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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Axle And Differential - Service Information (2 Of 2) >> REAR DIFFERENTIAL CARRIER ASSEMBLY (for Dynamic Torque Control AWD) >> Reassembly [12/2019 - ] >> Procedure

Reassembly [12/2019 - ]: Procedure

  1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR (for LH Side) 
    1. Using a 5 mm pin punch and a hammer, install a new rear differential dust deflector to the rear differential carrier assembly.
      GTY840253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Differential Dust Deflector

      Standard Distance (A)

      -0.5 to 0.5 mm (-0.00197 to 0.0197 in.)

      NOTE:
      • Install the rear differential dust deflector uniformly.
      • Install the rear differential dust deflector straight.
      • Do not damage the rear differential dust deflector.
      • Do not excessively press in the rear differential dust deflector.
  2. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR (for RH Side) 

    HINT: 

    Perform the same procedure as for the LH side.

  3. INSTALL REAR DRIVE SHAFT OIL SEAL LH 
    1. Using SST and a hammer, install a new rear drive shaft oil seal LH to the rear differential carrier assembly.
      GTY939828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Drive Shaft Oil Seal LH
      • SST: 09316-10010 
      • SST: 09950-70010 
        1. 09951-07150

      Standard Distance (A)

      -0.4 to 0.4 mm (-0.00157 to 0.0157 in.)

      NOTE:
      • Install the rear drive shaft oil seal LH uniformly.
      • Install the rear drive shaft oil seal LH straight.
      • Do not damage the rear drive shaft oil seal LH.
      • Do not damage the rear differential dust deflector.
      • Do not excessively press in the rear drive shaft oil seal LH.
      • Make sure to install the rear drive shaft oil seal LH as specified, otherwise a malfunction such as an oil leak may occur.
    2. Apply a light coat of MP grease to the lip of the rear drive shaft oil seal LH.
  4. INSTALL REAR DRIVE SHAFT OIL SEAL RH 

    HINT: 

    Use the same procedure as for the LH side.

  5. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL 

    See step  9 [12/2019 - 10/2022], or see step  9 [10/2022 - 11/2023], or see step  9 [11/2023 - ]

  6. INSTALL TRANSMISSION COUPLING DUST SEAL 

    See step  10 [12/2019 - 10/2022], or see step  10 [10/2022 - 11/2023], or see step  10 [11/2023 - ]

  7. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR (for Front Side) 
    1. Temporarily install a new rear differential dust deflector.
    2. Using SST, V-blocks and a press, install the rear differential dust deflector to the electro magnetic control coupling sub-assembly.
      GTY918923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Differential Dust Deflector
      *a V-block
      • SST: 09223-56010 

      Standard Distance (A)

      5.5 to 6.1 mm (0.217 to 0.240 in.)

      NOTE:
      • Make sure that the electro magnetic control coupling sub-assembly is supported as shown in the illustration.
      • Install the rear differential dust deflector uniformly.
      • Install the rear differential dust deflector straight.
      • Do not damage the end surface of the electro magnetic control coupling sub-assembly.
      • Do not excessively press in the rear differential dust deflector.

      If the end surface of the electro magnetic control coupling sub-assembly is damaged while installing the rear differential dust deflector, replace the electro magnetic control coupling sub-assembly with a new one.

  8. INSTALL CONICAL SPRING WASHER 
    1. Using a vernier caliper and precision straightedge, measure dimensions (B1) and (B2) of the electro magnetic control coupling sub-assembly.
      GTY935360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Electro Magnetic Control Coupling Sub-assembly
      *2 Rear Differential Carrier Assembly
    2. Calculate dimension (B) by subtracting dimension (B2) from (B1).

      HINT: 

      • Dimension (B) = Dimension (B1) - Dimension (B2)
      • Dimension (B1) is the distance from the installation surface of the electro magnetic control coupling sub-assembly to the edge of the bearing.
    3. Using a vernier caliper and precision straightedge, measure dimension (A) of the rear differential carrier assembly.

      HINT: 

      Dimension (A) is the distance from the installation surface of the rear differential carrier assembly to the edge of the differential drive pinion.

    4. Select a transmission coupling spacer and install it.
      NOTE:

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

      HINT: 

      Transmission coupling spacer thickness = Dimension (A) - Dimension (B) - 1.6

      Transmission Coupling Spacer

      Part No. Thickness
      90564-25045 1.79 to 1.81 mm (0.0705 to 0.0713 in.)
      90564-25046 1.89 to 1.91 mm (0.0744 to 0.0752 in.)
      90564-25047 1.99 to 2.01 mm (0.0783 to 0.0791 in.)
      90564-25048 2.09 to 2.11 mm (0.0823 to 0.0831 in.)
      90564-25049 2.19 to 2.21 mm (0.0862 to 0.0870 in.)
      90564-25050 2.29 to 2.31 mm (0.0902 to 0.0909 in.)
      90564-25051 2.39 to 2.41 mm (0.0941 to 0.0949 in.)
      90564-25052 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
      90564-25053 2.59 to 2.61 mm (0.1020 to 0.1028 in.)
      90564-25054 2.69 to 2.71 mm (0.1059 to 0.1067 in.)
      90564-25055 2.79 to 2.81 mm (0.1098 to 0.1106 in.)
      90564-25056 2.89 to 2.91 mm (0.1138 to 0.1146 in.)
      90564-25057 2.99 to 3.01 mm (0.1177 to 0.1185 in.)
    5. Install the transmission coupling spacer and conical spring washer to the rear differential carrier assembly as shown in the illustration.
      GTY880965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transmission Coupling Spacer
      *2 Conical Spring Washer

      HINT: 

      Make sure to install the conical spring washer with the concave side facing the front of the vehicle.

  9. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY 
    1. Apply gear oil to a new O-ring.
    2. Install the O-ring to the electro magnetic control coupling sub-assembly.
    3. Align the pin and hole, and install the electro magnetic control coupling sub-assembly with the 4 bolts.
      GTY849635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.6 N.m (200 kgf/cm, 14 ft.lbf) 

      NOTE:
      • Do not damage the rear differential carrier oil seal.
      • Do not damage the contact surface of the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      If the contact surface of the rear differential carrier assembly or electro magnetic control coupling sub-assembly is damaged while installing the electro magnetic control coupling sub-assembly, replace the rear differential carrier assembly or electro magnetic control coupling sub-assembly with a new one.

  10. INSTALL STUD BOLT 
    1. Temporarily install the 4 stud bolts to the electro magnetic control coupling sub-assembly.
      GTY864034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Nut
      *b Lower Nut
      *c Hold
      *d Turn
      NOTE:
      • Make sure to install the longer bolt on the electro magnetic control coupling sub-assembly side.
      • Prevent foreign matter from entering the electro magnetic control coupling sub-assembly.
    2. Install 2 service nuts to the stud bolt.

      Recommended Service Nut

      Thread Diameter 

      10 mm (0.394 in.)

      Thread Pitch 

      1.0 mm (0.0394 in.)

      HINT: 

      Lock the upper nut using the lower nut.

      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.

    3. 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 N.m (100 kgf/cm, 87 in.lbf) 

      Standard Distance (A)

      22.55 to 25.85 mm (0.888 to 1.017 in.)

      GTY430201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR DIFFERENTIAL FILLER PLUG 
    1. Using a 10 mm hexagon socket wrench, install a new gasket and the rear differential filler plug.

      Torque: 39 N.m (398 kgf/cm, 29 ft.lbf) 

  12. INSTALL REAR DIFFERENTIAL CARRIER COVER PLUG 
    1. Using an 8 mm hexagon socket wrench, install a new rear differential carrier cover plug.

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

  13. INSTALL REAR DIFFERENTIAL BREATHER PLUG 
    1. Using a 14 mm deep socket wrench and a hammer, install a new rear differential breather plug to the rear differential carrier assembly.
      GTY928719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tap in the rear differential breather plug until it sits flush with the rear differential carrier assembly.

  14. INSTALL CLUTCH CONTROL SOLENOID WIRE 
    1. Engage the clamp to install a new clutch control solenoid wire to the wire harness clamp bracket.
      GTY918469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the grommet to the wire harness clamp bracket as shown in the illustration.
      GTY878688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
    3. Connect the 2 connectors and grommet.
      GTY869054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      Bolt
      Connector
      NOTE:

      Make sure to push down on the grommet to connect the connector (A) and to securely install the grommet.

    4. Install the wire harness clamp bracket with the bolt.

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

  15. INSTALL TEMPERATURE SENSOR 

    See step  1

  16. INSTALL TRANSMISSION REVOLUTION SENSOR 
    1. Apply gear oil to a new O-ring.
    2. Install the O-ring to the transmission revolution sensor.
    3. Install the transmission revolution sensor to the rear differential carrier assembly with the bolt.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

  17. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Engage the clamp to connect the wire harness.
      NOTE:

      Do not damage the wire harness.

    2. Install the 3 wire harness clamp brackets with 3 bolts to the rear differential carrier assembly.

      Torque: 19.6 N.m (200 kgf/cm, 14 ft.lbf) 

  18. INSTALL CLUTCH CONTROL SOLENOID WIRE 
    1. Engage the 4 clamps to install the clutch control solenoid wire.
    2. Install the bolt.

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

    3. Connect the 4 connectors.
  19. INSTALL DIFFERENTIAL DISCONNECT COVER 
    1. Install the 4 bolts and differential disconnect cover to the rear differential carrier assembly.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

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