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.
   Fig 1: Locating Rear Differential Support Bolts

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1. Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.
   Fig 2: Locating Rear Differential Drain Plug

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1. Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.
   Fig 3: Locating Rear Differential Filler Plug

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

1. Using a chisel and hammer, slightly lift up the rear differential carrier cover breather plug.
   Fig 4: Locating Rear Differential Carrier Cover Plug

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2. Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.
   Fig 5: Removing Rear Differential Carrier Cover Breather Plug

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1. Install a dial gauge so that it is perpendicular to the inner side of the transmission coupling.
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 the illustration.
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 in.) 

   Fig 6: Identifying Vertical And Lateral Runout

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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 7: Locating Rear Differential Carrier Cover Bolts

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1. Using a snap ring expander, remove the snap ring.
   Fig 8: Removing Snap Ring Using Snap Ring Expander

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2. Remove the solenoid from the yoke.
3. Remove the O-ring from the solenoid.
   Fig 9: Removing O-Ring

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1. Using a 5 mm socket hexagon wrench, remove the 3 bolts and yoke from the differential carrier.
   Fig 10: Locating Differential Carrier Yoke Bolts

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1. Remove the spring washer from the differential carrier.
   Fig 11: Identifying Transmission Coupling Conical Spring Washer

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1. Remove the shim from the differential carrier.
   Fig 12: Identifying Transmission Coupling Shim

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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 13: Inspecting Differential Ring Gear Backlash

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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 N*m (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 14: 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 N*m (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 15: Inspecting Differential Drive Pinion 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 16: Removing Differential Side Gear Shaft Oil Seal

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

   SST 09308-10010 

   Fig 17: Removing Diaphragm Oil Seal

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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 18: 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 19: Removing Rear Drive Pinion Nut

   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 20: Removing Rear Drive Pinion Front Tapered Roller Bearing

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1. Remove the 8 bolts.
   Fig 21: Locating Differential Side Bearing Retainer Bolts

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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 22: Removing Differential Side Bearing Retainer

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1. Remove the rear differential case from the rear differential carrier.
   Fig 23: Identifying Rear Differential Case

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1. Remove the differential drive pinion from the rear differential carrier.
   Fig 24: Removing Differential Drive Pinion

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1. Remove the rear differential drive pinion bearing spacer from the differential drive pinion.
   Fig 25: Removing Differential Drive Pinion Bearing Spacer

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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 

   NOTE: If the rear differential drive pinion or differential ring gear is damaged, replace them both.
2. Remove the rear differential drive pinion washer.
   Fig 26: Removing Rear Drive Pinion Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 27: Removing Rear Drive Pinion Front Tapered Roller Bearing

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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 28: 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 29: Removing Rear 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 30: Removing Rear 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 31: 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.

   HINT:

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

   Fig 32: Removing Rear Differential Case Bearing LH (Inner Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 33: Locating Differential Ring Gear Bolts

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1. Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.
   Fig 34: Locating Differential Breather Plug Oil Deflector Bolts

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Fig 35: Locating Straight Pins

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

1. Remove the bolt and bracket.