Rear Differential Carrier Assembly: Disassembly

1. Remove the 8 bolts from the rear differential carrier cover.
2. Using a brass bar and a hammer, separate the rear differential carrier cover from rear differential carrier assembly.

Fig 1: Locating Rear Differential Carrier Cover With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the rear differential breather plug from the rear differential carrier cover.

Fig 2: Identifying Rear Differential Breather Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the differential carrier to an overhaul stand, etc. as shown in the illustration.

Fig 3: Locating Rear Differential Carrier Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, check the runout of the differential ring gear.

Maximum runout: 

0.07 mm (0.0028 in.) 

If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

Fig 4: Checking Runout Of Differential Ring Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, check the backlash of the differential ring gear.

Backlash: 

0.13 to 0.18 mm (0.0051 to 0.0071 in.) 

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

1. Using a dial indicator, check the backlash of the differential side gear while holding one of the pinion gears toward the differential case assembly.

Fig 6: Checking Backlash Of Differential Side Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Backlash: 

0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

If the backlash is not within the specification, install the 2 differential side gear thrust washers of different thicknesses (See INSTALLATION ).

HINT:

Measure the backlash of the differential side gear with the rear differential pinion shaft installed.

1. Using a dial indicator, measure the runout of the rear drive pinion companion flange sub-assembly vertically and horizontally.

(A): 

30 mm (1.18 in.) 

Maximum runout: 

0.10 mm (0.0039 in.) 

If the runout is greater than the maximum value, replace the rear drive pinion companion flange sub-assembly.

Fig 7: Measuring Runout Of Rear Drive Pinion Companion Flange Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a torque wrench, measure the preload of the differential drive pinion.

Drive pinion preload (Initial) 

If the preload is not within the specified range, adjust the total preload or repair as necessary.

Fig 8: Measuring Preload Of Differential Drive Pinion

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a torque wrench, measure the total preload.

Total preload (Initial): 

Drive pinion preload plus 0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf) 

If the preload is not within the specified range, adjust the total preload or repair as necessary.

Fig 9: Measuring Preload Of Differential Drive Pinion

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the 2 rear differential side gear shaft oil seals from the rear differential carrier sub-assembly.

SST 09308-00010 

Fig 10: Removing Rear Differential Side Gear Shaft Oil Seals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09930-00010 

   Fig 11: Unstaking Staked Part Of Rear Drive Pinion Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the rear drive pinion companion flange sub-assembly, remove the rear drive pinion nut.

SST 09330-00021 

Fig 12: Removing Rear Drive Pinion Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the rear drive pinion companion flange sub-assembly.

SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) 

Fig 13: Removing Rear Drive Pinion Companion Flange Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the rear differential dust deflector.

SST 09950-60010 (09951-00360), 09950-70010 (09951-07150), 09950-00020 

Fig 14: Removing Rear Differential Dust Deflector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the rear differential carrier oil seal from the rear differential carrier sub-assembly.

SST 09308-10010 

1. Using SST, remove the rear drive pinion front tapered roller bearing from the differential drive pinion.

SST 09556-22010 

1. Put matchmarks on the rear differential bearing cap and rear differential carrier sub-assembly.
2. Remove the 4 bolts and 2 rear differential bearing caps.
   Fig 17: Removing Bolts And Rear Differential Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, remove the 2 rear differential side gear shaft plate washers.

   SST 09504-22011 

   HINT:

   Measure the thicknesses of the rear differential side gear shaft plate washers and note them down.

   Fig 18: Removing Rear Differential Side Gear Shaft Plate Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the rear differential case and the 2 rear differential case bearing outer races from the differential carrier.

   HINT:

   Tag the 2 rear differential case bearing outer races to show the location for reassembly.

1. Remove the differential drive pinion.

Fig 19: Removing Rear Differential Case And Rear Differential Case Bearing Outer Races

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the rear drive pinion rear tapered roller bearing from the differential drive pinion.

   SST 09950-00020 

   HINT:

   If either the differential drive pinion or differential ring gear is damaged, replace both as a set.

2. Remove the rear differential drive pinion plate washer.

Fig 20: Removing Rear Drive Pinion Rear Tapered Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and a hammer, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier sub-assembly.

Fig 21: Removing Rear Drive Pinion Rear Tapered Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing (outer race) from the rear differential carrier sub-assembly.

Fig 22: Removing Rear Drive Pinion Rear Tapered Roller Bearing (Outer Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Put matchmarks on the differential ring gear and rear differential case.
2. Using a screwdriver and a hammer, unstake the 4 rear differential ring gear set bolt lock plates.
3. Remove the 8 bolts and 4 rear differential ring gear set bolt lock plates.

Fig 23: Unstaking Rear Differential Ring Gear Set Bolt Lock Plates

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform this procedure only if the runout of the differential ring gear exceeds the specified maximum value.

1. Install the rear differential case to the rear differential carrier sub-assembly.
2. Install the right and left rear differential bearing caps with the 4 bolts.

   Torque: 79 N*m (800 kgf*cm, 58 ft.*lbf) 

3. Using a dial indicator, measure the differential case runout.

   Maximum runout: 

   0.07 mm (0.0028 in.) 

   If the runout is greater than the maximum value, replace the differential case assembly with a new one.

4. Remove the rear differential case.

Fig 24: Inspecting Runout Of Rear Differential Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the rear differential case bearing from the rear differential case.

SST 09950-40011 (09951-00240, 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360) 

Fig 25: Removing Rear Differential Case Bearing From Rear Differential Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360) 

Fig 26: Removing Rear Differential Case Bearing (RH) From Rear Differential Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a pin punch (5 mm) and a hammer, remove the rear differential pinion shaft straight pin.
   Fig 27: Removing Rear Differential Pinion Shaft Straight Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the rear differential pinion shaft. (A)
3. Remove the 2 differential pinion gears. (B)
4. Remove the 2 rear differential pinion thrust washers. (C)
5. Remove the 2 differential side gears. (D)
6. Remove the 2 No. 1 rear differential side gear thrust washers. (E)

1. Check that there is no damage to the differential pinion gears and side gears. If the differential pinion gears and/or side gears are damaged, replace them with new ones.

Fig 28: Identifying Rear Differential Pinion Shaft, Differential Pinion And Side Gears

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that there is no damage to the differential case. If the differential case is damaged, replace it.