accurate measurement, rotate the case bearing forward and backward before measuring.
   Fig 13: Inspecting Differential Drive Pinion Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a torque wrench, inspect the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

   SST 09556-16011 

   Standard total preload: Standard drive pinion preload plus 0.99 to 1.63 

   Nm (10 to 17 kgf.cm, 9 to 14 in.lbf) 

   NOTE: For a more accurate measurement, rotate the case bearing forward and backward before measuring.
   Fig 14: Inspecting Total Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, tap out the 2 rear differential side shaft gear oil seals from the rear differential carrier.

   SST 09308-00010 

   Fig 15: Removing Differential Side Gear Shaft Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the diaphragm oil seal from the rear differential carrier.

   SST 09308-10010 

   Fig 16: Removing Diaphragm Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, unstake the rear drive pinion nut.

   SST 09930-00010 

   NOTE:

   • Use SST with the tapered part against the shaft side.
   • Do not modify the SST tip with a grinder or equivalent.
   • Fully unstake the rear drive pinion nut
     Fig 17: Unstaking Rear Drive Pinion Nut

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, fix the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.

   SST 09556-16011, 09564-16020 

   Fig 18: Removing Rear Drive Pinion Nut From Differential Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the rear drive pinion tapered roller bearing front (inner race) from the rear differential carrier.

   SST 09556-30010 

   Fig 19: Removing Rear Drive Pinion Front Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 8 bolts.
   Fig 20: Removing Differential Side Bearing Retainer Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, lightly tap out the differential side bearing retainer.
   NOTE: Set the brass bar on the ribbed part of the differential side bearing retainer.
   Fig 21: Removing Differential Side Bearing Retainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the rear differential case from the rear differential carrier.
   Fig 22: Identifying Differential Case Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the differential drive pinion from the rear differential carrier.
   Fig 23: Removing Differential Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the rear differential drive pinion bearing spacer from the differential drive pinion.
   Fig 24: Removing Differential Drive Pinion Bearing Spacer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press out the rear drive pinion tapered roller bearing rear (inner race) from the differential drive pinion.

   SST 09950-00020 

   Fig 25: Removing Rear Drive Pinion Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If the rear differential drive pinion or differential ring gear is damaged, replace them both.
2. Remove the rear differential drive pinion washer.

1. Using SST, remove the rear drive pinion tapered roller bearing front (outer race) from the rear differential carrier.

   SST 09612-65014 (09612-01020, 09612-01050) 

   Fig 26: Removing Rear Drive Pinion Front Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and hammer, lightly and uniformly tap out the rear drive pinion tapered roller bearing rear (outer race).
   NOTE: Set the brass bar on the notch.
   Fig 27: Removing Rear Drive Pinion Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09950-60010 (09951-00460), 09950-70010 (09951-07100), 09649-17010 (09951-00510) 

1. Using SST and a press, press out the rear differential case bearing RH (outer race) and rear differential side gear shaft plate washer from the rear differential carrier.

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

   Fig 28: Removing Differential Case Bearing RH (Outer Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the rear differential case bearing LH (outer race) and rear differential side gear shaft plate washer from the differential side bearing retainer.

   SST 09950-60010 (09951-00460), 09950-70010 (09951-07100), 09649-17010 

   Fig 29: Removing Differential Case Bearing LH (Outer Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the rear differential case bearing RH (inner race) from the rear differential case.

   SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00320, 09955-04071) 

   NOTE: Before using SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.
   Fig 30: Removing Rear Differential Case Bearing RH (Inner Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rear differential case bearing LH (inner race) from the rear differential case.

   SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011), 09950-60010 (09951-00320) 

   NOTE: Before using SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.
   Fig 31: Removing Rear Differential Case Bearing LH (Inner Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   If the race is remains on the rear differential case, repeat the step above to remove the race.

1. Place matchmarks on the rear differential case and differential ring gear.
2. Remove the 10 bolts.
3. Using a plastic-faced hammer, lightly tap the outer circumference of the differential ring gear to remove it from the rear differential case.
   Fig 32: Removing Differential Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.
Fig 33: Removing Differential Breather Plug Oil Deflector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 34: Removing Straight Pin

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using pliers, remove the 4 straight pins from the rear differential carrier.

1. Remove the bolt and bracket.