Part 2

AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

REASSEMBLY (Continued)

23. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY





(a) Install the rear differential case to the rear differential carrier.
24. INSTALL DIFFERENTIAL SIDE BEARING RETAINER





(a) Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft-lbf)
25. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Insert a dial indicator through the rear differential carrier cover plug hole, and set it perpendicular to a ring gear tooth tip.
(b) Using SST, hold the drive pinion in place.
SST: 09556-16011





(c) Using SST, rotate the rear differential case forward and backward, and measure the backlash.
SST: 09564-32011
Backlash:
0.10 to 0.15 mm (0.00394 to 0.00591 in.)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
NOTE: Measure at 3 or more areas on the circumference of the ring gear.

26. MEASURE TOTAL PRELOAD





(a) Using SST and a torque wrench, measure the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.
SST: 09556-16011
Standard total preload (New bearing):
Standard drive pinion preload plus 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
Standard total preload (Reused bearing):
Standard drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)
HINT: For a more accurate measurement, rotate the case bearing forward and backward before measuring.

(b) If the results are not within the specification, perform the procedure below:
(1) Select a thicker or thinner side gear shaft washer for the RH side, and then install the rear differential case bearing outer race (RH side only).
(2) Repeat the total preload measurement.
(3) Repeat the ring gear backlash inspection.
(4) Repeat the differential ring gear and drive pinion tooth contact pattern inspection.
27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove the 10 bolts and the differential side bearing retainer.





(b) Install the 2 bolts and rear differential breather plug oil deflector to the side bearing retainer.
Torque: 4.9 Nm (50 kgf-cm, 43 in-lbf)





(c) Using SST and a hammer, tap in the rear differential carrier cover breather plug to the side bearing retainer.
SST: 09612-10093
09612-10061
(d) Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.
NOTE: Do not damage the installation surface.





(e) 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

NOTICE:
- Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
- Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range A in the illustration.
- Perform the installation within 3 minutes after applying seal packing.
- Start applying seal packing within range A.





(f) Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft-lbf)
NOTE: After installing the cover, do not immediately add oil or drive the vehicle for at least one hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.

28. INSPECT TOTAL PRELOAD





(a) 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 (New bearing):
Standard drive pinion preload plus 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
Standard total preload (Reused bearing):
Standard drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)
NOTE: For a more accurate measurement, rotate the case bearing forward and backward before inspecting.

29. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Insert a dial indicator through the rear differential carrier cover plug hole, and set it perpendicular to a ring gear tooth tip.
(b) Using SST, hold the drive pinion in place.
SST: 09556-16011





(c) Using SST, rotate the rear differential case forward and backward, and measure the backlash.
SST: 09564-32011
Backlash:
0.10 to 0.15 mm (0.00394 to 0.00591 in.)
NOTE: Measure at 3 or more areas on the circumference of the ring gear.

30. INSTALL REAR DRIVE PINION NUT
(a) Using a chisel and a hammer, stake the rear drive pinion nut.
31. INSTALL REAR DIFFERENTIAL PRESSURE CONTROL HOSE





(a) Align the matchmarks on the differential pressure control hose elbows and differential carrier.





(b) Using the 2 differential pressure control hose clips, install the rear differential pressure control hose to the differential pressure control hose elbows.
NOTE: Confirm that the hose and the clips do not interfere with other parts.

32. INSTALL OIL DIAPHRAGM SEAL
(a) Apply a light coat of MP grease to the lip of a new oil diaphragm seal.





(b) Using SST and a hammer, tap the oil diaphragm seal into the rear differential carrier.
SST: 09506-35010
SST: 09554-22010
Oil seal driven in depth:
0.7 to 1.3 mm (0.0276 to 0.0512 in.)

NOTICE:
- Tap the oil seal uniformly so that it is driven in straight.
- Do not excessively tap the oil seal.

33. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL





(a) Apply a light coat of MP grease to the lip of a new rear differential side gear shaft oil seal.
(b) 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.
SST: 09554-22010
Oil seal driven in depth:
4.2 to 4.8 mm (0.165 to 0.189 in.)
NOTICE:
- Tap the oil seal uniformly so that it is driven in straight.
- Do not excessively tap the oil seal.

34. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR





(a) Using SST and a press, install the new rear differential dust deflector.
SST: 09518-36020
SST: 09950-70010
09951-07150
35. INSTALL TRANSMISSION COUPLING SPACER





(a) Install the transmission coupling spacer to the rear differential carrier.
36. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER





(a) Install the transmission coupling conical spring washer to the rear differential carrier.
NOTE: Install the transmission coupling conical spring washer so that the orange-marked surface faces the front of the vehicle (coupling side).

37. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY
(a) Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.
NOTE: Do not scratch the installation area.

(b) Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and the electro magnetic control coupling sub-assembly.





(c) Apply seal packing to the areas indicated in the illustration of the electro magnetic control coupling sub-assembly.
Seal Packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
- Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range A in the illustration.
- Perform the installation within 3 minutes after applying seal packing.
- Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
- Start applying seal packing within range A.
- (B) : 1.0 mm (0.0394 in.)
- (C) : 2.0 mm (0.0787 in.)
- (D) : 3.0 mm (0.1181 in.)
- (E) : 5.0 mm (0.1969 in.)





(d) Install the electro magnetic control coupling sub-assembly with the 4 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
38. INSTALL REAR DIFFERENTIAL DRAIN PLUG





(a) Install a new gasket with the rear differential drain plug.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
39. INSTALL REAR DIFFERENTIAL FILLER PLUG





(a) Install a new gasket with the rear differential filler plug (inspection plug).
Torque: 98 Nm (1000 kgf-cm, 72 ft-lbf)
40. INSPECT REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Install a dial indicator so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly.





(b) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward and measure the vertical runout.
SST: 09564-32011
Maximum runout:
0.04 mm (0.00157 in.)
If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.
(c) Install a dial indicator perpendicular to the electro magnetic control coupling sub-assembly, as shown in the illustration.
(d) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward and measure the lateral runout.
SST: 09564-32011
Maximum runout:
0.06 mm (0.00236 in.)
If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.
41. INSTALL STUD BOLT
(a) Temporarily install 4 new stud bolts to the electro magnetic control coupling sub-assembly.





(b) Install 2 service nuts to the stud bolt.
Recommended service nut:
Thread diameter
8 mm (0.3150 in.)
Thread pitch
1.25 mm (0.0492 in.)
(c) Lock the upper nut using the lower nut.





(d) Turn the upper nut and tighten the other 3 stud bolts to the electro magnetic control coupling sub-assembly in the same way.
Torque: 10 Nm (102 kgf-cm, 7. ft-lbf)
(A):
29.1 to 32.3 mm (1.146 to 1.272 in.)
42. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER
HINT: This step should be performed only when the rear differential dynamic damper is being replaced.





(a) Install the rear differential dynamic damper with the bolt.
Torque: 27 Nm (270 kgf-cm, 20 ft-lbf)
43. INSTALL DIFFERENTIAL SUPPORT





(a) Install the differential support to the differential carrier assembly with the new 3 bolts.
Torque: 167 Nm (1700 kgf-cm, 123 ft-lbf)
44. INSTALL REAR NO. 1 DIFFERENTIAL SUPPORT





(a) Install the rear No. 1 differential support assembly to the differential carrier assembly with the new 2 bolts and 2 nuts.
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)