Differential Carrier Assembly: Reassembly

1. Clean the differential ring gear set bolt hole.
2. Heat the ring gear to approximately 100°C (212°F) in boiling water.
   CAUTION: Use thick gloves to protect your hands as the ring gear is hot.
   Fig 1: Heating Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Carefully take the ring gear out of the boiling water.
4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case with matchmarks aligned.
   NOTE: Make sure there is no oil on the differential case and ring gear contact surfaces.

   HINT:

   Align the rear differential case bolt holes and differential ring gear screw holes.

   Fig 2: Identifying Ring Gear And Differential Case Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Hold the differential case in a vise between aluminum plates.
   NOTE: Do not overtighten the vise.
   Fig 3: Identifying Differential Case In Vise Between Aluminum Plates

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply adhesive to the threads and flanges of 10 new differential case bolts.

   Adhesive: 

   Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent 

   NOTE:

   • As the differential case bolts are plastic region tightening bolts, do not reuse them.
   • Make sure there is no oil on the threaded parts.
     Fig 4: Applying Adhesive To Differential Case Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Temporarily tighten the 10 differential case bolts uniformly in several passes, and then tighten them to the torque specification.

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

   NOTE:

   • Tighten the bolts after the ring gear has sufficiently cooled down.
   • Install the differential case bolts by tightening diametrically opposite pairs uniformly in several passes.
     Fig 5: Tightening Differential Case Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Tighten the bolts further by 60 to 90°.
   NOTE: Tighten the bolts in diametrically opposite pairs.
   Fig 6: Tightening Differential Case Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in the case bearing inner race LH and RH to the differential case

   SST 09950-60010 (09951-00560, 09951-00570), 09950-70010 (09951-07100) 

   Fig 7: Installing Rear Differential Case Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.
   • Do not deform the bearing cage. Set SST to the center of the differential case.
   • If the bearing is replaced, replace it with the bearing outer race and inner race as a set.

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

   SST 09316-60011 (09316-00031), 09612-10093 (09613-22011) 

   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.

   HINT

   Disassemble SST (09613-22011), and only use the pipe part.

   Fig 8: Installing Rear Drive Pinion Rear Tapered Roller Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in the rear drive pinion rear tapered roller bearing outer race and drive pinion washer.

   SST 09255-10012, 09950-70010 (09951 -07200) 

   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.

   HINT:

   Select a drive pinion washer of the same thickness as the one removed.

   Fig 9: Removing Rear Drive Pinion Rear Tapered Roller Bearing Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in the rear drive pinion front tapered roller bearing outer race.

   SST 09950-60020 (09951 -00710), 09950-70010 (09951-07100) 

   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.
     Fig 10: Installing Rear Drive Pinion Front Tapered Roller Bearing Outer Race

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform this procedure only when replacing the dust deflector.

1. Using SST and a press, insert a new dust deflector into the companion flange.

   SST 09316-60011 (09316-00011) 

   NOTE:

   • Slowly press in the dust deflector but not excessively.
   • If any burrs remain after pressing in the deflector, remove them.
     Fig 11: Installing Rear Differential Dust Deflector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rear drive pinion front tapered roller bearing inner race to the differential carrier
   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.
     Fig 12: Identifying Rear Drive Pinion Front Tapered Roller Bearing Inner Race

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in the drive pinion.

   SST 09608-04031, 09316-60011 (09316-00011, 09316-00041) 

   NOTE: Do not forcefully press in the bearing.

   HINT:

   • Install the spacer and oil seal after performing the ring gear tooth contact pattern inspection adjustment.
   • Make sure the press, SST and drive pinion are in a straight line when pressing
     Fig 13: Installing Differential Drive Pinion

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the drive pinion oil slinger to the differential carrier
   Fig 14: Identifying Rear Differential Drive Pinion Oil Slinger

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the companion flange.

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

   NOTE: Install the companion flange so that there is a slight looseness on the drive pinion because the bearing spacer is not yet installed.

   HINT

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

   Fig 15: Installing Companion Flange

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a torque wrench, tighten a new drive pinion nut so that the drive pinion preload (starting torque) value is within the torque specification

   SST 09229-55010, 09330-00021, 09950-30012 (09955-03040) 

   Maximum torque: 

   490 N*m (4997 kgf*cm, 361 ft.*lbf) 

   Fig 16: Tightening Drive Pinion Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • As the bearing spacer is not installed, tighten the drive pinion nut little by little. Do not overtighten the nut.
   • Do not overtighten the nut, as the threads will become damaged.
   • Perform the installation while supporting the overhaul attachment.

   HINT

   • Tighten the nut with a force of 100 N*m (1020 kgf*cm, 74 ft.*lbf) while checking the starting torque of the drive pinion.
   • Coat the threads of the drive pinion nut and drive pinion with hypoid gear oil LSD.
3. For a more accurate measurement, rotate the bearing forward and backward before the inspection
4. Using SST and a torque wrench, measure the preload.

   SST 09229-55010 

   Standard drive pinion preload (starting torque): 

   New bearing: 

   1.2 to 1.8 N*m (13 to 18 kgf*cm, 11 to 15 in.*lbf) 

   Reused bearing: 

   0.5 to 0.8 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf) 

   NOTE: Record the preload for total preload measurement.
   Fig 17: Measuring Differential Drive Pinion Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Insert the differential case from the ring gear tooth side to install it.
   NOTE: Do not damage the case bearing and ring gear.
   Fig 18: Installing Rear Differential Case Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.

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

   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.

   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 19: Installing Ring Gear Tooth Side Case Bearing Outer Race

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

   SST 09571-50010 

   Fig 20: Identifying SST Bolts And Disc

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten SST bolt until SST disc lightly touches the case bearing outer race.
4. Using SST and a hammer, tap in the ring gear back surface side case bearing outer race.

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

   NOTE:

   • When installing a new bearing, do not wipe off the anti-rust oil.
   • Do not apply hypoid gear oil to a new bearing.

   HINT:

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

   Fig 21: Installing Ring Gear Back Surface Side Case Bearing Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using snap ring pliers, install a side gear shaft snap ring on the back surface of the ring gear.

   If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential side gear shaft snap ring first

   If the differential case bearing, ring gear, or drive pinion are reused, select and install a differential side gear shaft snap ring with the same thickness as the one before the disassembly first

   Fig 22: Installing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a dial indicator to the differential carrier.
3. Tighten SST bolt to alter the differential carrier's shape by approximately 0 1 mm (0.00394 in)

   SST 09571-50010 

   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.

   • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race
   • Tighten SST bolt to apply the preload to the case bearing
     Fig 23: Tightening SST Bolt

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the ring gear clockwise and counterclockwise several times to stabilize the differential case bearing
5. Using a dial indicator, measure the backlash of the ring gear.

   Standard backlash: 

   0.08 to 0.13 mm (0.00315 to 0.00511 in.) 

   HINT.

   • Measure at 3 or more areas around the circumference of the ring gear
   • Record the measured value, as it is used to select the differential side gear shaft snap ring.
   • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring

   If the measured value is not within the specified range, replace the ring gear side differential side gear shaft snap ring with one of a different thickness in the a following steps.

   Fig 24: Measuring Backlash Of Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race.
   Fig 25: Loosening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST and a hammer, tap the ring gear back surface side to create clearance between the differential case bearing outer race and the differential side gear shaft snap ring of the ring gear back surface side

   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 26: Creating Clearance Between Differential Case Bearing Outer Race And Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side
   Fig 27: Removing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using snap ring pliers, install a side gear shaft snap ring with a different thickness than the one removed.

   HINT:

   When the side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash also changes by 0.02 mm (0 000787 in.).

   Fig 28: Installing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard snap ring thickness 

   SNAP RING THICKNESS REFERENCE
   
   

   Thickness	Thickness	Thickness
   3.66 mm (0 1441 in.)	3.92 mm (0.1543 in.)	4.18 mm (0.1646 in.)
   3.68 mm (0.1449 in.)	3.94 mm (0.1551 in.)	4.20 mm (0.1654 in.)
   3.70 mm (0.1457 in.)	3.69 mm (0.1559 in.)	4.22 mm (0.1661 in.)
   3.72 mm (0.1465 in.)	3.98 mm (0.1567 in.)	4.24 mm (0.1669 in.)
   3.74 mm (0.1472 in.)	4.00 mm (0.1575 in.)	4.26 mm (0.1677 in.)
   3.76 mm (0.1480 in.)	4.02 mm (0.1583 in.)	4.28 mm (0.1685 in.)
   3.78 mm (0 1488 in.)	4.04 mm (0.1591 in.)	4.30 mm (0.1693 in.)
   3.80 mm (0.1496 in.)	4.06 mm (0.1598 in.)	4.32 mm (0.1701 in.)
   3.82 mm (0.1503 in.)	4.08 mm (0.1606 in.)	4.34 mm (0.1709 in.)
   3.84 mm (0.1512 in.)	4.10 mm (0.1614 in.)	4.36 mm (0.1717 in.)
   3.86 mm (0.1520 in.)	4.12 mm (0.1622 in.)	4.38 mm (0.1724 in.)
   3 88 mm (0.1528 in.)	4.14 mm (0.1630 in.)	4.40 mm (0.1732 in.)
   3.90 mm (0.1535 in)	4.16 mm (0.1638 in.)	4.42 mm (0.1740 in.)

10. Using a plastic-faced hammer, lightly tap the ring gear tooth side of the differential carrier to stabilizer the differential case bearing.
    Fig 29: Tapping Ring Gear Tooth Side Of Differential Carrier

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install a dial indicator to the differential carrier
12. Tighten SST bolt to alter the differential carrier's shape approximately 0.1 mm (0.00394 in.).

    SST 09571-50010 

    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:

    • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
    • Tighten SST bolt to apply the preload to the case bearing.
      Fig 30: Tightening SST Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.
14. Fix the companion flange in place by hand, and measure the ring gear backlash

    Standard backlash: 

    0.08 to 0.13 mm (0.00315 to 0.00511 in.) 

    Fig 31: Measuring Ring Gear Backlash

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT.

    • Measure at 3 or more areas around the circumference of the ring gear
    • Record the measured value, as it is used to select the differential side gear shaft snap ring
    • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.
    • When adjusting the backlash, adjust to within 0.1 mm (0.00394 in) of the average of the measurements

    If the measured value is not within the specified range, replace the ring gear back surface side differential side gear shaft snap ring with one of a different thickness.

1. Install a dial indicator to the differential carrier.
2. Tighten SST bolt to alter the differential carrier's shape by approximately 0 1 mm (0.00394 in)

   SST 09571-50010 

   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.

   Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

   Fig 32: Tightening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using snap ring pliers, install a side gear shaft snap ring on the ring gear tooth side.

   If the differential case bearing, ring gear, or drive pinion are reused, select and install a differential side gear shaft snap ring with the same thickness as the one before the disassembly.

   Fig 33: Installing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the dial indicator and loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race
   NOTE: Do not remove SST.
   Fig 34: Loosening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a plastic-faced hammer, lightly tap the ring tooth side of the differential carrier to stabilize the differential case bearing
   Fig 35: Tapping Ring Gear Tooth Side Of Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.
7. Fix the companion flange in place by hand, and measure the ring gear backlash.

   Standard backlash: 

   0.08 to 0.13 mm (0.00315 to 0.00511 in.) 

   NOTE: Measure at 3 or more areas around the circumference of the ring gear.

   If the backlash is small even in one place, replace the ring gear tooth side differential side gear shaft snap ring with a thicker one.

   Fig 36: Measuring Ring Gear Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT.

   • Record the measured value, as it is used to select the differential side gear shaft snap ring
   • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion The results will be used as a reference for selecting the differential side gear shaft snap ring.
   • When adjusting the backlash, adjust to within 0 1 mm (0.00394 in.) of the average of the measurements.
8. Remove the 2 bolts and SST from the differential carrier
   Fig 37: Locating SST Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09229-55010 

   Standard total preload: 

   New bearing: 

   1.7 to 3.1 N*m (18 to 31 kgf*cm, 15 to 27 in.*lbf) 

   Reused bearing: 

   1.0 to 2.1 N*m (10 to 21 kgf*cm, 9 to 18 in.*lbf) 

   Fig 38: Measuring Total Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the measured preload is below the standard value, replace the differential side gear shaft snap ring with a thicker one

   If the measured preload is above the standard value, replace the differential side gear shaft snap ring with a thinner one.

   HINT:

   • If the thickness of the differential side gear shaft snap ring changes 0 02 mm (0.000787 in.), the total preload will change approximately 0.1 N*m (1 kgf*cm, 1 in *lbf).
   • For reassembly purposes, record the measured value
2. Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side
3. 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.) 

   NOTE: Measure at 3 or more areas around the circumference of the ring gear.

   If the backlash is not within the specified range, adjust it to the specified range by equally increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings.

   Fig 39: Measuring Differential Ring Gear Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT.

   • When adjusting the backlash, adjust to within 0 1 mm (0.00394 in) of the average of the measurements.
   • When the side gear shaft snap ring thickness changes by 0.02 mm (0.000787 in.), the backlash will also change by approximately 0 02 mm (0 000787 in)
   • Record the measured value, as it is used to select the differential side gear shaft snap ring.
   • Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring
4. Recheck the total preload.

1. Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear
   Fig 40: Applying Coat Of Prussian Blue On Differential Ring Gear Teeth

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Rotate the companion flange several times in the forward and backward rotation directions.
Fig 41: Rotating Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the tooth contact pattern.
   Fig 42: Identifying Tooth Contact Pattern

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT

   The patterns indicated by the Prussian blue are the tooth contact locations.

   NOTE: Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.
4. If the teeth are not contacting properly, use the following table to select a proper drive pinion washer for correction

   Remove the rear drive pinion front tapered roller bearing outer race, following the procedures listed below and then replace the rear differential drive pinion washer with a proper one.

   NOTE: Make sure to always replace the drive pinion washer with a new one.
   Fig 43: Identifying Drive Pinion Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard washer thickness 

   WASHER THICKNESS REFERENCE
   
   

   Thickness mm (in.)	No.	Thickness mm (in.)	No.	Thickness mm (in.)	No.
   1.865 to 1.875 (0.0734 to 0.0738)	87	2.005 to 2.015 (0.0789 to 0.0793)	01	2.145 to 2.155 (0.0844 to 0.0848)	15
   1.875 to 1.885 (0.0738 to 0.0742)	88	2.015 to 2.025 (0.0793 to 0.0797)	02	2.155 to 2.165 (0.0848 to 0.0852)	16
   1.885 to 1.895 (0.0742 to 0.0746)	89	2.025 to 2.035 (0.0797 to 0.0801)	03	2.165 to 2.175 (0.0852 to 0.0856)	17
   1.895 to 1.905 (0.0746 to 0.0750)	90	2.035 to 2.045 (0.0801 to 0.0805)	04	2.175 to 2.185 (0.0856 to 0.0860)	18
   1.905 to 1.915 (0.0750 to 0.0754)	91	2.045 to 2.055 (0.0805 to 0.0809)	05	2.185 to 2.195 (0.0860 to 0.0864)	19
   1.915 to 1925 (0.0754 to 0.0758)	92	2.055 to 2.065 (0.0809 to 0.0813)	06	2.195 to 2.205 (0.0864 to 0.0868)	20
   1.925 to 1.935 (0.0758 to 0.0762)	93	2.065 to 2.075 (0.0813 to 0.0817)	07	2.205 to 2.215 (0.0868 to 0.0872)	21
   1.935 to 1.945 (0.0762 to 0.0766)	94	2.075 to 2.085 (0.0817 to 0.0821)	08	2.215 to 2.225 (0.0872 to 0.0876)	22
   1.945 to 1.955 (0.0766 to 0.0770)	95	2.085 to 2.095 (0.0821 to 0.0825)	09	2.225 to 2.235 (0.0876 to 0.0880)	23
   1.955 to 1.965 (0.0770 to 0.0774)	96	2.095 to 2.105 (0.0825 to 0.0829)	10	2.235 to 2.245 (0 0880 to 0.0884)	24
   1.965 to 1.975 (0.0774 to 0.0778)	97	2.105 to 2.115 (0.0829 to 0.0833)	11	2.245 to 2.255 (0.0884 to 0.0888)	25
   1.975 to 1.985 (0.0778 to 0.0781)	98	2.115 to 2.125 (0.0833 to 0.0837)	12	2.255 to 2.265 (0.0888 to 0.0892)	26
   1.985 to 1.995 (0.0781 to 0.0785)	99	2.125 to 2.135 (0.0837 to 0.0841)	13	2.265 to 2.275 (0.0892 to 0.0896)	27
   1.995 to 2.005 (0 0785 to 0.0789)	00	2.135 to 2.145 (0.0841 to 0.0844)	14	2.275 to 2.285 (0.0896 to 0.0900)	28

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 44: 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.).
   Fig 45: Tightening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT

   • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race
   • The approximate 0.1 mm (0.00394 in.) clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.
5. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

   HINT:

   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 46: 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.
   NOTE: Do not remove SST.
   Fig 47: 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 48: 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:

   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 49: Removing Side Gear Shaft Snap Ring

   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 50: Pushing Out Case Bearing Outer Race On Ring Gear Back Surface Side

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and SST from the differential carrier.
   Fig 51: Locating SST Bolts

   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.
   • 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 52: Removing Ring Gear Tooth Side Case Bearing Outer Race

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Pull out the differential case from the back surface side of the ring gear, and remove it from the differential carrier.
   NOTE: Do not damage the case bearing and ring gear.
   Fig 53: Removing Rear Differential Case Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, fix the companion flange in place.

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

2. Using SST, remove the drive pinion nut from the differential carrier.

   SST 09229-55010 

   HINT:

   Perform the removal while supporting the overhaul attachment

   Fig 54: Removing Drive Pinion Nut From Differential Carrier

   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 55: Removing Rear Drive Pinion Companion Flange Rear Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the differential drive pinion oil slinger from the differential drive pinion
   Fig 56: 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 57: Removing Differential Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the rear drive pinion front tapered roller bearing from the differential carrier.
   Fig 58: Identifying Rear Drive Pinion Front Tapered Roller Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new drive pinion bearing spacer to the drive pinion.

   HINT.

   The bearing spacer can be installed facing either direction.

   Fig 59: Identifying Rear Differential Drive Pinion Bearing Spacer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rear drive pinion front tapered roller bearing inner race to the differential carrier.
   Fig 60: Identifying Rear Drive Pinion Front Tapered Roller Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in the differential drive pinion to the differential carrier.

   SST 09316-60011 (09316-00011,09316-00041), 09608-04031 

   Fig 61: Installing Differential Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the differential drive pinion oil slinger to the differential drive pinion.
   Fig 62: Identifying Rear Differential Drive Pinion Oil Slinger

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in a new oil seal

   SST 09316-60011 (09316-00011), 09710-04101 

   NOTE:

   • Tap the oil seal uniformly so that the oil seal is straight.
   • Do not excessively tap the oil seal.
   Fig 63: Installing Rear Differential Carrier Oil Seal
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the depth of the oil seal.

   Standard depth: 

   -0.5 to 0.5 mm (-0.0197 to 0.0196 in.) 

   NOTE:

   • Measure at 3 or more areas around the circumference of the oil seal.
   • Make sure the difference between the maximum and minimum measured values is less than 0.65 mm (0.0256 in.), as a greater difference may lead to oil leaks.
3. Apply MP grease to the lip of the oil seal.

1. Using SST, install the companion flange to the differential carrier.

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

   NOTE: Perform this procedure after aligning the companion flange with the spline of the drive pinion.

   HINT

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

   Fig 64: Installing Companion Flange To Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the threads of a new drive pinion nut with hypoid gear oil LSD.
3. Use SST to hold the companion flange

   SST 09950-30012 (09955-03040) 

4. Using SST and a torque wrench, tighten the drive pinion nut while checking the starting torque of the drive pinion.

   SST 09229-55010,09330-00021 

   Maximum torque: 490 N*m (4997 kgf*cm, 361 ft.*lbf) 

   Fig 65: Tightening Drive Pinion Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Do not overtighten the nut, as the threads will become damaged.
   • Perform the tightening while supporting the overhaul attachment.

   HINT:

   • Tighten the nut with a force of 100 N*m (1020 kgf*cm, 74 ft.*lbf) and keep tightening while checking the starting torque of the drive pinion.
   • Apply hypoid gear oil LSD to the threads of the nut and drive pinion.

1. Insert the differential case from the ring gear tooth side.
   NOTE: Do not damage the case bearing inner race and ring gear.
   Fig 66: Installing Rear Differential Case Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.

   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 67: Tapping Ring Gear Tooth Side Case Bearing Outer Race

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

   SST 09571-50010 

3. Tighten SST bolt until SST disc lightly touches the case bearing outer race
   Fig 68: Identifying SST Bolts And Disc

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

   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 69: Tapping Ring Gear Back Surface Side Case Bearing Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
   NOTE: Check that the differential side gear shaft snap ring is securely fitted into the groove.

   HINT:

   Use the side gear shaft snap ring that was used during the tooth contact adjustment.

   Fig 70: Installing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a dial indicator on the differential carrier.
3. Tighten SST bolt, and push in the differential case.

   HINT.

   • Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race
   • Approximate 0.1 mm (0.00394 in.) clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.
     Fig 71: Tightening SST Bolt

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.).
4. Remove the dial indicator and using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.

   HINT

   Use the side gear shaft snap ring that was used during the tooth contact adjustment.

   Fig 72: Installing Side Gear Shaft Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race
   Fig 73: Loosening SST Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tap the differential carrier on the ring gear tooth side using a plastic-faced hammer to stabilize the case bearing.
   Fig 74: Tapping Ring Gear Tooth Side Of Differential Carrier

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 2 bolts and SST from the differential carrier.
   Fig 75: Locating SST Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a torque wrench, measure the preload.

   SST 09229-55010 

   Standard drive pinion preload (starting torque): 

   New bearing: 

   1.2 to 1.8 N*m (13 to 18 kgf*cm, 11 to 15 in.*lbf) 

   Reused bearing: 

   0.5 to 0.8 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf) 

   Fig 76: Measuring Drive Pinion Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT.

   • For a more accurate measurement, rotate the flange forward and backward several times before the measurement.
   • Check the starting torque of the drive pinion for use with the total preload inspection
   NOTE:

   • The bearing spacer is made of plastic and changes shape when used. If the starting torque of the drive pinion is exceeded by mistake, make sure to replace the bearing spacer with a new one.
2. If the starting torque of the drive pinion is exceeded, replace the bearing spacer
3. If the starting torque of the drive pinion is insufficient, tighten the drive pinion nut 5 to 10° at a time

   Maximum torque: 

   490 N*m (4997 kgf*cm, 361 ft.*lbf) 

   Repeat the adjustment as necessary until the starting torque matches the specified torque.

4. If the tightening torque of the pinion nut exceeds the specified torque but the drive pinion starting torque is still insufficient, loosen the pinion nut. Then check if the pinion nut and drive pinion threads are damaged
5. If there are no problems, replace the bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

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

   SST 09229-55010 

   Standard total preload: 

   New bearing: 

   1.7 to 3.1 N*m (18 to 31 kgf*cm, 15 to 27 in.*lbf) 

   Reused bearing: 

   1.0 to 2.1 N*m (10 to 21 kgf*cm, 9 to 18 in.*lbf) 

   Fig 77: Measuring Drive Pinion Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. 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 at 3 or more areas around the circumference of the ring gear.

   Fig 78: Measuring Differential Ring 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.) 

   Fig 79: Measuring Runout Of Drive Pinion Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09930-00010 

   Fig 80: Staking Drive Pinion Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, install 2 new oil seals.

   SST 09223-15030, 09950-70010 (09951 -07150) 

   Standard depth: 

   -0.5 to 0.5 mm (-0.0197 to 0.0196 in.) 

   NOTE:

   • Tap the oil seal uniformly so that the oil seal is straight.
   • After the installation, check that the oil seal has been tapped securely onto the differential.
     Fig 81: Installing Rear Differential Side Gear Shaft Oil Seals

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the lips of the oil seal.

HINT:

Perform this procedure as necessary.

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

   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

HINT:

Perform this procedure as necessary.

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

   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

1. Remove the differential carrier from the overhaul stand.
Fig 82: Identifying Differential Carrier On Overhaul Stand
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then wipe off the oil with a non-residue solvent or equivalent.
   NOTE: Do not scratch the fitting surface.
2. Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   Fig 83: Locating Rear Differential Breather Plug Oil Deflector Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing to the differential carrier as shown in the illustration.

   Seal packing: 

   Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent 

   NOTE:

   • Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
   • Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.
     Fig 84: Identifying Seal Packing On Differential Carrier

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Install the differential carrier cover within 3 minutes of application.
2. Install the differential carrier cover with the 8 bolts

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

   NOTE: Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.
   Fig 85: Locating Differential Carrier Cover Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the breather plug to the differential carrier cover.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   Fig 86: Locating Rear Differential Carrier Cover Breather Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002