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Rear Differential Carrier Assembly: Reassembly

  1. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Install the 2 rear No. 1 differential side gear thrust washers to the 2 differential side gears.
      NOTE:
      • Make sure that there is no foreign matter on or cracks and chips in the thrust washers, side gears and pinion gears, before installation.
      • When replacing a side gear or pinion gears, replace both sides as one set.
      • Apply sufficient hypoid gear oil to any sliding or rotating parts.
    2. Install the 2 differential side gears, 2 differential pinion gears, 2 rear differential pinion thrust washers and rear differential pinion shaft in the differential case.

      HINT:

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

    3. Measure the differential side gear backlash while holding a differential pinion gear toward the differential case.

      Backlash: 

      0.05 to 0.20 mm (0.00197 to 0.00787 in.) 

      If the backlash is not within the specification, install the 2 rear No. 1 differential side gear thrust washers with different thicknesses.

      HINT:

      Refer to the table below and select 2 rear No. 1 differential side gear thrust washers which ensure that the backlash is within the specification.

      Fig 1: Measuring Differential Side Gear Backlash
      G05241309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Rear No. 1 Differential Side Gear Thrust Washer 

      THRUST WASHER SPECIFICATIONS

      Thickness mm (in.) Thickness mm (in.)
      1.48 to 1.52 (0.0583 to 0.0598) 1.63 to 1.67 (0.0642 to 0.0657)
      1.53 to 1.57 (0.0602 to 0.0618) 1.68 to 1.72 (0.0661 to 0.0677)
      1.58 to 1.62 (0.0622 to 0.0638) 1.73 to 1.77 (0.0681 to 0.0697)
    4. Using a pin punch and a hammer, install the rear differential pinion shaft pin through the differential case and hole of the pinion shaft.
    5. Using a chisel and a hammer, stake the outside of the differential case pin hole.
      Fig 2: Installing Rear Differential Pinion Shaft Pin
      G06025592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL DIFFERENTIAL RING GEAR 
    1. Clean the contact surfaces of the differential case and ring gear.
    2. Heat the ring gear in boiling water.
    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.
      Fig 3: Heating Ring Gear In Boiling Water
      G06034414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Align the matchmarks on the rear differential case and differential ring gear, and install the differential ring gear.
    6. Temporarily install 10 new bolts.
    7. After the ring gear cools down sufficiently, tighten the 10 bolts uniformly at a time.

      Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

      NOTE:
      • The new bolts are coated with heat resistant oil. Do not wash it off.
      • Install the rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.
      • Tighten the rear differential case bolts after the differential ring gear has cooled down sufficiently.
        Fig 4: Identifying Rear Differential Case And Differential Ring Gear Matchmarks
        G06034415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL REAR DIFFERENTIAL CASE BEARING 
    1. Using SST and a press, press-fit the rear differential case bearing RH (inner race) to the rear differential case.

      SST 09223-46011 

      NOTE: If the rear differential case bearing inner race is damaged, replace it with a new one.
      Fig 5: Installing Rear Differential Case Bearing (RH Inner Race)
      G06025595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL REAR DIFFERENTIAL CASE BEARING 
    1. Using SST and a press, press-fit the rear differential case bearing LH (inner race) to the rear differential case.

      SST 09223-46011 

      NOTE: If the rear differential case bearing inner race is damaged, replace it with a new one.
      Fig 6: Installing Rear Differential Case Bearing (LH Inner Race)
      G06025596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, install the 4 straight pins to the differential carrier.
      Fig 7: Locating Differential Carrier Straight Pins
      G06025597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      (A): 

      8 to 9 mm (0.315 to 0.354 in.) 

    2. Thoroughly remove oil and water from the surface of the rear differential case that will face the differential ring gear.
  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Rear side:

      Using SST, bolts, nuts and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier.

      SST 09950-60010 (09951-00540, 09951-00620), 09950-60020 (09951-00680) 

      HINT:

      Use M12 x P1.25 bolts with shaft lengths of 186 mm (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for installation.

      Fig 8: Installing Rear Drive Pinion Rear Tapered Roller Bearing (Outer Race)
      G06034419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Front side:

      Using SST, bolts, nuts and washers, install the rear drive pinion front tapered roller bearing (outer race) to the rear differential carrier.

      SST 09950-60010 (09951-00490, 09951-00540, 09951-00620), 09950-60020 (09951-00680) 

      HINT:

      Use M12 x P1.25 bolts with shaft lengths of 186 mm (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for installation.

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Install the rear differential drive pinion plate washer to the differential drive pinion.
      NOTE: Install each rear differential drive pinion washer to the position it was removed from.
      Fig 9: Installing Rear Drive Pinion Front Tapered Roller Bearing (Outer Race)
      G06034420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press-fit the rear drive pinion rear tapered roller bearing (inner race) to the differential drive pinion.

      SST 09316-60011 (09316-00071) 

      Fig 10: Installing Rear Drive Pinion Rear Tapered Roller Bearing
      G06025600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR DIFFERENTIAL CASE BEARING 
    1. Using SST and a press, press-fit the rear differential side gear shaft washer plate and rear differential case bearing RH (outer race) to the rear differential carrier.

      SST 09950-60010 (09951-00580, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100) 

      Fig 11: Installing Rear Differential Case Bearing RH (Outer Race)
      G06034422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install each rear differential side gear shaft washer plate to the position it was removed from.
      • When replacing a bearing, replace the inner and outer races as a set.
      • Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.
  10. INSTALL REAR DIFFERENTIAL CASE BEARING 
    1. Using SST and a press, press-fit the rear differential side gear shaft washer plate and rear differential case bearing LH (outer race) to the differential side bearing retainer.

      SST 09950-60010 (09951-00580, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100) 

      NOTE:
      • Install each rear differential side gear shaft washer to the position it was removed from.
      • When replacing a bearing, replace the outer race and the inner race together.
      • Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.
        Fig 12: Installing Rear Differential Case Bearing LH (Outer Race)
        G06034423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Install the differential drive pinion (with rear drive pinion rear tapered roller bearing (inner race)) to the rear differential carrier.
    2. Install the rear drive pinion front tapered roller bearing (inner race) and a new rear drive pinion nut to the differential drive pinion.
      NOTE:
      • New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.
      • If reusing a bearing, coat it with hypoid gear oil API GL-5.
    3. Using SST, gradually tighten the rear drive pinion nut until the specified preload is reached. Do not exceed the torque limit shown below.

      SST 09564-16020 

      Torque: without SST 

      245 N*m (2500 kgf*cm, 181 ft.*lbf) or less 

      with SST 

      223 N*m (2273 kgf*cm, 164 ft.*lbf) or less 

      Fig 13: Tightening Rear Drive Pinion Nut
      G06034424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Tighten the rear drive pinion nut gradually. Never tighten it excessively.

      HINT:

      Use a torque wrench with a fulcrum length of 500 mm (19.685 in.).

    4. Using SST and a torque wrench, measure the preload (starting torque) of the differential drive pinion.

      SST 09556-16011 

      Standard Drive Pinion Preload (Starting Torque) 

      DRIVE PINION PRELOAD SPECIFICATIONS

      New bearing 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
      Reused bearing 0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)
      Fig 14: Measuring Differential Drive Pinion Preload
      G06025604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • For a more accurate measurement, rotate the bearing forward and backward before inspecting.
      • Record the preload measurement for use with the total preload measurement.
  12. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Install the rear differential case to the rear differential carrier.
    2. Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.
      NOTE: Do not scratch the installation surface.
    3. Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 

      Fig 15: Removing/Installing Rear Differential Case Sub-Assembly
      G06025576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 surface's 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.
    4. If the result is not within the specified range, select washers that are thicker or thinner as necessary. Adjust the thickness of the left and right washers in equal increments. Then install the rear differential case bearing outer race.
      Fig 16: Measuring Differential Ring Gear Backlash
      G06034383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • When the backlash is smaller than the specified value, select a thick washer for the RH side and thin washer for the LH side.
      • When the backlash is larger than the specified value, select a thin washer for the RH side and thick washer for the LH side.

        Rear Differential Side Gear Shaft Washer Plate 

        REAR DIFFERENTIAL SIDE GEAR SHAFT WASHER PLATE SPECIFICATIONS

        Mark Thickness mm (in.) Mark Thickness mm (in.)
        25 1.59 to 1.61 (0.0626 to 0.0634) 43 2.13 to 2.15 (0.0839 to 0.0846)
        26 1.62 to 1.64 (0.0638 to 0.0646) 44 2.16 to 2.18 (0.0850 to 0.0858)
        27 1.65 to 1.67 (0.0650 to 0.0657) 45 2.19 to 2.21 (0.0862 to 0.0870)
        28 1.68 to 1.70 (0.0661 to 0.0669) 46 2.22 to 2.24 (0.0874 to 0.0882)
        29 1.71 to 1.73 (0.0673 to 0.0681) 47 2.25 to 2.27 (0.0886 to 0.0894)
        30 1.74 to 1.76 (0.0685 to 0.0693) 48 2.28 to 2.30 (0.0898 to 0.0906)
        31 1.77 to 1.79 (0.0697 to 0.0705) 49 2.31 to 2.33 (0.0909 to 0.0917)
        32 1.80 to 1.82 (0.0709 to 0.0717) 50 2.34 to 2.36 (0.0921 to 0.0929)
        33 1.83 to 1.85 (0.0720 to 0.0728) 51 2.37 to 2.39 (0.0933 to 0.0941)
        34 1.86 to 1.88 (0.0732 to 0.0740) 52 2.40 to 2.42 (0.0945 to 0.0953)
        35 1.89 to 1.91 (0.0744 to 0.0752) 53 2.43 to 2.45 (0.0957 to 0.0965)
        36 1.92 to 1.94 (0.0756 to 0.0764) 54 2.46 to 2.48 (0.0969 to 0.0976)
        37 1.95 to 1.97 (0.0768 to 0.0776) 55 2.49 to 2.51 (0.0980 to 0.0988)
        38 1.98 to 2.00 (0.0780 to 0.0787) 56 2.52 to 2.54 (0.0992 to 0.1000)
        39 2.01 to 2.03 (0.0791 to 0.0799) 57 2.55 to 2.57 (0.1004 to 0.1012)
        40 2.04 to 2.06 (0.0803 to 0.0811) 58 2.58 to 2.60 (0.1016 to 0.1024)
        41 2.07 to 2.09 (0.0815 to 0.0823) 59 2.61 to 2.63 (0.1028 to 0.1035)
        42 2.10 to 2.12 (0.0827 to 0.0835) 60 2.64 to 2.66 (0.1039 to 0.1047)
  14. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Remove the 10 bolts and the differential side bearing retainer.
    2. Remove the differential case from the differential carrier.
    3. Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.
    4. Install the differential case to the differential carrier.
    5. Install the differential side bearing retainer with the 10 bolts.

      Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 

    6. Turn the differential drive pinion several times.
    7. Remove the 10 bolts and the differential side bearing retainer.
    8. Inspect the tooth pattern.
      NOTE: Check the tooth contact pattern at 2 or more positions on the circumference of the differential ring gear.
      Fig 17: Identifying Ring Gear Tooth Contact Pattern
      G06025607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Perform the following procedure for face or flank contact:
      1. If the result is not within the specified range, select washers that are thicker or thinner as necessary. Adjust the thickness of the left and right washers in equal increments. Then install the rear differential case bearing outer race.
      2. Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.

        HINT:

        If the tooth contact pattern is not correct, repeat* 1.

      3. Repeat the differential ring gear and differential drive pinion backlash inspection.

        HINT:

        If the differential ring gear and differential drive pinion backlash are not as specified, replace the differential ring gear and differential drive pinion with new ones.

    10. Perform the following procedure for heel or toe contact:
      1. Select a drive pinion washer again and install the rear drive pinion rear tapered roller bearing.
        Fig 18: Identifying Plate Washer
        G06034429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Rear Differential Drive Pinion Plate Washer 

        REAR DIFFERENTIAL DRIVE PINION PLATE WASHER SPECIFICATIONS

        Mark Thickness mm (in.) Mark Thickness mm (in.)
        41 1.695 to 1.705 (0.0667 to 0.0671) 71 1.955 to 1.965 (0.0770 to 0.0774)
        42 1.705 to 1.715 (0.0671 to 0.0675) 72 1.965 to 1.975 (0.0774 to 0.0778)
        43 1.715 to 1.725 (0.0675 to 0.0679) 73 1.975 to 1.985 (0.0778 to 0.0781)
        44 1.725 to 1.735 (0.0679 to 0.0683) 74 1.985 to 1.995 (0.0781 to 0.0785)
        45 1.735 to 1.745 (0.0683 to 0.0687) 75 1.995 to 2.005 (0.0785 to 0.0789)
        46 1.745 to 1.755 (0.0687 to 0.0691) 76 2.005 to 2.015 (0.0789 to 0.0793)
        47 1.755 to 1.765 (0.0691 to 0.0695) 77 2.015 to 2.025 (0.0793 to 0.0797)
        48 1.765 to 1.775 (0.0695 to 0.0699) 78 2.025 to 2.035 (0.0797 to 0.0801)
        49 1.775 to 1.785 (0.0699 to 0.0703) 79 2.035 to 2.045 (0.0801 to 0.0805)
        50 1.785 to 1.795 (0.0703 to 0.0707) 80 2.045 to 2.055 (0.0805 to 0.0809)
        51 1.795 to 1.805 (0.0707 to 0.0711) 81 2.055 to 2.065 (0.0809 to 0.0813)
        52 1.805 to 1.815 (0.0711 to 0.0715) 82 2.065 to 2.075 (0.0813 to 0.0817)
        53 1.815 to 1.825 (0.0715 to 0.0719) 83 2.075 to 2.085 (0.0817 to 0.0821)
        54 1.825 to 1.835 (0.0719 to 0.0722) 84 2.085 to 2.095 (0.0821 to 0.0825)
        55 1.835 to 1.845 (0.0722 to 0.0726) 85 2.095 to 2.105 (0.0825 to 0.0829)
        56 1.845 to 1.855 (0.0726 to 0.0730) 86 2.105 to 2.115 (0.0829 to 0.0833)
        57 1.855 to 1.865 (0.0730 to 0.0734) 87 2.115 to 2.125 (0.0833 to 0.0837)
        58 1.865 to 1.875 (0.0734 to 0.0738) 88 2.125 to 2.135 (0.0837 to 0.0841)
        59 1.875 to 1.885 (0.0738 to 0.0742) 89 2.135 to 2.145 (0.0841 to 0.0844)
        60 1.885 to 1.895 (0.0742 to 0.0746) 90 2.145 to 2.155 (0.0844 to 0.0848)
        61 1.895 to 1.905 (0.0746 to 0.0750) 91 2.155 to 2.165 (0.0848 to 0.0852)
        62 1.905 to 1.915 (0.0750 to 0.0754) 92 2.165 to 2.175 (0.0852 to 0.0856)
        63 1.915 to 1.925 (0.0754 to 0.0758) 93 2.175 to 2.185 (0.0856 to 0.0860)
        64 1.925 to 1.935 (0.0758 to 0.0762) 94 2.185 to 2.195 (0.0860 to 0.0864)
        65 1.935 to 1.945 (0.0762 to 0.0766) 95 2.195 to 2.205 (0.0864 to 0.0868)
        70 1.945 to 1.955 (0.0766 to 0.0770) - -
  15. MEASURE TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

      SST 09556-16011 

      Standard total preload (New bearing): 

      Standard drive pinion preload plus 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf) 

      Standard total preload (Reused bearing): 

      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 19: Measuring Drive Pinion Total Preload
      G06025609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      For a more accurate measurement, rotate the case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:
      1. Select a thicker or thinner side gear shaft washer for the RH side, and then install the rear differential case bearing outer race (RH side only).
      2. Repeat the total preload measurement.
      3. Repeat the ring gear backlash inspection.
      4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.
  16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Remove the rear differential case from the rear differential carrier.
  17. REMOVE DIFFERENTIAL DRIVE PINION 
    1. Remove the rear differential drive pinion from the rear differential carrier.
  18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER 
    1. Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
      NOTE: Face the smaller inside diameter towards the front of the vehicle.
      Fig 20: Removing/Installing Rear Differential Drive Pinion Bearing Spacer
      G06025579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Install the rear differential drive pinion oil slinger to the differential drive pinion.
      Fig 21: Removing/Installing Rear Differential Drive Pinion Oil Slinger
      G06025578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL DIFFERENTIAL DRIVE PINION 
    1. Install the drive pinion and rear drive pinion front tapered roller bearing (inner race) to the differential carrier.
  21. INSTALL REAR DRIVE PINION NUT 
    1. Apply hypoid gear oil to the threads of the rear drive pinion nut.
      Fig 22: Removing/Installing Differential Drive Pinion
      G06025577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new rear drive pinion nut to the differential drive pinion. Using SST, tighten the nut while confirming the preload.

      SST 09564-16020 

      Torque: without SST 

      245 N*m (2500 kgf*cm, 181 ft.*lbf) or less 

      with SST 

      223 N*m (2273 kgf*cm, 164 ft.*lbf) or less 

      Fig 23: Installing Rear Drive Pinion Nut To Differential Drive Pinion
      G06034434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a torque wrench with a fulcrum length of 500 mm (19.685 in.).

  22. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD 
    1. Using SST and a torque wrench, inspect the preload (starting torque).

      SST 09556-16011 

      Standard Drive Pinion Preload 

      DRIVE PINION PRELOAD SPECIFICATIONS

      New bearing 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
      Reused bearing 0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)
      Fig 24: Measuring Differential Drive Pinion Preload
      G06025614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For a more accurate measurement, rotate the bearing forward and backward before adjusting.
    2. If the preload is insufficient, use SST to tighten the drive pinion nut 5 to 10° at a time. Measure the preload and repeat the adjustment as necessary until the preload matches the specified torque.
    3. If the tightening torque of the rear drive pinion nut exceeds 245 N*m (2500 kgf*cm, 181 ft.*lbf) but the preload is still insufficient, loosen the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.
    4. If there is no defect, replace the rear drive differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.
      Fig 25: Tightening Rear Drive Pinion Nut
      G06034436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Install the rear differential case to the rear differential carrier.
      Fig 26: Removing/Installing Rear Differential Case Sub-Assembly
      G06025576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL DIFFERENTIAL SIDE BEARING RETAINER 
    1. Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 

  25. 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 

      Fig 27: Locating Rear Differential Carrier Assembly Bolts
      G06025572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.) 

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

      NOTE: Measure at 3 or more areas on the circumference of the ring gear.
      Fig 28: Measuring Differential Ring Gear Backlash
      G06034439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. MEASURE TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

      SST 09556-16011 

      Standard total preload (New bearing): 

      Standard drive pinion preload plus 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf) 

      Fig 29: Measuring Drive Pinion Total Preload
      G06025619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard total preload (Reused bearing): 

      Standard drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf) 

      HINT:

      For a more accurate measurement, rotate the case bearing forward and backward before measuring.

    2. If the results are not within the specification, perform the procedure below:
      1. Select a thicker or thinner side gear shaft washer for the RH side, and then install the rear differential case bearing outer race (RH side only).
      2. Repeat the total preload measurement.
      3. Repeat the ring gear backlash inspection.
      4. Repeat the differential ring gear and drive pinion tooth contact pattern inspection.
  27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER 
    1. Remove the 10 bolts and the differential side bearing retainer.
    2. Install the 2 bolts and rear differential breather plug oil deflector to the side bearing retainer.

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

      Fig 30: Locating Rear Differential Breather Plug Oil Deflector Bolts
      G06025620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, tap in the rear differential carrier cover breather plug to the side bearing retainer.

      SST 09612-10093 (09612-10061) 

    4. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.
      NOTE: Do not damage the installation surface.
      Fig 31: Tapping Rear Differential Carrier Cover Breather Plug
      G06025621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply seal packing to the areas indicated in the illustration of the differential side bearing retainer.

      Seal Packing: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 32: Identifying Seal Packing Application Area On Differential Side Bearing Retainer
      G06025622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range A in the illustration.
      • Perform the installation within 3 minutes after applying seal packing.
      • Start applying seal packing within range A.
    6. Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.

      Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 

      NOTE: After installing the cover, do not immediately add oil or drive the vehicle for at least one hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.
      Fig 33: Locating Rear Differential Carrier Assembly Bolts
      G06025572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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 (New bearing): 

      Standard drive pinion preload plus 0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf) 

      Standard total preload (Reused bearing): 

      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 34: Measuring Differential Drive Pinion Preload
      G06025563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: For a more accurate measurement, rotate the case bearing forward and backward before inspecting.
  29. 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.
  30. INSTALL REAR DRIVE PINION NUT 
    1. Using a chisel and a hammer, stake the rear drive pinion nut.
      Fig 35: Measuring Differential Ring Gear Backlash
      G06034383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL REAR DIFFERENTIAL PRESSURE CONTROL HOSE 
    1. Align the matchmarks on the differential pressure control hose elbows and differential carrier.
      Fig 36: Identifying Matchmarks On Differential Pressure Control Hose Elbows And Rear Differential Carrier
      G06034392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the 2 differential pressure control hose clips, install the rear differential pressure control hose to the differential pressure control hose elbows.
      NOTE: Confirm that the hose and the clips do not interfere with other parts.
  32. INSTALL OIL DIAPHRAGM SEAL 
    1. Apply a light coat of MP grease to the lip of a new oil diaphragm seal.
      Fig 37: Identifying Differential Pressure Control Hose Clips
      G06034448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap the oil diaphragm seal into the rear differential carrier.

      SST 09506-35010, 09554-22010 

      Oil seal driven in depth: 

      0.7 to 1.3 mm (0.0276 to 0.0512 in.) 

      NOTE:
      • Tap the oil seal uniformly so that it is driven in straight.
      • Do not excessively tap the oil seal.
        Fig 38: Taping Oil Diaphragm Seal Into Rear Differential Carrier
        G06034449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Apply a light coat of MP grease to the lip of a new rear differential side gear shaft oil seal.
    2. Using SST and a hammer, tap the 2 rear differential side gear shaft oil seals into the rear differential carrier and differential side bearing retainer.

      SST 09554-22010 

      Oil seal driven in depth: 

      4.2 to 4.8 mm (0.165 to 0.189 in.) 

      NOTE:
      • Tap the oil seal uniformly so that it is driven in straight.
      • Do not excessively tap the oil seal.
        Fig 39: Taping Rear Differential Side Gear Shaft Oil Seals
        G06034450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR 
    1. Using SST and a press, install the new rear differential dust deflector.

      SST 09518-36020, 09950-70010 (09951-07150) 

      Fig 40: Installing Rear Differential Dust Deflector Using SST And Press
      G06034451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSMISSION COUPLING SPACER 
    1. Install the transmission coupling spacer to the rear differential carrier.
      Fig 41: Identifying Transmission Coupling Spacer
      G06034360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL TRANSMISSION COUPLING CONICAL SPRING WASHER 
    1. Install the transmission coupling conical spring washer to the rear differential carrier.
      NOTE: Install the transmission coupling conical spring washer so that the orange-marked surface faces the front of the vehicle (coupling side).
      Fig 42: Identifying Transmission Coupling Conical Spring Washer
      G06034359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY 
    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.
      NOTE: Do not scratch the installation area.
    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and the electro magnetic control coupling sub-assembly.
    3. Apply seal packing to the areas indicated in the illustration of the electro magnetic control coupling sub-assembly.

      Seal Packing: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      NOTE:
      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range A in the illustration.
      • Perform the installation within 3 minutes after applying seal packing.
      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
      • Start applying seal packing within range A.
        Fig 43: Identifying Seal Packing Application Area On Electro Magnetic Control Coupling Sub-Assembly
        G06025522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • (B): 1.0 mm (0.0394 in.)
      • (C): 2.0 mm (0.0787 in.)
      • (D) :3.0 mm (0.1181 in.)
      • (E) :5.0 mm (0.1969 in.)
    4. Install the electro magnetic control coupling sub-assembly with the 4 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 44: Locating Electro Magnetic Control Coupling Bolts
      G06025557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL REAR DIFFERENTIAL DRAIN PLUG 
    1. Install a new gasket with the rear differential drain plug.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      Fig 45: Locating Rear Differential Drain Plug
      G06025504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL REAR DIFFERENTIAL FILLER PLUG 
    1. Install a new gasket with the rear differential filler plug (inspection plug).

      Torque: 98 N*m (1000 kgf*cm, 72 ft.*lbf) 

  40. INSPECT REAR DIFFERENTIAL CARRIER ASSEMBLY 
    1. Install a dial indicator so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly.
      Fig 46: Locating Rear Differential Filler Plug
      G06025554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    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.) 

      Fig 47: Measuring Electro Magnetic Control Coupling Vertical And Lateral Runout
      G06025556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

  41. INSTALL STUD BOLT 
    1. Temporarily install 4 new stud bolts to the electro magnetic control coupling sub-assembly.
    2. Install 2 service nuts to the stud bolt.

      Recommended service nut: 

      Thread diameter: 

      8 mm (0.3150 in.) 

      Thread pitch: 

      1.25 mm (0.0492 in.) 

    3. Lock the upper nut using the lower nut.
      Fig 48: Turning Lower Nut
      G06034377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the upper nut and tighten the other 3 stud bolts to the electro magnetic control coupling sub-assembly in the same way.

      Torque: 10 N*m (102 kgf*cm, 7. ft.*lbf) 

      (A): 

      29.1 to 32.3 mm (1.146 to 1.272 in.) 

  42. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER 

    HINT:

    This step should be performed only when the rear differential dynamic damper is being replaced.

    Fig 49: Identifying Electro Magnetic Control Coupling Stud Bolts
    G06025639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the rear differential dynamic damper with the bolt.

      Torque: 27 N*m (270 kgf*cm, 20 ft.*lbf) 

      Fig 50: Locating Rear Differential Dynamic Damper Bolt
      G06025553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL DIFFERENTIAL SUPPORT 
    1. Install the differential support to the differential carrier assembly with the new 3 bolts.

      Torque: 167 N*m (1700 kgf*cm, 123 ft.*lbf) 

      Fig 51: Locating Differential Support Bolts
      G06034374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL REAR NO. 1 DIFFERENTIAL SUPPORT 
    1. Install the rear No. 1 differential support assembly to the differential carrier assembly with the new 2 bolts and 2 nuts.

      Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

      Fig 52: Locating Rear No. 1 Differential Support Bolts And Nuts
      G06034463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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