Reassembly [12/2019 - ]: Procedure

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

See step  13 [12/2019 - 10/2022], or see step  13 [10/2022 - 11/2023], or see step  13 [11/2023 - ]

1. Using a socket wrench, service nut and hammer, install a new rear differential breather plug to the rear differential carrier assembly.

   HINT: 

   • Use a service nut with an inner diameter of 13 mm (0.512 in.) and a socket wrench appropriate for the service nut.
   • Tap in the rear differential breather plug until it sits flush with the rear differential carrier assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Rear Differential Breather Plug
   *a	Service Nut
   *b	Socket Wrench

See step  1

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09816-30010 

   Torque: 40.2 N.m (410 kgf/cm, 30 ft.lbf) 

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Using an 8 mm hexagon socket wrench, install a new rear differential carrier cover plug to the rear differential carrier assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Using SST and a hammer, install a new transmission coupling dust seal to the electro magnetic control coupling sub-assembly.
   • SST: 09316-10010 
   • SST: 09950-70010 
     1. 09951-07150

   Standard Distance (A)

   2.0 to 2.8 mm (0.0788 to 0.1102 in.)

   NOTE:

   • Install the transmission coupling dust seal uniformly.
   • Press fit the transmission coupling dust seal straight.
   • Do not damage the transmission coupling dust seal.
   • Do not excessively press in the transmission coupling dust seal.
   • Make sure to install the transmission coupling dust seal as specified, otherwise a malfunction such as an oil leak may occur.

   HINT: 

   Make sure to place the electro magnetic control coupling sub-assembly on a clean piece of cloth when performing this step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Transmission Coupling Dust Seal
   *a	Cloth

2. Apply a light coat of MP grease to the lip of the transmission coupling dust seal.

HINT: 

Perform the same procedure as for the LH side.

1. Apply gear oil to a new O-ring.
2. Install the O-ring to the rear differential carrier assembly.
3. Install the electro magnetic control coupling sub-assembly to the rear differential carrier assembly with the 5 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 47 N.m (479 kgf/cm, 35 ft.lbf) 

HINT: 

Perform the same procedure as for the LH side.

1. Install the No. 1 rear differential dust deflector and No. 2 rear differential dust deflector to the electro magnetic control coupling sub-assembly with the 3 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

HINT: 

Perform the same procedure as for the LH side.

See step  7 [12/2019 - 10/2022], or see step  7 [10/2022 - 11/2023], or see step  7 [11/2023 - ]

1. Using SST, install 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Turn
   *b	Hold

2. Using SST, temporarily install a new rear drive pinion nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Turn
   *b	Hold

   • SST: 09330-00021 

   Torque: 140 N.m (1428 kgf/cm, 103 ft.lbf) 

   WARNING:

   The total preload may be within the standard even when the rear drive pinion companion flange sub-assembly is loose. If the rear drive pinion companion flange sub-assembly is installed in this state, the vehicle may be damaged or lead to a serious accident.

   NOTE:

   Tighten the rear drive pinion nut until there is no more looseness in the rear drive pinion companion flange sub-assembly and it turns to the right and left with the same amount of force.

   HINT: 

   After temporarily installing the rear drive pinion nut, be sure to adjust the preload.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   • The torque wrench should be installed as shown in the illustration.
   • For a more accurate measurement, rotate the bearing forward and backward several times before the measurement.
   • Use the preload value measured prior to disassembling the torque vectoring differential carrier assembly as the standard value.
   • Adjust within the standard value (Adjustable range within +/- 0.2 N.m of the measured preload value).
2. If the preload is not as specified, perform the procedures below.
   1. If the measured preload is higher than the standard value:

      Replace the rear drive pinion bearing and rear differential drive pinion bearing spacer, and then adjust the preload again.

   2. If the measured preload is lower than the standard value:

      Tighten the rear drive pinion nut, and then adjust the preload again.

1. Using a chisel and hammer, stake the rear drive pinion nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the differential disconnect cover to the torque vectoring differential carrier assembly with the 4 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install the 4 wire harness clamp brackets to the torque vectoring differential carrier assembly with the 4 bolts.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Engage the 3 clamps.

1. Engage the 5 clamps to install the clutch control solenoid wire.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Connector
   	Breather Tube
   	Bolt

2. Install the bolt.

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

3. Connect the 6 connectors and 2 breather tubes.