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Part 2








AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

REASSEMBLY (Continued)

22. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD





(a) Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque).
SST: 09556-16011
Standard drive pinion preload (New bearing):
0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
Standard drive pinion preload (Reused bearing):
0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)
NOTICE: For a more accurate measurement, rotate the bearing forward and backward before adjustment.





(b) If the preload is insufficient, use SST to tighten the rear drive pinion nut 5 to 10° at a time. Measure the preload and repeat the adjustment as necessary until the preload matches the specified torque.
(c) If the tightening torque of the rear drive pinion nut exceeds 245 N*m (2498 kgf*cm, 181 ft.*lbf) 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.
(d) If there is no defect, replace the rear differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.
23. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY





(a) Install the rear differential case sub-assembly 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 (428 kgf-cm, 31ft-lbf)
25. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.
(b) Using SST, hold the differential drive pinion in place.
SST: 09556-16011





(c) Using SST, rotate the rear differential case sub-assembly 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.
NOTICE: 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 total 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 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
Standard total preload (Reused bearing):
Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
HINT: For a more accurate measurement, rotate the rear differential 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 rear differential side gear shaft plate 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 differential 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 differential side bearing retainer.





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





(c) Using SST and a hammer, tap in the rear differential carrier cover breather plug to the differential 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.
NOTICE: 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.
- Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).
- 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 (428 kgf-cm, 31ft-lbf)
NOTICE: After installing the differential side bearing retainer, do not immediately add oil or drive the vehicle for at least 1 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 total 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 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
Standard total preload (Reused bearing):
Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
NOTICE: For a more accurate measurement, rotate the rear differential case bearing forward and backward before inspection.

29. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Insert a dial indicator and magnetic base through the rear differential filler 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 sub-assembly forward and backward, and measure the backlash.
SST: 09564-32011
Backlash:
0.10 to 0.15 mm (0.00394 to 0.00591 in.)
NOTICE: Measure at 3 or more areas on the circumference of the differential ring gear.

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





(a) Align the matchmarks on the 2 differential pressure control hose elbows and rear differential carrier assembly.

Text in Illustration





32. INSTALL DIFFERENTIAL PRESSURE CONTROL HOSE





(a) Using the 2 differential pressure control hose clips, install the differential pressure control hose to the 2 differential pressure control hose elbows in the order shown in the illustration.

Text in Illustration





NOTICE:
- Be sure to install the clips in the direction shown in the illustration.
- Confirm that the differential pressure control hose and the differential pressure control hose clips do not interfere with other parts.
- Confirm that the differential pressure control hose is not cracked.

33. INSTALL DIAPHRAGM OIL SEAL





(a) Using SST and a hammer, install a new diaphragm oil seal into the rear differential carrier assembly.

Text in Illustration





SST: 09506-35010
SST: 09554-22010
Diaphragm oil seal driven in depth:
0.7 to 1.3 mm (0.0276 to 0.0512 in.)

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

(b) Apply a light coat of MP grease to the lip of the new diaphragm oil seal.
34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL





(a) Using SST and a hammer, install 2 new rear differential side gear shaft oil seals into the rear differential carrier and differential side bearing retainer.

Text in Illustration





SST: 09554-22010
Oil seal driven in depth (A):
4.2 to 4.8 mm (0.165 to 0.189 in.)

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

(b) Apply a light coat of MP grease to the lip of the 2 new rear differential side gear shaft oil seals.
35. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR





(a) Using SST and a press, install the rear differential dust deflector.

Text in Illustration





SST: 09518-36020
SST: 09950-70010
09951-07150

NOTICE:
- Be sure to press in the rear differential dust deflector until it contacts the bearing end surface.
- Do not damage the end surface of the electro magnetic control coupling sub-assembly.

36. INSTALL CONNECTOR CLAMP BRACKET





(a) Install the connector clamp bracket with the bolt.
Torque: 15 Nm (150 kgf-cm, 11ft-lbf)
NOTICE: Do not damage the electro magnetic control coupling wire harness.

(b) Install the connector with the claw.
37. INSTALL TRANSMISSION COUPLING SPACER





(a) Install the transmission coupling spacer to the rear differential carrier assembly.

Text in Illustration





NOTICE: Keep the transmission coupling spacer free of oil and foreign matter.

38. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER





(a) Install the transmission coupling conical spring washer to the rear differential carrier assembly.

Text in Illustration





NOTICE:
- Install the transmission coupling conical spring washer so that the marked surface faces the front of the vehicle (coupling side).
- Keep the transmission coupling conical spring washer free of oil and foreign matter.

39. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY
(a) Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.
NOTICE: 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 assembly 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.
- Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).
- Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing.
- Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

HINT:
- (B) : 1.0 mm (0.0394 in.)
- (C) : 2.0 mm (0.0787 in.)
- (D) : 3.0 mm (0.118 in.)
- (E) : 5.0 mm (0.197 in.)

(d) Apply hypoid gear oil to the splines of the rear drive pinion.





(e) Install the electro magnetic control coupling sub-assembly with the 4 bolts.
Torque: 20 Nm (200 kgf-cm, 14ft-lbf)

NOTICE:
- Do not damage the diaphragm oil seal.
- Do not damage the contact surface of the electro magnetic control coupling sub-assembly.

40. INSTALL REAR DIFFERENTIAL FILLER PLUG





(a) Install a new gasket with the rear differential filler plug (inspection plug).
Torque: 98 Nm (999 kgf-cm, 72ft-lbf)
41. INSPECT ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY





(a) Install a dial indicator and magnetic base so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.
(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 and magnetic base so that it is 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:
0.063 mm (0.00248 in.)
If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.
42. 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.

Text in Illustration





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: 9.8 Nm (100 kgf-cm, 87in-lbf)
(A):
29.1 to 32.3 mm (1.15 to 1.27 in.)
HINT: If the threads of the electro magnetic control coupling sub-assembly are damaged while installing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

43. REMOVE DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the differential carrier assembly from the overhaul attachment.
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