Rear Extension Housing: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL BALL BEARING 
   1. Using SST and a press, press in the ball bearing.

      SST 09316-60011 (09316-00011, 09316-00031) 

      Fig 1: Pressing In Ball Bearing Using SST & Press

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Select a snap ring that will allow the minimum axial play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      A	1.70 (0.0669)	B	1.80 (0.0709)

   3. Using a screwdriver, install a new snap ring.
      Fig 2: Installing New Snap Ring Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL OIL SEAL 
   1. Apply MP grease to the lip of a new oil seal.
   2. Using SST and a hammer, tap in the oil seal.

      SST 09316-60011 (09316-00011, 09316-00031) 

      Fig 3: Tapping In Oil Seal Using SST & Hammer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL DUST DEFLECTOR 
   1. Using SST and a hammer, tap in a new rear extension housing dust deflector.

      SST 09316-60011 (09316-00011, 09316-00041) 

      Fig 4: Tapping In New Rear Extension Housing Dust Deflector Using SST & Hammer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST and a press, press in a new rear output shaft dust deflector.

      SST 09316-20011, 09316-60011 (09316-00011) 

      Fig 5: Pressing In New Rear Output Shaft Dust Deflector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL REAR OUTPUT SHAFT 
   1. Using SST and a press, press in the output shaft.

      SST 09316-20011, 09316-60011 (09316-00011, 09316-00031) 

   2. Install the 2 seal rings to the output shaft.
      Fig 6: Pressing In Output Shaft Using SST & Press

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Select a snap ring that will allow the minimum axial play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      1	1.95 (0.0768)	3	2.15 (0.0847)
      2	2.05 (0.0807)	4	2.25 (0.0886)

   4. Using a snap ring expander, install a new snap ring.
      Fig 7: Installing New Snap Ring Using Snap Ring Expander

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL SPEEDOMETER DRIVE GEAR 
   1. Install the drive gear.
   2. Using a snap ring expander, install the snap ring.
6. INSTALL OIL PUMP PLATE 
   1. Install the oil pump plate.
   2. Install the 3 bolts.

      Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

      Fig 8: Installing Oil Pump Plate

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG 
   1. Apply gear oil to the ball.
   2. Install the valve seat, ball and spring.
   3. Apply liquid sealer to the screw plug threads.

      Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

   4. Using a hexagon wrench, install the screw plug.

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 9: Installing Valve Seat, Ball, Spring & Screw Plug

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL OIL PUMP DRIVEN ROTOR 
   1. Apply gear oil to the driven rotor.
   2. Install the drive rotor to the rear extension housing.
9. INSTALL OIL PUMP DRIVE ROTOR 
   1. Apply gear oil to the drive rotor.
   2. Install the drive rotor.

      HINT:

      Align the alignment marks to the driven rotor.

      Fig 10: Aligning Alignment Marks To Driven Motor

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL OIL PUMP COVER 
    1. Install the oil pump cover.
    2. Using a T30 "torx" socket, install the 3 screws.

       Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

       NOTE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.
11. INSTALL OIL PUMP DRIVE SHAFT 
    Fig 11: Installing Oil Pump Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002