Rear Differential Carrier Assembly: Reassembly

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INSTALL WIRING HARNESS CLAMP BRACKET
1. Install the bracket with the bolt.
INSTALL ELBOW TUBE
INSTALL STRAIGHT PIN

Fig 1: Installing Straight Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a plastic hammer, install the 4 straight pins to the rear differential carrier.
2. Thoroughly clean oil and water from the surface of the rear differential case that will face the differential ring gear.
INSTALL DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Using a 5 mm socket hexagon wrench, install the rear differential breather plug oil deflector with the 2 bolts.
  Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)
  
  NOTE: Install it so that the arrow mark faces the front (transmission coupling side) of the vehicle.
  
  Fig 2: Installing Differential Breather Plug Oil Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL RING GEAR
1. Align the matchmarks on the rear differential case and differential ring gear, and install the differential ring gear.
2. Install 10 new differential case bolts.
  Torque: 90 Nm (918 kgf.cm, 66 ft.lbf)
  NOTE:
  - The new bolts are coated with heat resistant oil. Do not wash it off.
  - Install the rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.
INSTALL DIFFERENTIAL CASE BEARING
1. Using SST and a press, press-fit the rear differential case bearing RH (inner race) to the rear differential case.
  SST 09223-50010
  
  NOTE: If the rear differential case bearing inner race is damaged, replace it with a new one.
  
  Fig 4: Installing Rear Differential Case Bearing RH (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press-fit the rear differential case bearing LH (inner race) to the rear differential case.
  SST 09223-50010
  
  NOTE: If the rear differential case bearing inner race is damaged, replace it with a new one.
  
  Fig 5: Installing Rear Differential Case Bearing LH (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CASE BEARING
1. Using SST and a press, press-fit the rear differential side gear shaft washer and rear differential case bearing LH (outer race) to the differential side bearing retainer. (See Fig 6)
  SST 09950-60010 (09951-00510, 09951-00620, 09952-06010), 09950-70010 (09951-07150)
  NOTE:
  - Install each rear differential side gear shaft washer to the place it was removed from.
  - When replacing a bearing, replace the inner and outer races as a set.
  - Install the rear differential side gear shaft oil seal after performing the teeth contact inspection and backlash adjustment.
    
    Fig 6: Installing Rear Differential Case Bearing LH (Outer Race)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press-fit the rear differential side gear shaft washer and rear differential case bearing RH (outer race) to the rear differential carrier. (See Fig 7)
  SST 09950-60010 (09951-00510, 09951-00620, 09952-06010), 09950-70010 (09951-07150)
  NOTE:
  - Install each rear differential side gear shaft washer to the place it was removed from.
  - When replacing a bearing, replace the inner and outer races as a set.
  - Install the rear differential side gear shaft oil seal after performing the teeth contact inspection and backlash adjustment.
    
    Fig 7: Installing Rear Differential Case Bearing RH (Outer Race)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press-fit the rear drive pinion tapered roller bearing front (outer race) to the rear differential carrier.
  SST 09950-60010 (09951-00550), 09950-60020 (09951-00680), 09950-70010 (09951-07100)
  
  Fig 8: Installing Rear Drive Pinion Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using SST, bolts, nuts and washers, install the rear drive pinion tapered roller bearing rear (outer race) to the rear differential carrier.
  SST 09950-60010 (09951-00600), 09950-60020 (09951-00680, 09951-00750)
  
  HINT:
  
  Use M12 x P1.25 bolts with shaft lengths of 186 mm (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for the installation.
INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Install the rear differential drive pinion washer to the differential drive pinion.
  NOTE: Install each rear differential drive pinion washer to the place it was removed from.
  
  Fig 9: Installing Rear Drive Pinion Rear Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press-fit the tapered roller rear (inner race) to the differential drive pinion.
  SST 09506-30012

ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

Install the differential drive pinion (with rear drive pinion tapered roller bearing rear inner race) to the rear differential carrier.
Install the rear drive pinion tapered roller bearing front inner race and a new rear drive pinion nut to the differential drive pinion.
NOTE:
- New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.
- If reusing a bearing, coat it with hypoid gear oil SX.
Using SST, tighten a new rear drive pinion nut a little at a time until the specified preload is reached. Do not exceed the torque limit shown below.
SST 09556-16011, 09564-16020

Torque:

245 Nm (2,500 kgf.cm, 181 ft.lbf) for use without SST

223 Nm (2,273 kgf.cm, 164 ft.lbf) for use with SST

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.)

Fig 11: Tightening Rear Drive Pinion Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a torque wrench, measure the starting torque of the differential drive pinion.

SST 09556-16011

Standard drive pinion preload (start torque)

BEARING PRELOAD SPECIFICATION

Bearing	Preload
New bearing	1.31 to 2.18 Nm (13 to 22 kgf.cm, 12 to 19 in.lbf)
Reused bearing	0.24 to 0.37 Nm (2 to 4 kgf.cm, 2 to 3 in.lbf)

Fig 12: Measuring Starting Torque Of Differential Drive Pinion

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

For a more accurate measurement, rotate the bearing forward and backward before inspecting.
Record the preload measurement for use with the total preload inspection.

INSTALL DIFFERENTIAL CASE
1. Install the rear differential case to the rear differential carrier.
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
1. Using a scraper and wire brush, clean the seal packing from the rear differential carrier and differential side bearing retainer.
  
  Fig 13: Installing Differential Side Bearing Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not scratch the installation area.
2. Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.
  Torque: 34 Nm (350 kgf.cm, 25 ft.lbf)
  
  Fig 14: Installing Differential Side Bearing Retainer To Rear Differential Carrier With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL RING GEAR BACKLASH

Insert a dial gauge through the rear differential carrier cover plug hole, and set it perpendicular to the ring gear tooth surface's tip. (See Fig 15)
Using SST, fix the drive pinion in place.
SST 09556-16011
Using SST, rotate the rear differential case forward and backward, and measure the backlash.
SST 09564-16020

NOTE: Measure at 3 or more areas around the circumference of the ring gear.

If the result is not within the specified range, select washers that are thicker or thinner as necessary, where the thickness for the left and right side is the same. Then perform the rear differential case bearing outer race installation.

HINT:

If the backlash is small, select a thick washer for the RH side and a thin washer for the LH side.
If the backlash is large, select a thin washer for the RH side and a thick washer for the LH side.

Fig 15: Adjusting Differential Ring Gear Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Rear differential side gear shaft washer list

REAR DIFFERENTIAL SIDE GEAR SHAFT WASHER THICKNESS SPECIFICATION

Part No.	Thickness mm (in.)	Identifying Mark	Part No.	Thickness mm (in.)	Identifying Mark
90564-37022	1.59 to 1.61 (0.0625 to 0.0633)	A0	90564-37040	2.13 to 2.15 (0.0839 to 0.0846)	B8
90564-37023	1.62 to 1.64 (0.0637 to 0.0649)	A1	90564-37041	2.16 to 2.18 (0.0850 to 0.0858)	B9
90564-37024	1.65 to 1.67 (0.0650 to 0.0657)	A2	90564-37042	2.19 to 2.21 (0.0862 to 0.0870)	C0
90564-37025	1.68 to 1.70 (0.0661 to 0.0669)	A3	90564-37043	2.22 to 2.24 (0.0874 to 0.0882)	C1
90564-37026	1.71 to 1.73 (0.0673 to 0.0681)	A4	90564-37044	2.25 to 2.27 (0.0886 to 0.0894)	C2
90564-37027	1.74 to 1.76 (0.0685 to 0.0693)	A5	90564-37045	2.28 to 2.30 (0.0898 to 0.0906)	C3
90564-37028	1.77 to 1.79 (0.0697 to 0.0705)	A6	90564-37046	2.31 to 2.33 (0.0909 to 0.0917)	C4
90564-37029	1.80 to 1.82 (0.0709 to 0.0717)	A7	90564-37047	2.34 to 2.36 (0.0921 to 0.0929)	C5
90564-37030	1.83 to 1.85 (0.0720 to 0.0728)	A8	90564-37048	2.37 to 2.39 (0.0930 to 0.0941)	C6
90564-37031	1.86 to 1.88 (0.0732 to 0.0740)	A9	90564-37049	2.40 to 2.42 (0.0945 to 0.0953)	C7
90564-37032	1.89 to 1.91 (0.0744 to 0.0752)	B0	90564-37050	2.43 to 2.45 (0.0957 to 0.0965)	C8
90564-37033	1.92 to 1.94 (0.0756 to 0.0764)	B1	90564-37051	2.46 to 2.48 (0.0969 to 0.0976)	C9
90564-37034	1.95 to 1.97 (0.0768 to 0.0776)	B2	90564-37052	2.49 to 2.51 (0.0980 to 0.0988)	D0
90564-37035	1.98 to 2.00 (0.0780 to 0.0787)	B3	90564-37053	2.52 to 2.54 (0.0992 to 0.1000)	D1
90564-37036	2.02 to 2.04 (0.0795 to 0.0803)	B4	90564-37054	2.55 to 2.57 (0.1004 to 0.1012)	D2
90564-37037	2.04 to 2.06 (0.0803 to 0.0811)	B5	90564-37055	2.58 to 2.60 (0.1016 to 0.1024)	D3
90564-37038	2.07 to 2.09 (0.0815 to 823)	B6	90564-37056	2.61 to 2.63 (1.1028 to 0.1035)	D4
90564-37039	2.10 to 2.12 (0.0827 to 0.0835)	B7	90564-37057	2.64 to 2.66 (0.1039 to 0.1047)	D5

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Remove the 8 bolts and differential side bearing retainer from the rear differential carrier.
Remove the rear differential carrier case.
Uniformly apply a light coat of Prussian blue on both sides of the differential ring gear teeth.
Install the rear differential case.
Temporarily install the differential side bearing retainer to the differential carrier with the 8 bolts.
Rotate the differential side pinion several times.
Remove the 8 bolts and rear differential side bearing retainer from the differential carrier.
Check the tooth contact pattern of the differential drive pinion and differential ring gear.

Fig 16: Inspecting Tooth Contact Between Ring Gear And Drive Pinion
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Check the tooth contact pattern at 2 or more positions around circumference of the differential ring gear.
Perform the following procedures for face or flank contact.
1. Select washers that are thicker or thinner as necessary, where the thickness for the left and right side is the same. Then install the rear differential case bearing outer race.(*1)
2. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.
  HINT:
  
  If the tooth contact pattern is not correct, repeat*1.
3. Repeat the differential ring gear and differential drive pinion backlash inspection.
  HINT:
  
  If the differential ring gear and differential drive pinion backlash is not as specified, replace the differential ring gear and differential drive pinion with new ones.

Perform the following procedures for heel or toe contact.

Select a drive pinion washer again and perform the rear drive pinion tapered roller bearing rear installation.

Rear differential drive pinion washer

REAR DIFFERENTIAL DRIVE PINION WASHER THICKNESS SPECIFICATION

Part No.	Thickness (mm)	Identifying Mark	Part No.	Thickness (mm)	Identifying Mark
90564-35041	1.695 to 1.705 (0.0667 to 0.0671)	41	90564-35071	1.955 to 1.965 (0.0770 to 0.0774)	71
90564-35042	1.705 to 1.715 (0.0671 to 0.0675)	42	90564-35072	1.965 to 1.975 (0.0774 to 0.0778)	72
90564-35043	1.715 to 1.725 (0.0675 to 0.0679)	43	90564-35073	1.975 to 1.985 (0.0778 to 0.0781)	73
90564-35044	1.725 to 1.735 (0.0679 to 0.0683)	44	90564-35074	1.985 to 1.995 (0.0781 to 0.0785)	74
90564-35045	1.735 to 1.745 (0.0683 to 0.0687)	45	90564-35075	1.995 to 2.005 (0.0785 to 0.0789)	75
90564-35046	1.745 to 1.755 (0.0687 to 0.0690)	46	90564-35076	2.005 to 2.015 (0.0789 to 0.0793)	76
90564-35047	1.755 to 1.765 (0.0690 to 0.0695)	47	90564-35077	2.015 to 2.025 (0.0793 to 0.0797)	77
90564-35048	1.765 to 1.775 (0.0695 to 0.0699)	48	90564-35078	2.025 to 2.035 (0.0797 to 0.0801)	78
90564-35049	1.775 to 1.785 (0.0699 to 0.0703)	49	90564-35079	2.035 to 2.045 (0.0801 to 0.0805)	79
90564-35050	1.785 to 1.795 (0.0703 to 0.0707)	50	90564-35080	2.045 to 2.055 (0.0805 to 0.0809)	80
90564-35051	1.795 to 1.805 (0.0707 to 0.0711)	51	90564-35081	2.055 to 2.065 (0.0809 to 0.0813)	81
90564-35052	1.805 to 1.815 (0.0707 to 0.0715)	52	90564-35082	2.065 to 2.075 (0.0813 to 0.0817)	82
90564-35053	1.815 to 1.825 (0.0715 to 0.0719)	53	90564-35083	2.075 to 2.085 (0.0817 to 0.0821)	83
90564-35054	1.825 to 1.835 (0.0719 to 0.0720)	54	90564-35084	2.085 to 2.095 (0.0821 to 0.0825)	84
90564-35055	1.835 to 1.845 (0.0719 to 0.0726)	55	90564-35085	2.095 to 2.105 (0.0825 to 0.0829)	85
90564-35056	1.845 to 1.855 (0.0726 to 0.0730)	56	90564-35086	2.105 to 2.115 (0.0829 to 0.0833)	86
90564-35057	1.855 to 1.865 (0.0730 to 0.0734)	57	90564-35087	2.115 to 2.125 (0.0833 to 0.0837)	87
90564-35058	1.865 to 1.875 (0.0734 to 0.0738)	58	90564-35088	2.125 to 2.135 (0.0837 to 0.0841)	88
90564-35059	1.875 to 1.885 (0.0734 to 0.0742)	59	90564-35089	2.135 to 2.145 (0.0841 to 0.0844)	89
90564-35060	1.885 to 1.895 (0.0742 to 0.0746)	60	90564-35090	2.145 to 2.155 (0.0844 to 0.0848)	90
90564-35061	1.895 to 1.905 (0.0746 to 0.0750)	61	90564-35091	2.155 to 2.165 (0.0848 to 0.0852)	91
90564-35062	1.905 to 1.915 (0.0750 to 0.0754)	62	90564-35092	2.165 to 2.175 (0.0852 to 0.0856)	92
90564-35063	1.915 to 1.925 (0.0754 to 0.0758)	63	90564-35093	2.175 to 2.185 (0.0856 to 0.0860)	93
90564-35064	1.925 to 1.935 (0.0758 to 0.0762	64	90564-35094	2.185 to 2.195 (0.0860 to 0.0864)	94
90564-35065	1.935 to 1.945 (0.0762 to 0.0766)	65	90564-35095	2.195 to 2.205 (0.0864 to 0.0868)	95
90564-35070	1.945 to 1.955 (0.0766 to 0.0770)	70	-	-	-

INSPECT TOTAL PRELOAD

Using SST and a torque wrench, measure the starting torque with the teeth of the differential drive pinion and differential ring gear in contact.

SST 09556-16011

Fig 17: Inspecting Starting Torque Using SST And Torque Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard total preload: Standard drive pinion preload plus

BEARING PRELOAD SPECIFICATION

Bearing	Preload
New bearing	1.18 to 1.63 Nm (12 to 17 kgf.cm, 10 to 14 in.lbf)
Reused bearing	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.

If the results are not within the specification, perform the procedures below.
1. Select a side gear shaft washer for the RH side again, and then perform the rear differential case bearing outer race installation (RH side only).
2. Repeat the total preload inspection.
3. Repeat the ring gear backlash inspection.
4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

REMOVE DIFFERENTIAL SIDE BEARING RETAINER
1. Remove the 8 bolts and differential side bearing retainer from the rear differential carrier.
REMOVE DIFFERENTIAL CASE
1. Remove the rear differential case from the rear differential carrier.
REMOVE DIFFERENTIAL DRIVE PINION
INSTALL DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
  
  Fig 18: Installing Differential Drive Pinion Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL DRIVE PINION
1. Install the differential drive pinion to the rear differential carrier.
INSTALL REAR DRIVE PINION NUT
1. Apply hypoid gear oil LSD to the threads of the rear drive pinion nut.
  
  Fig 19: Installing Differential Drive Pinion To Rear Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new rear drive pinion nut to the differential drive pinion. Using SST, tighten the nut while confirming the preload. (See Fig 20)
  SST 09556-16011, 09564-16020 SST 09564-16020
  
  Torque:
  
  245 Nm (2,500 kgf.cm, 181 ft.lbf) for use without SST
  
  223 Nm (2,273 kgf.cm, 164 ft.lbf) for use with SST
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
  
  Fig 20: Installing New Rear Drive Pinion Nut To Differential Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

Using SST and a torque wrench, inspect the starting torque.

SST 09556-16011

Standard drive pinion preload

Fig 21: Inspecting Starting Torque Using SST And Torque Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

BEARING PRELOAD SPECIFICATION

Bearing	Preload
New bearing	1.31 to 2.18 Nm (13 to 22 kgf.cm, 12 to 19 in.lbf)
Reused bearing	0.24 to 0.37 Nm (2 to 4 kgf.cm, 2 to 3 in.lbf)

NOTE:

For a more accurate measurement, rotate the bearing forward and backward before adjusting.
Adjust it so that it matches the drive pinion temporary adjustment starting torque.

If the preload is insufficient, use SST to tighten the drive pinion nut 5 to 10° at a time. Measure the starting torque and repeat the adjustment as necessary until the preload matches the specified torque.
SST 09564-16020

Fig 22: Tightening Torque Of Rear Drive Pinion Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the tightening torque of the rear drive pinion nut exceeds 245 Nm (2500 kgf.cm) but the preload is still insufficient, loosen the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.
If there is no defect, replace the rear drive differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

INSTALL DIFFERENTIAL CASE
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
1. Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.
  Torque: 34 Nm (350 kgf.cm, 25 ft.lbf)
INSPECT DIFFERENTIAL RING GEAR BACKLASH

INSPECT TOTAL PRELOAD

Using SST and a torque wrench, measure the 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

Fig 23: Measuring Starting Torque With Teeth Of Differential Drive Pinion

BEARING PRELOAD SPECIFICATION

Bearing	Preload
New bearing	1.18 to 1.90 Nm (12 to 19 kgf.cm, 10 to 17 in.lbf)
Reused bearing	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.

If the results are not within the specified range, select a rear differential side gear shaft washer for the RH side again, and then perform the rear differential case bearing outer race installation (RH side only).
NOTE: If using a different rear differential side gear shaft washer, adjust the ring gear backlash. Then adjust the total preload.

REMOVE DIFFERENTIAL SIDE BEARING RETAINER
1. Remove the 8 bolts and side bearing retainer from the rear differential carrier.
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
1. Using white gasoline, remove grease and oil from the alignment surfaces of the rear differential carrier and differential side bearing retainer.
2. Apply seal packing to the areas indicated in the illustration of the differential side bearing retainer.
  Seal Packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  NOTE:
  - Apply seal packing in a continuous line 2 to 3 mm (0.08 to 0.12 in.) in diameter.
  - Perform the installation with 3 minutes of applying seal packing.
  Fig 24: Applying Seal Packing To Differential Side Bearing Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.
  Torque: 34 Nm (350 kgf.cm, 25 ft.lbf)
  
  NOTE: After installing the cover, do not add oil or drive the vehicle, and leave it alone for 1 hour or more. Also, avoid sudden acceleration and deceleration for 12 hours or more.
  
  Fig 25: Installing Differential Side Bearing Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT TOTAL PRELOAD

Using SST and a torque wrench, inspect the 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

Fig 26: Inspecting Drive Pinion Total Preload

DRIVE PINION PRELOAD SPECIFICATION

Bearing	Preload
New bearing	1.18 to 1.90 Nm (12 to 19 kgf.cm, 10 to 17 in.lbf)
Reused bearing	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 inspecting.

INSPECT DIFFERENTIAL RING GEAR BACKLASH
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 inspect the backlash.
  SST 09564-16020
  
  Standard backlash: 0.09 to 0.16 mm (0.0004 to 0.006 in.)
  
  Fig 27: Inspecting Differential Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Inspect at 3 or more areas around the circumference of the ring gear.
INSTALL REAR DRIVE PINION NUT
1. Using a chisel and hammer, stake the rear drive pinion nut.
INSTALL DIAPHRAGM OIL SEAL
1. Apply a light coat of MP grease No. 2 to the lip of a new diaphragm oil seal.
2. Using SST and a hammer, tap the diaphragm oil seal into the rear differential carrier according to the specification.
  SST 09710-30021 (09710-03121)
  
  SST 09950-60010 (09951-00570)
  
  SST 09950-70010 (09951-07100)
  
  Standard distance: 7.0 +-0.5 mm (0.28 +-0.02 in.)
  
  Fig 28: Installing Diaphragm Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Apply a light coat of MP grease No. 2 to the lip of a new rear differential side gear shaft oil seal.
2. Using SST and a hammer, tap the 2 rear differential side gear shaft oil seals into the rear differential carrier and differential side bearing retainer according to the specification.
  SST 09223-00010
  
  Standard distance: 7.2 +-0.5 mm (0.28 +-0.02 in.)
  
  Fig 29: Tapping Rear Differential Side Gear Shaft Oil Seals Into Rear Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION COUPLING SHIM

Measure each of the dimensions.
HINT:
- Dimension A: Bearing axis distance
- Dimension B: Drive pinion axis distance

Select a transmission coupling shim based on the difference between dimensions A and B, and install the shim.

Fig 30: Measuring Bearing And Drive Pinion Axis Distance

Transmission coupling shim

TRANSMISSION COUPLING SHIM THICKNESS SPECIFICATION

Difference of dimension A and B mm (in.)	Part No.	Thickness mm (in.)	Identifying Mark
3.96 to 4.01 (0.148 to 0.154)	90564-25024	1.98 to 2.02 (0.078 to 0.080)	1
4.26 to 4.31 (0.161 to 0.168)	90564-25025	2.28 to 2.32 (0.090 to 0.091)	2
4.56 to 4.61 (0.174 to 0.181)	90564-25026	2.58 to 2.62 (0.102 to 0.103)	3
3.81 to 3.86 (0.141 to 0.148)	90564-25027	1.83 to 1.87 (0.072 to 0.074)	4
4.11 to 4.16 (0.154 to 0.161)	90564-25028	2.13 to 2.17 (0.084 to 0.085)	5
4.41 to 4.16 (0.168 to 0.174)	90564-25029	2.43 to 2.47 (0.096 to 0.097)	6
3.71 to 3.76 (0.146 to 0.148)	90564-25031	1.73 to 1.77 (0.068 to 0.700)	8
3.76 to 3.81 (0.148 to 0.150)	90564-25032	1.78 to 1.82 (0.070 to 0.072)	9
3.86 to 3.91 (0.151 to 0.154)	90564-25033	1.88 to 1.92 (0.074 to 0.076)	10
3.91 to 3.96 (0.154 to 0.156)	90564-25034	1.93 to 1.97 (0.076 to 0.078)	11
4.01 to 4.06 (0.158 to 0.160)	90564-25035	2.03 to 2.07 (0.080 to 0.081)	12
4.06 to 4.11 (0.160 to 0.162)	90564-25036	2.08 to 2.12 (0.082 to 0.083)	13
4.16 to 4.21 (0.164 to 0.166)	90564-25037	2.18 to 2.22 (0.086 to 0.087)	14
4.21 to 4.26 (0.166 to 0.168)	90564-25038	2.23 to 2.27 (0.088 to 0.089)	15
4.31 to 4.36 (0.170 to 0.172)	90564-25039	2.33 to 2.37 (0.092 to 0.093)	16
4.36 to 4.41 (0.172 to 0.174)	90564-25040	2.38 to 2.42 (0.094 to 0.095)	17
4.46 to 4.51 (0.176 to 0.178)	90564-25041	2.48 to 2.52 (0.098 to 0.099)	18
4.51 to 4.56 (0.178 to 0.180)	90564-25042	2.53 to 2.57 (0.100 to 0.101)	19
4.61 to 4.66 (0.181 to 0.183)	90564-25043	2.63 to 2.67 (0.104 to 0.105)	20
4.66 to 4.71 (0.183 to 0.185)	90564-25044	2.68 to 2.72 (0.106 to 0.107)	21

REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER
1. Install the transmission coupling conical spring washer to the rear differential carrier.
  NOTE: Install the transmission coupling conical spring washer so that the green marking (protruding part) is facing the front of the vehicle (coupling side).
  
  Fig 31: Identifying Transmission Coupling Conical Spring Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL YOKE
1. Using a 5 mm socket hexagon wrench, install the yoke with the 3 bolt.
  Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)
INSTALL 4WD LINEAR SOLENOID
1. Install a new O-ring to the solenoid.
  NOTE: Do not damage or twist the O-ring.
2. Install the solenoid to the yoke.
3. Install the snap ring.
INSTALL ELECTROMAGNETIC COUPLING
1. Using white gasoline, remove grease and oil from the alignment surfaces of the rear differential carrier and transmission coupling.
2. Apply seal packing 1281 to the areas indicated in the illustration of the transmission coupling.
  Seal Packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  NOTE:
  - Apply seal packing 1281 in a continuous line 2 to 3 mm (0.08 to 0.12 in.) in diameter.
  - Perform the installation with 3 minutes of applying seal packing 1281.
    
    Fig 32: Applying Seal Packing Transmission Coupling
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear differential carrier cover to the rear differential carrier assembly with the 4 bolts.
  Torque: 19.6 Nm (200 kgf.cm, 14 ft.lbf)
  
  Fig 33: Installing Rear Differential Carrier Cover To Rear Differential Carrier Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CARRIER COVER BREATHER PLUG
1. Using a plastic-faced hammer, tap in the breather plug.
  SST 09612-07010 (09612-10061)
  
  Fig 34: Installing Differential Carrier Cover Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CARRIER COVER PLUG
1. Using an 8 mm socket hexagon wrench, install a new rear differential carrier cover plug.
  Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)
  
  Fig 35: Installing Differential Carrier Cover Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL FILLER PLUG
1. Install a new gasket to the rear differential filler plug.
2. Using a 10 mm socket hexagon wrench, install the rear differential filler plug.
  Torque: 39 Nm (400 kgf.cm, 29 ft.lbf)
  
  Fig 36: Installing Rear Differential Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL DRAIN PLUG
1. Install a new gasket to the rear differential drain plug.
2. Using a 10 mm socket hexagon wrench, install the rear differential drain plug.
  Torque: 39 Nm (400 kgf.cm, 29 ft.lbf)
  
  Fig 37: Installing Differential Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RUNOUT OF TRANSMISSION COUPLING ASSEMBLY
1. Install a dial gauge so that it is perpendicular to the inner side of the transmission coupling. (See Fig 38)
2. Using SST, rotate the transmission coupling forward and backward and measure the vertical runout.
  SST 09564-16020
  
  Maximum vertical runout: 0.06 mm (0.0024 in.)
3. Install a dial gauge perpendicularly onto the transmission coupling, as shown in the illustration.
4. Using SST, rotate the transmission coupling forward and backward and measure the lateral runout.
  SST 09564-16020
  
  Maximum lateral runout: 0.07 mm (0.0028 in.)
  
  Fig 38: Checking Transmission Coupling Assembly Vertical/Lateral Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT
1. Install the differential support assembly rear with the 4 bolts.
  Torque: 8 Nm (82 kgf.cm, 71 in.lbf)
  
  Fig 39: Installing Differential Support Assembly Rear With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002