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Rear Differential Carrier Assembly: Reassembly

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  1. INSTALL WIRING HARNESS CLAMP BRACKET 
    1. Install the bracket with the bolt.
  2. INSTALL ELBOW TUBE 
  3. INSTALL STRAIGHT PIN 
    Fig 1: Locating Straight Pins
    G05584852Courtesy 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.
  4. 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 N*m (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: Locating Differential Breather Plug Oil Deflector Bolts
      G05584853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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 N*m (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.
        Fig 3: Locating Differential Ring Gear Bolts
        G05584849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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)
      G05584855Courtesy 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)
      G05584856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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.

      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)
        G05584857Courtesy 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.

      SST 09950-60010 (09951-00510, 09951-00620, 09952-06010), 09950-(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)
        G05584858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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
      G05584859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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.

      Fig 9: Installing Rear Drive Pinion Rear Tapered Roller Bearing
      G05584860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. 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.
    2. Using SST and a press, press-fit the tapered roller rear (inner race) to the differential drive pinion.

      SST 09506-30012 

  11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Install the differential drive pinion (with rear drive pinion tapered roller bearing rear inner race) to the rear differential carrier.
    2. 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.
        Fig 10: Installing Tapered Roller Rear (Inner Race) To Differential Drive Pinion
        G05584861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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 N*m (2,500 kgf*cm, 181 ft.*lbf) for use without SST 

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

      Fig 11: Tightening Rear Drive Pinion Nut
      G05584862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

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

      SST 09556-16011 

      Standard drive pinion preload (start torque) 

      STANDARD DRIVE PINION PRELOAD (START TORQUE)

      Bearing Preload
      New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12 to 19 in.*lbf)
      Reused bearing 0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3 in.*lbf)
      Fig 12: Measuring Starting Torque Of Differential Drive Pinion
      G05584863Courtesy 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.
  12. INSTALL DIFFERENTIAL CASE 
    1. Install the rear differential case to the rear differential carrier.
  13. 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.
      NOTE: Do not scratch the installation area.
      Fig 13: Identifying Differential Case
      G05584839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

      Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf) 

      Fig 14: Locating Differential Side Bearing Retainer Bolts
      G05584837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. ADJUST 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 measure the backlash.

      SST 09564-16020 

      NOTE: Measure at 3 or more areas around the circumference of the ring gear.
    4. 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
        G05584866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Rear differential side gear shaft washer 

      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
      90S64-37023 1.62 to 1.64 (0.0637 to 0.0646) 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 (0.0933 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) BO 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 0.0823) B6 90564-37056 2.61 to 2.63 (0.1028 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
  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Remove the 8 bolts and differential side bearing retainer from the rear differential carrier.
    2. Remove the rear differential carrier case.
    3. Uniformly apply a light coat of prussian blue on both sides of the differential ring gear teeth.
    4. Install the rear differential case.
    5. Temporarily install the differential side bearing retainer to the differential carrier with the 8 bolts.
    6. Rotate the differential side pinion several times.
    7. Remove the 8 bolts and rear differential side bearing retainer from the differential carrier.
    8. Check the tooth contact pattern of the differential drive pinion and differential ring gear.
      Fig 16: Identifying Differential Ring Gear Tooth Contact Pattern
      G05584867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Check the tooth contact pattern at 2 or more positions around circumference of the differential ring gear.
    9. 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.

    10. Perform the following procedures for heel or toe contact.
      1. 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 (0.0711 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 0.0722) 54 90564-35084 2.085 to 2.095 (0.0821 to 0.0825) 84
        90564-35055 1.835 to 1.845 (0.0722 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 (0.0738 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 - - -
  16. INSPECT TOTAL PRELOAD 
    1. 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 

      DRIVE PINION PRELOAD SPECIFICATION

      Bearing Preload
      New bearing 1.18 to 1.63 N*m (12 to 17 kgf*cm, 10 to 14 in.*lbf)
      Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)
      Fig 17: Measuring Differential Drive Pinion Total Preload
      G05584830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For a more accurate measurement, rotate the case bearing forward and backward before measuring.
    2. 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.
  17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER 
    1. Remove the 8 bolts and differential side bearing retainer from the rear differential carrier.
  18. REMOVE DIFFERENTIAL CASE 
    1. Remove the rear differential case from the rear differential carrier.
  19. REMOVE DIFFERENTIAL DRIVE PINION 
  20. 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
      G05584841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL DIFFERENTIAL DRIVE PINION 
    1. Install the differential drive pinion to the rear differential carrier.
  22. 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
      G05584840Courtesy 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.

      SST 09556-16011, 09564-16020 

      SST 09564-16020 

      Torque: 

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

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

      Fig 20: Tightening Rear Drive Pinion Nut
      G05584862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

  23. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using SST and a torque wrench, inspect the starting torque.

      SST 09556-16011 

      Standard drive pinion preload 

      DRIVE PINION PRELOAD SPECIFICATION

      Bearing Preload
      New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12 to 19 in.*lbf)
      Reused bearing 0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3 in.*lbf)
      Fig 21: Inspecting Differential Drive Pinion Preload
      G05584863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. 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 

    3. If the tightening torque of the rear drive pinion nut exceeds 245 N*m {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.
    4. 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.
      Fig 22: Tightening Rear Drive Pinion Nut
      G05584873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL DIFFERENTIAL CASE 
  25. INSTALL DIFFERENTIAL SIDE BEARING RETAINER 
    1. Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

      Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf) 

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH 
  27. INSPECT TOTAL PRELOAD 
    1. 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 

      DRIVE PINION PRELOAD SPECIFICATION

      Bearing Preload
      New bearing 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10 to 17 in.*lbf)
      Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)
      Fig 23: Measuring Differential Drive Pinion Preload
      G05584830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For a more accurate measurement, rotate the case bearing forward and backward before measuring.
    2. 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.
  28. REMOVE DIFFERENTIAL SIDE BEARING RETAINER 
    1. Remove the 8 bolts and side bearing retainer from the rear differential carrier.
  29. 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: Identifying Seal Packing Applying Area Of Differential Side Bearing Retainer
        G05584875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the differential side bearing retainer to the rear differential carrier with the 8 bolts.

      Torque: 34 N*m (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: Locating Differential Side Bearing Retainer Bolts
      G05584837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSPECT TOTAL PRELOAD 
    1. 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 

      DRIVE PINION PRELOAD SPECIFICATION

      Bearing Preload
      New bearing 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10 to 17 in.*lbf)
      Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)
      Fig 26: Inspecting Differential Drive Pinion Preload
      G05584830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For a more accurate measurement, rotate the case bearing forward and backward before inspecting.
  31. 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 0.0063 in.) 

      NOTE: Inspect at 3 or more areas around the circumference of the ring gear.
      Fig 27: Inspecting Differential Ring Gear Backlash
      G05584829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL REAR DRIVE PINION NUT 
    1. Using a chisel and hammer, stake the rear drive pinion nut.
  33. 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), 09950-60010 (09951-00570), 09950-70010 (09951-07100) 

      Standard distance: 7.0 +-0.5 mm (0.28 +-0.02 in.) 

      Fig 28: Installing Diaphragm Oil Seal
      G05584879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. 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: Installing Rear Differential Side Gear Shaft Oil Seals
      G05584880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSMISSION COUPLING SHIM 
    1. Measure each of the dimensions.

      HINT:

      • Dimension A: Bearing axis distance
      • Dimension B: Drive pinion axis distance
    2. Select a transmission coupling shim based on the difference between dimensions A and B, and install the shim.
      Fig 30: Identifying Bearing And Drive Pinion Axis Distance
      G05584881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 (0.156 to 0.158) 90564-25024 1.98 to 2.02 (0.078 to 0.080) 1
      4.26 to 4.31 (0.168 to 0.170) 90564-25025 2.28 to 2.32 (0.090 to 0.091) 2
      4.56 to 4.61 (0.180 to 0.181) 90564-25026 2.58 to 2.62 (0.102 to 0.103) 3
      3.81 to 3.86 (0.150 to 0.152) 90564-25027 1.83 to 1.87 (0.072 to 0.074) 4
      4.11 to 4.16 (0.162 to 0.164) 90564-25028 2.13 to 2.17 (0.084 to 0.085) 5
      4.41 to 4.46 (0.174 to 0.176) 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 0.070) 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
  36. 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
      G05584827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL YOKE 
    1. Using a 5 mm socket hexagon wrench, install the yoke with the 3 bolt.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  38. 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.
  39. 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: Identifying Seal Packing Area Of Transmission Coupling
        G05584883Courtesy 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 N*m (200 kgf*cm, 14 ft.*lbf) 

      Fig 33: Locating Rear Differential Carrier Cover Bolts
      G05584823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. 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
      G05584885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL DIFFERENTIAL CARRIER COVER PLUG 
    1. Using an 8 mm socket hexagon wrench, install a new rear differential carrier cover plug.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 35: Locating Rear Differential Carrier Cover Plug
      G05584820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. 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 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 36: Locating Rear Differential Filler Plug
      G05584819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. 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 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 37: Locating Rear Differential Drain Plug
      G05584818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSPECT RUNOUT OF TRANSMISSION COUPLING ASSEMBLY 
    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 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: Measuring Transmission Coupling Runout
      G05584889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL STUD BOLT 
    1. Install the differential support assembly rear with the 4 bolts.

      Torque: 8 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 39: Identifying Stud Bolt Dimension
      G05584890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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