Disassembly [12/2019 - ]: Procedure

1. Disconnect the 6 connectors and 2 breather tubes.

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   	Connector
   	Breather Tube
   	Bolt

2. Remove the bolt.
3. Disengage the 5 clamps to remove the clutch control solenoid wire.

1. Disengage the 3 clamps.

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2. Remove the 4 bolts and 4 wire harness clamp brackets from the torque vectoring differential carrier assembly.

1. Remove the 4 bolts and differential disconnect cover from the torque vectoring differential carrier assembly.

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

   Maximum Runout

   Item	Specified Condition
   Vertical runout	0.1 mm (0.00394 in.)
   Lateral runout	0.1 mm (0.00394 in.)

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   *a	Vertical Runout
   *b	Lateral Runout
   *c	30 mm (1.18 in.)

   NOTE:

   Measure the runout of the rear drive pinion companion flange sub-assembly horizontally at a position 30 mm (1.18 in.) away from the center of the differential drive pinion shaft.

   HINT: 

   If the runout is more than the maximum value, replace the torque vectoring differential carrier assembly.

1. Using a torque wrench, check the starting torque (total preload) with the teeth of the drive pinion and ring gear in contact.

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   HINT: 

   • The torque wrench should be installed as shown in the illustration.
   • Record the measured value as it is used during assembly.
   • For a more accurate measurement, rotate the bearing forward and backward several times before the measurement.

1. Using SST and a hammer, release the staked part of the rear drive pinion nut.
   • SST: 09930-00010 
     1. 09931-00010
     2. 09931-00020

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   NOTE:

   • Loosen the staked part of the rear drive pinion nut completely.
   • Do not damage the threads of the differential drive pinion shaft.

1. Using SST, remove the rear drive pinion companion flange sub-assembly.
   • SST: 09950-30012 
     1. 09951-03010
     2. 09953-03010
     3. 09954-03010
     4. 09955-03030
     5. 09956-03020

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   *a	Turn
   *b	Hold

See step  6 [12/2019 - 10/2022], or see step  6 [10/2022 - 11/2023], or see step  6 [11/2023 - ]

1. Remove the 3 bolts, No. 1 rear differential dust deflector and No. 2 rear differential dust deflector from the electro magnetic control coupling sub-assembly.

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   *1	No. 1 Rear Differential Dust Deflector
   *2	No. 2 Rear Differential Dust Deflector

HINT: 

Perform the same procedure as for the LH side.

1. Remove the 5 bolts and electro magnetic control coupling sub-assembly from the rear differential carrier assembly.

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2. Remove the O-ring.

HINT: 

Perform the same procedure as for the LH side.

1. Secure the electro magnetic control coupling sub-assembly in a vise using aluminum plates and cloths.
   NOTE:

   Do not overtighten the vise, as the electro magnetic control coupling sub-assembly may become deformed.

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   *1	Transmission Coupling Dust Seal
   *a	Cloth

2. Using SST, remove the transmission coupling dust seal from the electro magnetic control coupling sub-assembly.
   • SST: 09308-00010 

HINT: 

Perform the same procedure as for the LH side.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Secure the rear differential carrier assembly to the overhaul attachment.

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

   Maximum Runout

   Item	Specified Condition
   Vertical runout	0.1 mm (0.00394 in.)
   Lateral runout	0.1 mm (0.00394 in.)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Vertical Runout
   *b	Lateral Runout
   *c	30 mm (1.18 in.)

   NOTE:

   Measure the runout of the rear drive pinion companion flange sub-assembly horizontally at a position 30 mm (1.18 in.) away from the center of the differential drive pinion shaft.

   HINT: 

   If the runout is more than the maximum value, replace the rear differential carrier assembly.

1. Using a 10 mm hexagon socket wrench, remove the rear differential filler plug and gasket.

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1. Using a 10 mm hexagon socket wrench, remove the rear differential drain plug and gasket.

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1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Using an 8 mm hexagon socket wrench, remove the rear differential carrier cover plug.

1. Remove the bolt and transmission revolution sensor from the rear differential carrier assembly.

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2. Remove the O-ring.

1. Using SST, remove the No. 2 4 wheel drive position switch from the rear differential carrier assembly.

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   • SST: 09816-30010 

See step  2

1. Using a chisel and a hammer, lift the rear differential breather plug slightly.

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2. Using a screwdriver, remove the rear differential breather plug.

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

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