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Front Differential: Overhaul

WARNING: This page is about a different car, the 2003 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE FRONT WHEELS 
  2. REMOVE ENGINE UNDER COVER ASSY. REAR 
    1. Remove the 6 bolts and engine under cover assy. rear.
  3. REMOVE ENGINE UNDER COVER SUB-ASSY. NO. 1 
    1. Remove the 4 bolts and engine under cover sub-assy. No. 1.
  4. DRAIN DIFFERENTIAL OIL  See DIFFERENTIAL OIL .
  5. REMOVE PROPELLER SHAFT ASSY. FRONT  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  6. REMOVE FRONT AXLE HUB LH NUT  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  7. REMOVE FRONT AXLE HUB RH NUT  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  8. SEPARATE FRONT STABILIZER LINK ASSY. LH  See OVERHAUL under STABILIZER BAR FRONT in FRONT SUSPENSION.
  9. SEPARATE FRONT STABILIZER LINK ASSY. RH  See STABILIZER BAR FRONT in FRONT SUSPENSION.
  10. SEPARATE SPEED SENSOR FRONT LH  See SPEED SENSOR FRONT LH in BRAKE.
  11. SEPARATE SPEED SENSOR FRONT RH  See SPEED SENSOR FRONT LH in BRAKE.
  12. SEPARATE TIE ROD END SUB-ASSY. LH  See OVERHAUL in POWER STEERING.

    SST 09628-62011

  13. SEPARATE TIE ROD END SUB-ASSY. RH  See OVERHAUL in POWER STEERING.

    SST 09628-62011

  14. REMOVE FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 LH  See FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 LH in FRONT SUSPENSION.
  15. REMOVE FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 RH  See FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 LH in FRONT SUSPENSION.
  16. REMOVE FRONT DRIVE SHAFT ASSY. LH  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  17. REMOVE FRONT DRIVE SHAFT ASSY. RH  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  18. REMOVE DIFFERENTIAL CARRIER ASSY. FRONT 
    1. Remove the bolt and separate the front differential breather tube bracket.
    2. Support the front differential with a jack.
    3. Remove the front differential mount nut No. 1.
      Fig 1: Removing Differential Carrier Assy. Front
      G02812889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 front mounting bolts and 2 nuts.
    5. Disconnect the actuator hose and connector.
    6. Lower the jack and remove the front differential assembly.
    7. Remove the 2 bolts and front differential support No. 3.
    8. Remove the 5 bolts and 2 front differential supports.
  19. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION 
    1. Using SST and a dial indicator, measure the ring gear backlash.
      Fig 2: Measuring Ring Gear Backlash
      G02812890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09564-32011

      Backlash: 0.11 - 0.18 mm (0.0043 - 0.0071 in.) 

    If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

  20. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
      Fig 3: Measuring Preload Of Backlash Between Drive Pinion And Ring Gear
      G02812891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      0.49 - 0.78 N.m (5 - 8 kgf.cm, 4.3 - 6.9 in.lbf) 

  21. INSPECT TOTAL PRELOAD 
    1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

      Total preload (at starting): 

      Drive pinion preload plus 0.20 - 0.63 N.m (2.0 - 6.4 kgf.cm, 1.8 - 5.6 in.lbf) 

    If necessary, disassemble and inspect the differential.

  22. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSY. 
    1. Remove the 4 bolts.
    2. Using a hammer, handle, remove the actuator assy.
      Fig 4: Removing Differential Vacuum Actuator Assy.
      G02812892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DIFFERENTIAL TUBE ASSY. 
    1. Remove the 4 bolts.
      Fig 5: Removing Front Differential Tube
      G02812893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the differential tube.
  24. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Using SST, remove the oil seal.
      Fig 6: Removing Differential Side Gear Shaft Oil Seal
      G02812894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09308-00010

  25. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSY. 
    1. Using SST, remove the side gear inter shaft.
      Fig 7: Removing Side Gear Inter Shaft
      G02812895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011)

    2. Remove the snap ring from the side gear inter shaft.
  26. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY. FRONT 
    1. Using SST and a hammer, unstake the nut.
      Fig 8: Unstaking Companion Flange Front Nut
      G02812896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09930-00010

    2. Using SST to hold the companion flange, remove the nut.
      Fig 9: Removing Front Drive Pinion Companion Flange Sub-Assy. Front Nut
      G02812897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09330-00021 (09330-00030)

    3. Using SST, remove the companion flange.
      Fig 10: Removing Front Drive Pinion Companion Flange Sub-Assy. Front
      G02812898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

  27. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL 
    1. Using SST, remove the oil seal from the differential carrier assy.
      Fig 11: Removing Front Differential Carrier Oil Seal
      G02812899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09308-10010

  28. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 
  29. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the rear bearing from the drive pinion.
      Fig 12: Removing Rear Bearing From Drive Pinion
      G02812900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09556-22010

    2. Remove the bearing spacer.
  30. REMOVE DIFFERENTIAL SIDE BEARING RETAINER 
    1. Using a screwdriver, remove the union.
    2. Remove the 10 bolts and tap out the side bearing retainer with a plastic hammer.
  31. REMOVE DIFFERENTIAL CASE ASSY. 
  32. REMOVE DIFFERENTIAL DRIVE PINION 
  33. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING 
      NOTE:

      If the drive gear or ring gear are damaged, replace them as a set.

      Fig 13: Removing Front Bearing And Washer From Drive Pinion
      G02812901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, remove the front bearing and washer from the drive pinion.

      SST 09950-00020

  34. REMOVE FRONT BEARING OUTER RACE 
    1. Using a brass bar and a hammer, remove the front bearing outer race.
      Fig 14: Removing Front Bearing Outer Race
      G02812902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REAR BEARING OUTER RACE 
    1. Using SST, remove the rear bearing outer race.
      Fig 15: Removing Rear Bearing Outer Race
      G02812903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09502-12010, 09612-65014 (09612-01020, 09612-01050)

    2. Using a brass bar and a hammer, remove the oil storage ring.
  36. REMOVE SIDE BEARING OUTER RACE 
    NOTE:
    • Measure the plate washer and note the thickness.
    • Tag the bearing outer races to show the location for reassembly.
    1. Using SST and a press, remove the outer race and plate washer from the bearing retainer.
      Fig 16: Removing Outer Race And Plate Washer From Bearing Retainer
      G02812904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

    2. Using SST and a press, remove the outer race and plate washer from the differential carrier assy.
      Fig 17: Removing Outer Race And Plate Washer From Differential Carrier Assy.
      G02812905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

  37. REMOVE DIFFERENTIAL RING GEAR 
    1. Place matchmarks on the ring gear and differential case assy.
    2. Remove the 10 bolts.
    3. Using a plastic hammer, tap on the ring gear to separate it from the differential case assy.
  38. REMOVE FRONT DIFFERENTIAL CASE BEARING 
      NOTE:

      Fix the clews of SST to the notch in the differential case assy.

      Fig 18: Removing Differential Case Bearings From Differential Case Assy.
      G02812906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the 2 differential case bearings from the differential case assy.

      SST 09950-60010 (09951-00390), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

  39. DISASSEMBLE DIFFERENTIAL CASE 
    1. Using a pin punch and a hammer, remove the straight pin.
      Fig 19: Removing Straight Pin
      G02812907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove there part from the differential case assy.
      1. Differential side gear (2 pieces)
      2. Differential side gear thrust washer (2 pieces)
      3. Differential pinion shaft
      4. Differential pinion gear (2 pieces)
      5. Differential pinion gear thrust washer (2 pieces)
  40. INSPECT DIFFERENTIAL GEAR KIT 
    1. Check that no damage is identified on the pinion gear and side gear.

    If the pinion gear and/or side gear is damaged, replace the differential gear kit.

  41. INSPECT FRONT DIFFERENTIAL CASE 
    1. Check that no damaged is differential case assy.

    If the differential case assy. is damaged, replace the differential case assy.

  42. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING 
    1. Using a brass bar and hammer, remove the 2 bearings.
      Fig 20: Removing Front Differential Side Gear Needle Roller Bearing
      G02812908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE DIFFERENTIAL CLUTCH HUB 
    1. Using a snap ring expander, remove the snap ring.
      Fig 21: Removing Differential Clutch Hub Snap Ring
      G02812909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the differential clutch hub.
  44. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Using SST, remove the oil seal from the differential tube.
      Fig 22: Removing Oil Seal From Differential Tube
      G02812910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09308-00010

  45. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY. RH 
    1. Using a snap ring expander, remove the snap ring.
      Fig 23: Removing Differential Side Gear Shaft Sub-Assy. RH Snap Ring
      G02812911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the side gear shaft from the differential tube.
  46. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING 
    1. Using a snap ring expander, remove the snap ring.
      2. NOTE: Do not damage the bearing.
      Fig 24: Removing Front Differential Side Gear Shaft RH Bearing
      G02812912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, a brass bar and a press, remove the bearing.

      SST 09950-00020

  47. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR 
    1. Using SST, a socket wrench and a press, remove the dust deflector
      Fig 25: Removing Front Differential Dust Deflector
      G02812913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-00020

  48. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB 
    1. Check the wear and damage of the clutch hub and clutch sleeve.

      If necessary replace them

    2. Check that clutch sleeve slides smoothly on the clutch hub.
      Fig 26: Inspecting Differential Clutch Sleeve And Differential Clutch Hub
      G02812914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT 
    1. Check the wear and damage of the clutch hub and side gear inter shaft.
    2. Check that clutch sleeve slides smoothly on the side gear inter shaft.
      Fig 27: Inspecting Differential Clutch Sleeve And Differential Side Gear Inter Shaft
      G02812915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE 
    1. Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
      Fig 28: Measuring Clearance Between Sleeve Fork And Clutch Sleeve
      G02812916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum clearance: 0.35 mm (0.0138 in.) 

    If the clearance exceeds the maximum, replace the fork or clutch sleeve.

  51. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR 
      NOTE: Do not damage the dust deflector.
      Fig 29: Installing Front Differential Dust Deflector
      G02812917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a steel plate and a press, install a new dust deflector.
  52. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING 
    1. Using SST and a press, install the bearing.
      Fig 30: Installing Front Differential Side Gear Shaft RH Bearing
      G02812918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09223-00010

    2. Using a snap ring expander, install the snap ring.
  53. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY. RH 
    1. Install the side gear shaft into the differential tube.
      Fig 31: Installing Differential Side Gear Shaft Sub-Assy. RH Snap Ring
      G02812919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using snap ring pliers, install the snap ring.
  54. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Using SST and a plastic hammer, install a new oil seal.
      Fig 32: Installing Differential Side Gear Shaft Oil Seal
      G02812920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09608-32010

      Oil seal drive in depth: 5.3 +/- 0.5 mm (0.2087 +/- 0.0197 in.) 

    2. Coat the oil seal lip with MP grease.
  55. INSTALL DIFFERENTIAL CLUTCH HUB 
      NOTE: Make sure to install the differential clutch hub in the correct direction.
      Fig 33: Installing Clutch Hub To Side Gear Inter Shaft
      G02812921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the clutch hub to the side gear inter shaft.
    2. Using snap ring pliers install the snap ring.
  56. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING 
    1. Using SST and press, install 2 new bearings.
      Fig 34: Installing Front Differential Side Gear Needle Roller Bearing
      G02812922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60010 (09951-00380)

      Bearing press in depth: 1.7 +/- 0.3 mm (0.067 +/- 0.012 in.) 

  57. INSTALL FRONT DIFFERENTIAL CASE 
    1. Install the 2 proper thrust washers on the 2 side gears.
      NOTE:

      Using WASHER THICKNESS , select thrust washer which will ensure that the backlash is within the specifications.

      WASHER THICKNESS

      Thickness mm (in.) Thickness mm (in.)
      1.48 - 1.52 (0.0583 - 0.0598) 1.73 - 1.77 (0.0681 - 0.0697)
      1.53 - 1.57 (0.0602 - 0.0618) 1.78 - 1.82 (0.0701 - 0.0717)
      1.58 - 1.62 (0.0622 - 0.0638) 1.83 - 1.87 (0.0720 - 0.0736)
      1.63 - 1.67 (0.0642 - 0.0657) 1.88 - 1.92 (0.0740 - 0.0756)
      1.68 - 1.72 (0.0661 - 0.0677) .....
      2. NOTE:

      Align the holes of the differential case assy. and pinion shaft.

      Fig 35: Installing proper Thrust Washers On Side Gears
      G02812923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the differential case assy.
    3. Measure the side gear backlash.
      1. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case assy.
        Fig 36: Measuring Side Gear Backlash
        G02812924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Backlash: 0 - 0.15 mm (0 - 0.00591 in.) 

        If the backlash is not within the specification, install side gear thrust washer with different thicknesses.

    4. Using a pin punch and hammer, install the straight pin through the differential case assy. and hole of the pinion shaft.
      5. Fig 37: Installing Straight Pin Through Differential Case Assy. & Pinion Shaft
      G02812925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Stake the differential case assy.
  58. INSTALL DIFFERENTIAL RING GEAR 
    1. Clean the contact surfaces of the differential case assy. and ring gear.
    2. Heat the ring gear to about 100°C (212°F) in boiling water.
      Fig 38: Heating Ring Gear In Boiling Water
      G02812926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Carefully remove the ring gear from the boiling water.
    4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case assy.
      NOTE:

      Align the matchmarks on the ring gear and differential case assy.

    5. Temporarily install 10 bolts so that the bolt holes in the ring gear and differential case assy. are not misaligned.
    6. After the ring gear has cooled sufficiently, torque the ring gear set bolts to which thread lock has been applied.

      Torque: 97 N.m (985 kgf.cm, 71 ft.lbf) 

      Thread lock: Part No. 08833-00100, THREE BOND 1360k or equivalent 

  59. INSTALL FRONT DIFFERENTIAL CASE BEARING 
    1. Using SST and a press, install the 2 differential case bearings into the differential case assy.
      Fig 39: Installing Differential Case Bearings Into Differential Case Assy.
      G02812927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09226-10010

  60. INSTALL SIDE BEARING OUTER RACE 
    NOTE:

    When replacing the 2 differential case bearings, fit 2 new thinnest washers to each bearing and when reusing the bearings, fit the thickness washers with the same thickness as removed.

    1. Install a new plate washer to the side bearing retainer.
    2. Using SST and a press, install the bearing outer race to the differential case bearing retainer assy.
      Fig 40: Installing Bearing Outer Race To Differential Case Bearing Retainer Assy.
      G02812928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)

    3. Install a new plate washer to the differential carrier assy.
    4. Using SST and a press, install the bearing outer race to the differential carrier assy.
      Fig 41: Installing Bearing Outer Race To Differential Carrier Assy.
      G02812929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)

  61. INSTALL FRONT BEARING OUTER RACE 
    1. Using SST, install the outer race.

      SST 09950-00020 (09951-00680, 09951-00890)

  62. INSTALL REAR BEARING OUTER RACE 
    1. Install the oil stage ring.
    2. Using SST, install the outer race.
      Fig 42: Installing Bearing Outer Race
      G02812930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-00020 (09951-00680, 09951-00890)

  63. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Install the washer on the drive pinion.
      NOTE:

      First fit a washer with the same thickness with the removed washer, then after checking the tooth contact pattern, replace the washer with one of a differential thickness if necessary.

    2. Using SST and a press, install the front bearing onto the drive pinion.
      Fig 43: Installing Front Bearing Onto Drive Pinion
      G02812931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09506-30012

  64. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Install the drive pinion.
      NOTE:

      Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern.

    2. Using SST, install the rear bearing, oil slinger and companion flange.
      Fig 44: Installing Rear Bearing, Oil Slinger And Companion Flange
      G02812932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

    3. Coat the threads of the nut with hypoid gear oil.
    4. Adjust the drive pinion preload by tightening the companion flange nut.
      5. NOTE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
      Fig 45: Tightening Companion Flange Nut
      G02812933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST to hold the companion flange, tighten the nut.

      SST 09330-00021 (09330-00030)

    6. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
      Fig 46: Measuring Preload Of Backlash Between Drive Pinion And Ring Gear
      G02812934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload (at starting) 

      New bearing: 0.98 - 1.57 N.m (10 - 16 kgf.cm, 8.7 - 13.9 in.lbf) 

      Reused bearing: 0.49 - 0.78 N.m (5 - 8 kgf.cm, 4.3 - 6.9 in.lbf) 

  65. INSTALL DIFFERENTIAL CASE ASSY. 
  66. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION 
    1. Install the side bearing retainer with the 10 bolts.

      Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    2. Using SST and a dial indicator, measure the ring gear backlash.

      SST 09564-32011

      Backlash: 0.11 - 0.18 mm (0.0043 - 0.0071 in.) 

    3. If it is not within the specification, adjust it by either in creasing or decreasing the washers on both sides by an equal amount. Refer to SELECTIVE WASHER THICKNESS  table.
    NOTE:

    There should be no clearance between the plate washer and differential case.

    Make sure that there is ring gear backlash.

    Fig 47: Measuring Ring Gear Backlash
    G02812935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    SELECTIVE WASHER THICKNESS

    Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
    1.59 - 1.61 (0.0626 - 0.0634) 1.89 - 1.91 (0.0744 - 0.0752) 2.19 - 2.21 (0.0862 - 0.0870)
    1.62 - 1.64 (0.0638 - 0.0646) 1.92 - 1.94 (0.0756 - 0.0764) 2.22 - 2.24 (0.0874 - 0.0882)
    1.65 - 1.67 (0.0650 - 0.0657) 1.95 - 1.97 (0.0768 - 0.0776) 2.25 - 2.27 (0.0886 - 0.0894)
    1.68 - 1.70 (0.0661 - 0.0669) 1.98 - 2.00 (0.0780 - 0.0787) 2.28 - 2.30 (0.0898 - 0.0906)
    1.71 - 1.73 (0.0673 - 0.0681) 2.01 - 2.03 (0.0791 - 0.0800) 2.31 - 2.33 (0.0909 - 0.0917)
    1.74 - 1.76 (0.0685 - 0.0693) 2.04 - 2.06 (0.0803 - 0.0811) 2.34 - 2.36 (0.0921 - 0.0929)
    1.77 - 1.79 (0.0697 - 0.0705) 2.07 - 2.09 (0.0815 - 0.0823) 2.37 - 2.39 (0.0933 - 0.0941)
    1.80 - 1.82 (0.0709 - 0.0717) 2.10 - 2.12 (0.0827 - 0.0835) 2.40 - 2.42 (0.0945 - 0.0953)
    1.83 - 1.85 (0.0720 - 0.0728) 2.13 - 2.15 (0.0839 - 0.0846) 2.43 - 2.45 (0.0957 - 0.0965)
    1.86 - 1.88 (0.0732 - 0.0740) 2.16 - 2.18 (0.0850 - 0.0858) 2.46 - 2.48 (0.0969 - 0.0976)
  67. INSPECT TOTAL PRELOAD 
    1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
      Fig 48: Measuring Total Preload
      G02812936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Total preload (at starting): 

      Drive pinion preload plus: 0.20 - 0.63 N.m (2.0 - 6.4 kgf.cm, 1.8 - 5.6 in.lbf) 

      If necessary, disassemble and inspect the differential.

  68. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Remove the side bearing retainer and differential case assy.
    2. Coat 3 or 4 teeth are the 3 different positions on the ring gear with red lead.
      Fig 49: Coating Ring Gear With Red Lead
      G02812937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the differential case assy. and side bearing retainer.

      Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    4. Hold the companion flange firmly and rotate the ring gear in both directions.
    5. Remove the differential case and side bearing retainer and differential case assy.
    6. Inspect the tooth contact pattern.
      Fig 50: Inspecting Tooth Contact Pattern
      G02812938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the teeth are not contacting properly, use the following chart to select a proper washer for correction.

      Fig 51: Identifying Selective Washer
      G02812939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SELECTIVE WASHER THICKNESS

      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      1.69 - 1.71 (0.0665 - 0.0673) 1.93 - 1.95 (0.0760 - 0.0768) 2.17 - 2.19 (0.0854 - 0.0862)
      1.72 - 1.74 (0.0677 - 0.0685) 1.96 - 1.98 (0.0772 - 0.0780) 2.20 - 2.22 (0.0866 - 0.0874)
      1.75 - 1.77 (0.0689 - 0.0697) 1.99 - 2.01 (0.0783 - 0.0791) 2.23 - 2.25 (0.0878 - 0.0886)
      1.78 - 1.80 (0.0701 - 0.0709) 2.02 - 2.04 (0.0795 - 0.0803) 2.26 - 2.28 (0.0890 - 0.0898)
      1.81 - 1.83 (0.0713 - 0.0720) 2.05 - 2.07 (0.0807 - 0.0815) 2.29 - 2.31 (0.0902 - 0.0909)
      1.84 - 1.86 (0.0724 - 0.0732) 2.08 - 2.10 (0.0819 - 0.0827) 2.32 - 2.34 (0.0913 - 0.0921)
      1.87 - 1.89 (0.0736 - 0.0744) 2.11 - 2.13 (0.0831 - 0.0839) .....
      1.90 - 1.92 (0.0748 - 0.0756) 2.14 - 2.16 (0.0843 - 0.0850) .....
    7. Remove the companion flange and oil slinger.

      SST 09330-00021 (09330-00030), 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

    8. Remove the rear bearing.

      SST 09556-22010

  69. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER 
    1. Install a new bearing spacer and oil stage ring.
  70. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 
  71. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 
  72. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY. FRONT 
    1. Place the companion flange on the drive pinion.
    2. Coat the threads of a new nut with hypoid gear oil LSD.
    3. Using SST and the companion flange, install the rear tapered roller bearing, then remove the companion flange.
      Fig 52: Installing Rear Tapered Roller Bearing
      G02812940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

  73. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL 
    1. Using SST and a hammer, install the oil seal.
      Fig 53: Installing Front Differential Carrier Oil Seal
      G02812941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09330-00021 (09330-00030), 09554-22010

      Oil seal drive in depth: 4.35 +/- 0.45 mm (0.171 +/- 0.018 in.) 

    2. Coat the oil seal lip with MP grease.
    3. Using SST to hold the flange, torque the nut.
      Fig 54: Torquing Companion Flange Nut
      G02812942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 370 N.m (3,770 kgf.cm, 37 ft.lbf) 

  74. INSTALL DIFFERENTIAL SIDE BEARING RETAINER 
    1. Remove the any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
    2. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
    3. Apply FIPG to the side bearing retainer, as shown in Fig 55.

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 55: Applying FIPG To Side Bearing Retainer
      G02812943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install the side bearing retainer within 10 minutes after applying FIPG.

    4. Install the side bearing retainer with the 10 bolts.

      Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    5. Install a union.
  75. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
      Fig 56: Measuring Preload Of Backlash Between Drive Pinion And Ring Gear
      G02812944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload (at starting) 

      New bearing: 0.98 - 1.57 N.m (10 - 16 kgf.cm, 8.7 - 13.9 in.lbf) 

      Reused bearing: 0.49 - 0.78 N.m (5 - 8 kgf.cm, 4.3 - 6.9 in.lbf) 

    If the preload is greater than the specification, replace the bearing spacer.

    If the preload is less than the specification, retighten the nut 13 N.m (130 kgf.cm, 9 ft.lbf) a little at a time until the specified preload is reached.

    Torque: 370 N.m (3773 kgf.cm, 268 ft.lbf) or less 

    If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repair the preload procedure. Do not back off the nut to reduce the preload.

  76. INSPECT TOTAL PRELOAD 
  77. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION 
  78. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY. FRONT 
  79. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT 
  80. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end.
      Fig 57: Installing Differential Side Gear Shaft Oil Seal
      G02812945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09608-32010

    2. Coat the oil seal lip with MP grease.

      Oil seal drive in depth: 0 +/- 0.45 mm (0 +/- 0.0177 in.) 

  81. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSY. 
    1. Install a new snap ring to the side gear inter shaft.
    2. Using a plastic hammer, side gear inter shaft to the differential case.
      Fig 58: Installing Differential Side Gear Inter Shaft Sub-Assy.
      G02812946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that there 2 - 3 mm (0.08 - 0.12 in.) of play in axial direction.
    4. Check that the side gear inter shaft will not come out by trying to pull it completely out by hand.
  82. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR 
      NOTE: Make sure to install the side bearing retainer deflector in the correct direction.
      Fig 59: Installing Side Bearing Retainer Deflector
      G02812947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a brass bar and a hammer, install the side bearing retainer deflector.
  83. INSTALL FRONT DIFFERENTIAL TUBE ASSY. 
    1. Remove the any oil FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
    2. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
    3. Apply FIPG to the differential.
      Fig 60: Applying FIPG To Differential
      G02812948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

      NOTE:

      Install the differential tube within 10 minutes after applying FIPG.

    4. Install the differential tube to the differential carrier assy.
    5. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
    6. Apply adhesive to 2 to 3 threads of the bolts end.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

    7. Install the 4 bolts.
      Fig 61: Installing Front Differential Tube Assy. Bolts
      G02812949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 110 N.m (1,122 kgf.cm, 81 ft.lbf) or less 

  84. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSY. 
    1. Remove the any oil FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case.
    2. Clean connecting surfaces of any residual FIPG material using gasoline or alcohol.
    3. Apply FIPG to the differential tube, as shown in Fig 62.
      Fig 62: Applying FIPG To Differential Tube
      G02812950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

      NOTE:

      Install the actuator within 10 minutes after applying FIPG.

    4. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
    5. Install the actuator assy. to the differential tube.
    6. Apply adhesive to 2 to 3 threads of the bolts end.

      Adhesive: Part No. 08833-00070, THREE BOND 1281 or equivalent 

    7. Install the 4 bolts.
      Fig 63: Identifying Differential Vacuum Actuator Assy. Bolts
      G02812951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 

  85. INSTALL DIFFERENTIAL CARRIER ASSY. FRONT 
    1. Connect the actuator hose and connector.
    2. Install the No. 1 mounting support with the 3 bolts.
      Fig 64: Installing Differential Carrier Assy. Front
      G02812952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 186 N.m (1900 kgf.cm, 137 ft.lbf) 

    3. Install the No. 2 mounting support with the 2 bolts.

      Torque: 160 N.m (1630 kgf.cm, 118 ft.lbf) 

    4. Install the front differential support No. 3 with the 2 bolts.

      Torque: 108 N.m (1100 kgf.cm, 80 ft.lbf) 

    5. Support the front differential with a jack.
    6. Install the 2 front mounting bolts and nuts.

      Torque: 137 N.m (1400 kgf.cm, 101 ft.lbf) 

    7. Install the front differential mount nuts No. 1.

      Torque: 87 N.m (887 kgf.cm, 64 ft.lbf) 

    8. Install the front differential breather tube bracket with a bolt.

      Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

    9. Lower the jack.
  86. INSTALL FRONT DRIVE SHAFT ASSY. LH  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  87. INSTALL FRONT DRIVE SHAFT ASSY. RH  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  88. INSTALL FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 LH  See OVERHAUL in FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 LH .
  89. INSTALL FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 RH  See OVERHAUL in FRONT SUSPENSION ARM SUB-ASSY. LOWER NO. 1 LH .
  90. INSTALL TIE ROD END SUB-ASSY. LH  See OVERHAUL in POWER STEERING LINK ASSY.
  91. INSTALL TIE ROD END SUB-ASSY. RH  See OVERHAUL in POWER STEERING LINK ASSY.
  92. INSTALL SPEED SENSOR FRONT LH  See SPEED SENSOR FRONT LH in BRAKE.
  93. INSTALL SPEED SENSOR FRONT RH  See SPEED SENSOR FRONT LH in BRAKE.
  94. INSTALL FRONT STABILIZER LINK ASSY. LH  See OVERHAUL under STABILIZER BAR FRONT .
  95. INSTALL FRONT STABILIZER LINK ASSY. RH  See OVERHAUL under STABILIZER BAR FRONT .
  96. INSTALL FRONT AXLE HUB LH NUT  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  97. INSTALL FRONT AXLE HUB RH NUT  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  98. INSTALL PROPELLER SHAFT ASSY. FRONT  See OVERHAUL in DRIVE SHAFT/PROPELLER SHAFT.
  99. FILL UP DIFFERENTIAL OIL  See DIFFERENTIAL OIL .
  100. INSPECT DIFFERENTIAL OIL  See DIFFERENTIAL OIL .
  101. INSTALL ENGINE UNDER COVER SUB-ASSY. NO. 1 
    1. Install the engine under cover sub-assy. No. 1 with the 4 bolts.
  102. INSTALL ENGINE UNDER COVER ASSY. REAR 
    1. Install the engine under cover assy. rear with the 6 bolts.
  103. INSTALL FRONT WHEEL 

    Torque: 112 N.m (1142 kgf.cm, 83 ft.lbf) 

  104. CHECK ABS SPEED SENSOR SIGNAL  See on PRE-CHECK .
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