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Home >> Toyota Truck >> 2005 >> Tacoma 2WD L4-2.7L (2TR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Rear >> W/O Diff. Lock >> Part 2

Part 2

Overhaul Continued





48. INSTALL DIFFERENTIAL CASE ASSY (2 PINION DIFFERENTIAL)
a. Install the 2 thrust washers onto the side gears.
b. Install the 2 side gears with the thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft.

HINT: Align the holes for the straight pin in the differential case and pinion shaft.





c. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specified value, replace the side gear thrust washer with one of an appropriate thickness.

HINT: Refer to the table to select thrust washers so that the backlash is within the specified value.





Washer thickness





d. Using a pin punch and hammer, install the straight pin through the holes in the differential case and pinion shaft.
e. Using a chisel and hammer, stake the outside of the differential case pin hole.





49. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to approximately 100°C (212°F) in boiling water.
c. Carefully take the ring gear out of the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.

HINT: Align the matchmarks on the ring gear and differential case.





e. After the ring gear has cooled sufficiently, torque the set bolts to which the thread lock has been applied.
Thread lock: Part No.08833-00100, THREE BOND 1360K or equivalent.
Torque: 125 Nm (1,270 kgf-cm, 92 ft. lbs.)





50. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 side bearings into the differential case.
SST 09950-60010 (09951-00480, 09951-00640), 09950-70010 (09951-07150)





51. INSPECT DIFFERENTIAL RING GEAR RUNOUT
a. Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
c. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.05 mm (0.0020 inch)
d. Remove the 2 bearing caps, 2 adjusting nuts and differential case.





52. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using a press, install the dust deflector.
SST 09636-20010

NOTICE: Be careful not to damage the dust deflector.





53. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, install the oil storage ring.
b. Using SST and a press, install the tapered roller bearing onto the carrier.
SST 09316-60011 (09316-00011, 09316-00021)





54. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the tapered roller bearing onto the carrier.
SST 09316-60011 (09316-00041, 09316-00011)





55. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the plate washer onto the drive pinion.
b. Using SST and a press, install the tapered roller bearing onto the drive pinion.
SST 09506-30012





56. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and rear drive pinion tapered roller bearing.

HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.





b. Using SST, install the drive pinion companion flange.
c. Coat the threads of the nut with hypoid gear oil LSD.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





d. Using SST to hold the drive pinion companion flange, tighten the nut.
Torque: 451 Nm (4,600 kgf-cm, 333 ft. lbs.) or less

NOTICE:
^ As there is no spacer, tighten a little at a time, being careful not to overtighten it.
^ Apply hypoid gear oil LSD to the nut.

SST 09330-00021





e. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.27 to 1.86 Nm (13 to 20 kgf-cm, 11 to 16 inch lbs.)
Reused bearing: 0.78 to 1.07 Nm (8.0 to 11 kgf-cm, 6.9 to 9.5 inch lbs.)
If necessary, disassemble and inspect the differential assy.





57. INSTALL DIFFERENTIAL CASE ASSY
a. Place the 2 bearing outer races on their corresponding bearings.

HINT: Make sure the right and left races are not interchanged.

b. Install the differential case into the carrier.





58. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Install the plate washer onto the ring gear back side.

HINT: Make sure that the ring gear has backlash.





b. Tap on the ring gear with a plastic hammer so that the washer fits into the bearing.





c. Using a dial indicator, measure the ring gear backlash while holding the companion flange.
Backlash (reference): 0.13 to 0.18 mm (0.0051 to 0.0071 inch)





d. Select a plate washer for the back side ring gear using the backlash as a reference.





e. Select a ring gear teeth side plate washer so that there is no clearance between the outer race and the case.
f. Remove the 2 plate washers and differential case.
g. Install the plate washer into the ring gear back side of the carrier.





h. Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
i. Tap on the ring gear with a plastic hammer so that the washers fit into the bearing.





j. Using a dial indicator, measure the ring gear backlash while holding the companion flange.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
If the backlash is not within the specified value, adjust it by either increasing or decreasing the thickness of washers on both sides by an equal amount.

HINT: There should be no clearance between the plate washer and the case. Make sure that there is a ring gear backlash.





59. INSPECT SIDE BEARING PRELOAD
a. Remove the ring gear teeth side plate washer and using a micrometer, measure the thickness.
b. Using the backlash as a reference, install a new washer 0.06 to 0.09 mm (0.0024 to 0.0035 inch) thicker than the removed one.

HINT: Select a washer which can be pressed in 2/3 of the way with your finger.





c. Using SST and a plastic hammer, install the plate washer.





d. Recheck the ring gear backlash.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
If the backlash is not within the specified value, adjust it by either increasing or decreasing the thickness of washers on both sides by an equal amount.

HINT: The backlash will change by about 0.02 mm (0.0008 inch) corresponding to 0.03 mm (0.0012 inch) change in the plate washer.





Washer thickness





e. Tighten the bearing cap bolts.
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)





60. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total Preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf-cm, 3.5 to 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.





61. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.





c. Inspect the tooth contact pattern.





d. If the teeth are not properly in contact, use the chart to select an appropriate washer for correction.





Plate washer thickness





62. REMOVE REAR DRIVE PINION NUT
a. Using SST to hold the drive pinion companion flange, remove the nut.
SST 09330-00021





63. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





64. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the drive pinion tapered roller bearing from the drive pinion.
SST 09556-22010





65. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer onto the drive pinion.





66. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING





67. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Apply MP grease to the oil seal lip.
b. Using SST and a hammer, install a new carrier oil seal.
SST 09554-30011
Oil seal drive in depth: 0.5 to 0.5 mm (-0.0197 to 0.0197 inch)





68. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, install the drive pinion companion flange onto the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





b. Coat the threads of a new nut with hypoid gear oil LSD.
c. Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 451 Nm (4,600 kgf-cm, 333 ft. lbs.) or less





69. INSPECT DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the back lash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.27 to 1.86 Nm (13 to 19 kgf-cm, 11 to 16 inch lbs.)
Reused bearing: 0.78 to 1.07 Nm (8.0 to 11 kgf-cm, 6.9 to 9.5 inch lbs.)
^ If the preload is greater than the specification, re place the bearing spacer.
^ If the preload is less than the specification, retighten the nut to 13 Nm (130 kgf-cm, 9 ft lbs.) of torque at a time until the specified preload is reached.
Torque: 451 Nm (4,600 kgf-cm, 333 ft. lbs.) or less
^ If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.





70. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total Preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4 to 6 kgf-cm, 4.0 to 5.2 inch lbs.)
If the necessary, disassemble and inspect the differential.





71. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.





72. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the vertical and horizontal runout of the drive pinion companion flange.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)





73. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and hammer, stake the drive pinion nut.





74. INSTALL DIFFERENTIAL CARRIER ASSY REAR
a. Remove any dust and oil from the differential carrier assy and contact surface of the axle housing.
b. Apply liquid gasket to both sides of the gasket.

NOTICE: Do not put the liquid gasket on the stud bolt.





c. Install a new gasket and the differential carrier assembly with the 10 nuts and 10 washers.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
75. INSTALL REAR AXLE SHAFT W/BACKING PLATE
76. INSTALL REAR AXLE SHAFT W/BACKING PLATE
77. INSTALL PARKING BRAKE CABLE ASSY NO.3
78. INSTALL PARKING BRAKE CABLE ASSY NO.2
79. INSTALL SPEED SENSOR REAR LH
80. INSTALL SPEED SENSOR REAR RH
81. INSTALL PROPELLER SHAFT ASSY (2WD DRIVE TYPE, REGULAR CAB)
82. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (2WD DRIVE TYPE, EXCEPT REGULAR CAB)
83. INSTALL PROPELLER SHAFT ASSY (4WD DRIVE TYPE, REGULAR CAB)
84. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE, EXCEPT REGULAR CAB)
85. INSTALL REAR BRAKE SHOE
SST 09718-00010
86. INSTALL FRONT BRAKE SHOE
SST 09718-00010, 09921-00010
87. CHECK REAR DRUM BRAKE INSTALLATION
88. INSTALL REAR BRAKE DRUM SUB-ASSY
89. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
90. FILL RESERVOIR WITH BRAKE FLUID (W/ VSC)
91. FILL RESERVOIR WITH BRAKE FLUID (W/O VSC)
92. BLEED MASTER CYLINDER (W/O VSC)
SST 09023-00101
93. BLEED BRAKE LINE (W/VSC)
94. BLEED BRAKE LINE (W/O VSC)
95. CHECK FLUID LEVEL IN RESERVOIR (W/ VSC)
96. CHECK FLUID LEVEL IN RESERVOIR (W/O VSC)
97. CHECK FOR BRAKE FLUID LEAKAGE
98. ADD DIFFERENTIAL OIL
99. INSPECT DIFFERENTIAL OIL
100. INSPECT FOR DIFFERENTIAL OIL LEAKAGE
101. INSTALL REAR WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 inch lbs.)
102. INSPECT PARKING BRAKE PEDAL TRAVEL (AUTOMATIC TRANSAXLE)
103. INSPECT PARKING BRAKE LEVER TRAVEL (MANUAL TRANSAXLE)
104. ADJUST PARKING BRAKE PEDAL TRAVEL (AUTOMATIC TRANSAXLE)
105. ADJUST PARKING BRAKE LEVER TRAVEL (MANUAL TRANSAXLE)
106. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
107. CHECK ABS SENSOR SIGNAL (W/ VSC)
108. CHECK ABS SENSOR SIGNAL (W/O VSC)
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