Differential Carrier Assembly: Disassembly

1. Remove the breather plug from the differential carrier cover
   Fig 1: Locating Rear Differential Carrier Cover Breather Plug

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1. Remove the 8 bolts from the differential carrier cover
   Fig 2: Locating Rear Differential Carrier Cover Bolts

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2. Using a brass bar and hammer, remove the differential carrier cover from the differential carrier.
   NOTE:

   • Set the brass bar on the ribbed part of the differential carrier cover.
   • Do not damage the installation surface of the differential carrier.
     Fig 3: Removing Differential Carrier Cover From Differential Carrier

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and oil deflector from the rear differential carrier cover.
   Fig 4: Locating Rear Differential Breather Plug Oil Deflector Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the differential carrier to an overhaul stand as shown in the illustration.

   HINT:

   Install the differential carrier with the back surface of the ring gear facing the overhaul stand as shown in the illustration

   Fig 5: Identifying Differential Carrier On Overhaul Stand

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a dial indicator so that it is perpendicular to the back surface of the ring gear.
2. Rotate the ring gear and measure the ring gear runout

   Maximum runout: 

   0.05 mm (0.00197 in.) 

   HINT:

   For reassembly purposes, record the result before disassembly.

   If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case

   Fig 6: Measuring Differential Ring Gear Runout

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side
2. Fix the companion flange in place, and measure the ring gear backlash.

   Standard backlash: 

   0.08 to 0.13 mm (0.00315 to 0.00511 in.) 

   HINT

   • Measure the ring gear at 3 or more different places
   • For reassembly purposes, record the result before disassembly.
     Fig 7: Measuring Differential Ring Gear Backlash

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1. Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.
   Fig 8: Applying Coat Of Prussian Blue On Differential Ring Gear Teeth

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2. Rotate the companion flange several times in the forward and backward rotation directions
   Fig 9: Rotating Companion Flange

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3. Inspect the tooth contact pattern.
   Fig 10: Identifying Tooth Contact Pattern

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   HINT.

   • The patterns indicated by the Prussian blue are the tooth contact locations.
   • For reassembly purposes, record the result before disassembly.
   NOTE: Check the tooth contact pattern at 4 positions around the circumference of the ring gear.

1. Place a dial indicator on the tip of the side gear tooth at a right angle.
2. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.). If not, replace the rear differential case with a new one.
   Fig 11: Measuring Differential Side Gear Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.394 in.) from the end of the shaft.

   Maximum runout: 

   0.08 mm (0.00315 in.) 

   HINT.

   For reassembly purposes, record the result before disassembly.

   Fig 12: Measuring Runout Of Differential Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the 2 oil seals.

   SST 09308-00010 

   Fig 13: Removing Rear Differential Side Gear Shaft Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 bolts and SST to the differential carrier.

   SST 09571-50010 

2. Tighten SST bolt until SST disc lightly touches the case bearing outer race.
   Fig 14: Identifying SST Bolts And Disc

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a dial indicator to the rear differential carrier
4. Tighten SST bolt and alter the differential carrier's shape to create a 0 1 mm (0.00394 in.) clearance between the case bearing outer race and side gear shaft snap ring.
   NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.00787 in.).

   HINT

   Approximately 0 1 mm (0.00394 in.) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly

   Fig 15: Tightening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side

   HINT.

   • For reassembly purposes, measure the thickness of the differential side gear shaft snap ring, and record the result
   • Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately
     Fig 16: Removing Side Gear Shaft Snap Ring

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the dial indicator from the differential carrier
7. Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race.

   HINT.

   Do not remove SST.

   Fig 17: Loosening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, create a clearance between the case bearing outer race on the back surface of the ring gear and side gear shaft snap ring

   SST 09608-32010, 09950-70010 (09951 -07200) 

   HINT

   The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough

   Fig 18: Creating Clearance Between Case Bearing Outer Race On Back Surface Of Ring Gear And Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.

   HINT

   • For reassembly purposes, measure the thickness of the differential side gear shaft snap ring, and record the result
   • Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.
     Fig 19: Removing Side Gear Shaft Snap Ring On Back Surface Of Ring Gear

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Tighten SST bolt and push out the case bearing outer race on the ring gear back surface side

   SST 09571-50010 

   NOTE: Do not drop the case bearing outer race.

   HINT:

   • For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring
   • Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side) Then store them separately
     Fig 20: Tightening SST Bolt

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and SST from the differential carrier.
   Fig 21: Identifying SST Bolts And Disc

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Raise the ring gear of the differential case slightly and remove the ring gear tooth side case bearing outer race.
   NOTE: Do not drop the case bearing outer race.

   HINT.

   • For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring
     Fig 22: Removing Ring Gear Tooth Side Case Bearing Outer Race

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

1. Remove the rear differential case from the differential carrier as shown in the illustration.
   NOTE: Do not damage the case bearing and ring gear.
   Fig 23: Removing Rear Differential Case Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, unstake the staked part of the drive pinion nut.

   SST 09930-00010 

   NOTE:

   • Do not grind the tip of SST with a grinder, etc.
   • Completely unstake the drive pinion nut to prevent damaging the threads of the drive pinion.
     Fig 24: Unstaking Staked Part Of Drive Pinion Nut

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, fix the companion flange in place.

   SST 09330-00021, 09950-30012 (09955-03040) 

3. While supporting the overhaul attachment, using SST, remove the rear drive pinion nut.

   SST 09229-55010 

   Fig 25: Removing Rear Drive Pinion Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the companion flange from the differential carrier.

   SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060) 

   HINT

   Before using SST center bolt, apply hypoid gear oil to its threads and tip.

   Fig 26: Removing Rear Drive Pinion Companion Flange Rear Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform this procedure only when the dust deflector is damaged.

1. Using SST and a press, press out the dust deflector.

   SST 09950-00020, 09950-60010 (09951 -00440), 09950-70010 (09951-07100) 

   HINT

   Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the dust deflector

   NOTE: Do not drop the companion flange.
   Fig 27: Removing Rear Differential Dust Deflector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the oil seal from the differential carrier.

   SST 09308-00010 

   Fig 28: Removing Rear Differential Carrier Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a magnet hand, remove the oil slinger from the differential carrier.
   Fig 29: Identifying Rear Differential Drive Pinion Oil Slinger

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a press, press out the drive pinion from the differential carrier
   NOTE: Do not drop the drive pinion.
   Fig 30: Removing Differential Drive Pinion

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1. Remove drive pinion bearing spacer from the drive pinion.
   Fig 31: Identifying Rear Differential Drive Pinion Bearing Spacer

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1. Remove the rear drive pinion front tapered roller bearing inner race from the differential carrier.
   Fig 32: Identifying Rear Drive Pinion Front Tapered Roller Bearing Inner Race

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1. Using a brass bar and hammer, tap out the rear drive pinion front tapered roller bearing outer race from the differential carrier
   NOTE: Make sure to preform this procedure with the brass bar placed on the rear drive pinion front tapered roller bearing outer race. Do not damage the differential carrier.
   Fig 33: Removing Rear Drive Pinion Front Tapered Roller Bearing Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press out the rear drive pinion rear tapered roller bearing inner race from the drive pinion.

   SST 09950-00020 

   HINT

   Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the rear tapered roller bearing inner race.

   NOTE: Do not drop the drive pinion.
   Fig 34: Removing Rear Drive Pinion Rear Tapered Roller Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and hammer, tap out the rear drive pinion rear tapered roller bearing outer race and drive pinion washer from the differential carrier
   NOTE: Make sure to perform this procedure with the brass bar placed on the differential drive pinion washer. Do not damage the differential carrier.

   HINT:

   For reassembly purposes, measure the thickness of the differential drive pinion washer, and record the result.

   Fig 35: Removing Rear Drive Pinion Rear Tapered Roller Bearing Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the differential case in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
   Fig 36: Identifying Differential Case In Vise Between Aluminum Plates

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Put matchmarks on the ring gear and differential case.
Fig 37: Identifying Matchmarks On Ring Gear And Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 10 ring gear set bolts.
4. Remove the differential case from the vise.
5. Using a plastic-faced hammer, tap off the ring gear to separate it from the differential case

   HINT:

   Place a cloth on the tooth side of the ring gear to prevent damage

   Fig 38: Removing Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT

Only perform this procedure if the runout exceeded the maximum value during the inspection of the ring gear runout inspection.

1. Install the differential case to the differential carrier.
   NOTE: Do not damage the case bearing.
   Fig 39: Installing Differential Case To Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in the case bearing outer race on the ring gear tooth side.

   SST 09608-32010, 09950-70010 (09951 -07200) 

   HINT:

   Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

   Fig 40: Installing Case Bearing Outer Race On Ring Gear Tooth Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install SST to the differential carrier with the 2 bolts.

   SST 09571-50010 

4. Tighten SST bolt until SST disc lightly touches the case bearing outer race.

   HINT:

   Tighten SST bolt to apply preload to the differential case bearing

   Fig 41: Identifying SST Bolts And Disc

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and a hammer, tap in the case bearing outer race on the ring gear back surface side.

   SST 09608-32010, 09950-70010 (09951 -07200) 

   HINT:

   Tap in the case bearing outer race until it touches the case bearing inner race roller bearing.

   Fig 42: Installing Case Bearing Outer Race On Ring Gear Back Surface Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using snap ring pliers, install the side gear shaft snap ring on the back surface of the ring gear
   Fig 43: Installing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Place a dial indicator so that it is perpendicular to the differential case flange face.
8. Using a dial indicator, measure the differential case runout.

   Maximum runout: 

   0.05 mm (0.00197 in.) 

   NOTE: Do not remove SST.
   Fig 44: Measuring Differential Case Runout

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.
   Fig 45: Removing Side Gear Shaft Snap Ring On Back Surface Of Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Tighten SST bolt to push out the ring gear back surface side case bearing outer race.

    SST 09571-50010 

    NOTE: Do not drop the case bearing outer race.
    Fig 46: Pushing Out Ring Gear Back Surface Side Case Bearing Outer Race

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Remove the 2 bolts and SST from the differential carrier
    Fig 47: Locating SST Bolts

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12. Raise the ring gear side of the differential case slightly and remove the ring gear tooth side case bearing outer race.
    Fig 48: Removing Ring Gear Tooth Side Case Bearing Outer Race

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Remove the differential case from the differential carrier
    NOTE: Do not damage the case bearing.
    Fig 49: Removing Differential Case From Differential Carrier

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT.

Do not remove the rear differential case bearing unless replacing the differential case or differential case bearing.

1. Hold the differential case in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
2. Using SST, remove the case bearing inner race LH and RH from the differential case.

   SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00350, 09951-00480,09952-06010) 

   NOTE: Do not deform the bearing cage if the bearing is to be reused.

   HINT.

   • Before using SST center bolt, apply hypoid gear oil to its threads and tip.
   • Hook SST claw from the recess of the differential case to the bearing inner race.
     Fig 50: Removing Case Bearing Inner Race From Differential Case

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the differential case in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
2. Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.)

   If the backlash is not as specified, replace the rear differential case with a new one.

   Fig 51: Measuring Differential Side Gear Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002