Replacement

AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER OIL SEAL: REPLACEMENT

REPLACEMENT

1. REMOVE CENTER EXHAUST PIPE ASSEMBLY
(a) Remove the center exhaust pipe assembly.
HINT: Refer to the instructions for Removal of the exhaust pipe Removal for 2GR-FE, Removal for 1AR-FE).

2. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Removal
3. DRAIN DIFFERENTIAL OIL





(a) Using a hexagon wrench (10 mm), remove the rear differential carrier cover plug and gasket.





(b) Using a hexagon wrench (10 mm), remove the rear differential drain plug and gasket, then drain the differential oil.
(c) Using a hexagon wrench (10 mm), install the rear differential drain plug with a new gasket.
Torque: 39 Nm (398 kgf-cm, 29ft-lbf)





(d) Using a hexagon wrench (10 mm), temporarily install the rear differential carrier cover plug.
HINT: Add differential oil before installing a new gasket and fully tightening the rear differential carrier cover plug.

4. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY





(a) Disconnect the electro magnetic control coupling sub-assembly connector and vacuum hose.
NOTICE: Do not damage the electro magnetic control coupling wire harness.





(b) Remove the 4 bolts.
(c) Using a brass bar and a hammer, tap the electro magnetic control coupling sub-assembly to remove the electro magnetic control coupling sub-assembly from the rear differential carrier assembly.
NOTICE: Do not drop the electro magnetic control coupling sub-assembly.

5. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER





(a) Remove the transmission coupling conical spring washer from the rear differential carrier assembly.

Text in Illustration





6. REMOVE TRANSMISSION COUPLING SPACER





(a) Remove the transmission coupling spacer from the rear differential carrier assembly.

Text in Illustration





7. REMOVE DIAPHRAGM OIL SEAL





(a) Using SST, remove the diaphragm oil seal.
SST: 09308-10010
8. INSTALL DIAPHRAGM OIL SEAL





(a) Using SST and a hammer, install a new diaphragm oil seal.
SST: 09506-35010
SST: 09554-22010
Oil seal driven in depth (A):
0.7 to 1.3 mm (0.0276 to 0.0512 in.)
(b) Apply MP grease to the lip of the new diaphragm oil seal.
9. 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.

10. 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.

11. 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 contact surfaces of the diaphragm oil seal, stud bolt or electro magnetic control coupling sub-assembly.





(f) Connect the electro magnetic control coupling sub-assembly connector and vacuum hose.
NOTICE: Do not damage the electro magnetic control coupling wire harness.

12. ADD DIFFERENTIAL OIL





(a) Remove the rear differential carrier cover plug.
(b) Add differential oil Service and Repair.
13. INSPECT AND ADJUST DIFFERENTIAL OIL Service and Repair
14. INSTALL REAR DIFFERENTIAL CARRIER COVER PLUG Service and Repair
15. INSPECT FOR DIFFERENTIAL OIL LEAK
16. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation
17. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation
18. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Install the center exhaust pipe assembly.
HINT: Refer to the instructions for Install of the exhaust pipe Installation for 2GR-FE, Installation for 1AR-FE).

19. INSPECT AND ADJUST TRANSFER OIL
(a) Inspect and adjust transfer oil Testing and Inspection.
20. INSPECT FOR TRANSFER OIL LEAK