Rear Differential Carrier Assembly: Disassembly

SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY

Fig 1: Locating Rear Differential Dynamic Damper Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL FILLER PLUG
1. Using a hexagon wrench (17 mm), remove the rear differential filler plug (inspection plug) and gasket.
  
  Fig 2: Locating Rear Differential Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE STUD BOLT

Install 2 service nuts to the stud bolt.

Recommended service nut

RECOMMENDED SERVICE NUT

Thread diameter	8 mm (0.3150 in.)
Thread pitch	1.25 mm (0.0492 in.)

Lock the upper nut using the lower nut.
Turn the lower nut and remove the other 3 stud bolts in the same way.

Fig 3: Turning Lower Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT RUNOUT OF ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY
1. Install a dial indicator perpendicular to the inner side of the electro magnetic control coupling sub-assembly, as shown in the illustration.
2. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward and measure the vertical runout.
  SST 09564-32011
  
  Maximum runout:
  
  0.04 mm (0.00157 in.)
  
  If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.
  
  Fig 4: Measuring Electro Magnetic Control Coupling Vertical And Lateral Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a dial indicator perpendicular to the electro magnetic control coupling sub-assembly, as shown in the illustration.
4. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward and measure the lateral runout.
  SST 09564-32011
  
  Maximum runout:
  
  0.06 mm (0.00236 in.)
  
  If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.
REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY
1. Remove the 4 bolts. Using a plastic-faced hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier.
  
  Fig 5: Locating Electro Magnetic Control Coupling Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER
1. Remove the transmission coupling conical spring washer from the differential carrier.
  
  Fig 6: Identifying Transmission Coupling Conical Spring Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION COUPLING SPACER
1. Remove the transmission coupling spacer from the differential carrier.
  
  Fig 7: Identifying Transmission Coupling Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
1. Using a screwdriver, remove the rear differential dust deflector.
  NOTE:
  - Tape the screwdriver tip before use.
  - Pry the circumference of the rear differential dust deflector uniformly to prevent deformation.
    
    Fig 8: Removing Rear Differential Dust Deflector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. Insert a dial indicator through the rear differential carrier cover plug hole, and set it perpendicular to a ring gear tooth tip.
2. Using SST, hold the drive pinion in place.
  SST 09556-16011
3. Using SST, rotate the rear differential case forward and backward, and measure the backlash.
  SST 09564-32011
  
  Backlash:
  
  0.10 to 0.15 mm (0.00394 to 0.00591 in.)
  
  NOTE: Measure at 3 or more areas on the circumference of the ring gear.
  
  If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
  
  Fig 9: Measuring Differential Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
1. Using SST and a torque wrench, inspect the preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.
  SST 09556-16011
  
  Standard drive pinion preload:
  
  0.4 to 0.7 N*m (4 to 7 kgf*cm, 3.0 to 6.0 in.*lbf)
  
  NOTE: For a more accurate measurement, rotate the case bearing forward and backward before measuring.
  
  Fig 10: Measuring Differential Drive Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the preload is not within the specified range, adjust the total preload or repair as necessary.
INSPECT TOTAL PRELOAD
1. Using SST and a torque wrench, inspect the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.
  SST 09556-16011
  
  Standard total preload:
  
  Standard drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)
  
  Fig 11: Measuring Differential Drive Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: For a more accurate measurement, rotate the case bearing forward and backward before measuring.
  
  If the preload is not within the specified range, adjust the total preload or repair as necessary.
REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Using SST, tap out the 2 rear differential side gear shaft oil seals from the rear differential carrier.
  SST 09308-00010
  
  Fig 12: Removing Rear Differential Side Gear Shaft Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION NUT
1. Using SST and a hammer, unstake the rear drive pinion nut.
  SST 09930-00010
  NOTE:
  - Use SST with the tapered part facing against the shaft.
  - Do not modify the SST tip with a grinder or equivalent.
  - Fully unstake the rear drive pinion nut.
    
    Fig 13: Unstaking Rear Drive Pinion Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, hold the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.
  SST 09556-16011, 09564-16020
  
  Fig 14: Removing Rear Drive Pinion Nut From Differential Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL DIAPHRAGM SEAL
1. Using SST, remove the oil diaphragm seal from the rear differential carrier.
  SST 09308-10010
  
  Fig 15: Removing Oil Diaphragm Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the drive pinion.
  SST 09556-30010
  
  Fig 16: Removing Rear Drive Pinion Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL PRESSURE CONTROL HOSE
1. Remove the 2 differential pressure control hose clips and rear differential pressure control hose.
  
  Fig 17: Identifying Differential Pressure Control Hose Clips And Rear Differential Pressure Control Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL PRESSURE CONTROL HOSE ELBOW
1. Put matchmarks on the differential pressure control hose elbows and rear differential carrier.
2. Using a screwdriver, remove the 2 differential pressure control hose elbows.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 18: Identifying Matchmarks On Differential Pressure Control Hose Elbows And Rear Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING RETAINER
1. Remove the 10 bolts from the differential carrier.
  
  Fig 19: Locating Rear Differential Carrier Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, lightly tap out the differential side bearing retainer from the differential carrier.
  NOTE: Set the brass bar on the ribbed part of the differential side bearing retainer.
  
  Fig 20: Removing Side Bearing Retainer From Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG
1. Using a screwdriver, remove the rear differential carrier cover breather plug from the side bearing retainer.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 21: Removing Rear Differential Carrier Cover Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Remove the 2 bolts and rear differential breather plug oil deflector.
  
  Fig 22: Locating Rear Differential Breather Plug Oil Deflector And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
1. Remove the rear differential case from the rear differential carrier.
  
  Fig 23: Removing/Installing Rear Differential Case Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL DRIVE PINION
1. Remove the differential drive pinion from the rear differential carrier.
  
  Fig 24: Removing/Installing Differential Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Remove the rear differential drive pinion oil slinger from the differential drive pinion.
  
  Fig 25: Removing/Installing Rear Differential Drive Pinion Oil Slinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Remove the rear differential drive pinion bearing spacer from the differential drive pinion.
  
  Fig 26: Removing/Installing Rear Differential Drive Pinion Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using SST and a press, press out the rear drive pinion rear tapered roller bearing (inner race) from the differential drive pinion.
  SST 09950-00020
  
  NOTE: If the rear differential drive pinion or differential ring gear is damaged, replace them both.
2. Remove the rear differential drive pinion plate washer.
  
  Fig 27: Pressing Out Rear Drive Pinion Rear Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier.
  SST 09612-65014 (09612-01020, 09612-01050)
  
  Fig 28: Removing Rear Drive Pinion Front Tapered Roller Bearing (Outer Race) From Rear Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using a brass bar and a hammer, lightly and uniformly tap out the rear drive pinion rear tapered roller bearing (outer race) from the differential carrier.
  NOTE: Set the brass bar on the notch.
  
  Fig 29: Removing Rear Drive Pinion Rear Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE BEARING
1. Using SST and a press, press out the rear differential case bearing RH (outer race) and rear differential side gear shaft plate washer from the rear differential carrier.
  SST 09950-60010 (09951-00580), 09950-70010 (09951-07100)
  
  Fig 30: Removing Rear Differential Case Bearing (RH Side Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE BEARING
1. Using SST and a press, press out the rear differential case bearing LH (outer race) and rear differential side gear shaft plate washer from the differential side bearing retainer.
  SST 09950-60010 (09951-00580), 09950-70010 (09951-07100), 09223-15020
REMOVE STRAIGHT PIN
1. Remove the 4 straight pins from the differential carrier.
  
  Fig 31: Removing Rear Differential Case Bearing (LH Side Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 32: Locating Differential Carrier Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE BEARING
1. Using SST, remove the rear differential case bearing RH (inner race) from the rear differential case.
  SST 09950-40011 (09951-04020,09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011), 09950-60010 (09951-00370)
  
  NOTE: Before using the SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.
  
  HINT:
  
  If the race remains on the rear differential case, repeat the step above to remove the race.
  
  Fig 33: Removing Rear Differential Case Bearing RH (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE BEARING
1. Using SST, remove the rear differential case bearing LH (inner race) from the rear differential case.
  SST 09950-40011 (09951-04020,09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00370)
  
  NOTE: Before using the SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.
  
  HINT:
  
  If the race remains on the rear differential case, repeat the step above to remove the race.
  
  Fig 34: Removing Rear Differential Case Bearing LH (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL RING GEAR
1. Place matchmarks on the rear differential case and differential ring gear.
2. Remove the 10 ring gear set bolts.
3. Using a plastic-faced hammer, lightly tap the outer circumference of the differential ring gear to remove it from the rear differential case.
  
  Fig 35: Locating Ring Gear Set Bolts And Matchmark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
1. Using a pin punch and a hammer, remove the rear differential pinion shaft pin.
  
  Fig 36: Removing Rear Differential Pinion Shaft Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL PINION AND SIDE GEAR
1. Remove the following components from the rear differential case:
  1. Differential pinion gear (A)
  2. Rear differential pinion thrust washer (B)
  3. Rear differential pinion shaft (C)
  4. Differential side gear (D)
  5. Rear No. 1 differential side gear thrust washer (E)
    
    Fig 37: Identifying Rear Differential Case Components
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL PINION AND SIDE GEAR
1. Check the differential pinion gears and differential side gears for wear.
INSPECT REAR DIFFERENTIAL CASE SUB-ASSEMBLY
1. Check the differential case for cracks or damage.