Rear Extension Housing: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL BALL BEARING 
   1. Using SST and a press, install the ball bearing.

      SST 09316-6001 1 (09316-00011, 09316-00031)

      Fig 1: Installing Ball Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Select a snap ring that will allow the minimum axial play.
      SNAP RING THICKNESS SPECIFICATION
      
      

      Mark	Thickness mm (in.)
      A	1.70 (0.0669)
      B	1.80 (0.0709)

   3. Using a screwdriver, install a new snap ring.
   Fig 2: Installing New Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL DUST DEFLECTOR 
   1. Using SST and a hammer, install a new rear extension housing dust deflector.

      SST 09316-6001 1 (09316-00011, 09316-00041)

      Fig 3: Installing Rear Extension Housing Dust Deflector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST and a press, install a new rear output shaft dust deflector.

      SST 09316-2001 1, 09316-60011 (09316-00011)

   Fig 4: Installing Rear Output Shaft Dust Deflector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL OIL SEAL 
   1. Apply MP grease to the lip of a new oil seal.
   2. Using SST and a hammer, drive in the oil seal.

      SST 09316-6001 1 (09316-00011, 09316-00031)

   Fig 5: Installing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL REAR OUTPUT SHAFT 
   1. Using SST and a press, install the rear output shaft.

      SST 09316-20011, 09316-60011 (09316-00011, 09316-00031)

   2. Install the 2 seal rings to the rear output shaft.
      Fig 6: Installing Rear Output Shaft

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Select a snap ring that will allow the minimum axial play.
      SNAP RING THICKNESS SPECIFICATION
      
      

      Mark	Thickness mm (in.)
      1	1.95 (0.0768)
      2	2.05 (0.0807)
      3	2.15 (0.0847)
      4	2.25 (0.0886)

   4. Using a snap ring expander, install a new snap ring.
5. INSTALL SPEED SENSOR DRIVE GEAR 
   1. Install the speed sensor drive gear.
   2. Using a snap ring expander, install the snap ring.
   Fig 7: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL OIL PUMP PLATE 
   1. Install the oil pump plate.
   2. Install and torque the 3 bolts.

      Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

   Fig 8: Locating Oil Pump Plate Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG 
   1. Apply gear oil to the ball.
   2. Install the valve seat, ball and spring.
   3. Apply liquid sealer to the screw plug threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

   4. Using a hexagon wrench, install and torque the screw plug.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

   Fig 9: Installing Valve Seat, Ball, Spring And Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL DRIVEN ROTOR 
   1. Apply gear oil to the driven rotor.
   2. Install the driven rotor.
9. INSTALL DRIVE ROTOR 
   1. Apply gear oil to the drive rotor.
   2. Install the drive rotor.

   HINT:

   Align the alignment marks.

   Fig 10: Installing Drive Rotor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL OIL PUMP COVER 
    1. Install the oil pump cover.
    2. Using a torx socket wrench (T30), install and torque the 3 screws.

       Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

    NOTE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.
    Fig 11: Installing Oil Pump Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL OIL PUMP DRIVE SHAFT