Reassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

REASSEMBLY





1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
(a) Using SST and a press, press in the shaft bearing.
SST: 09223-00010
(b) Using a snap ring expander, install the snap ring.
HINT: Install the snap ring securely.





2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
(a) Install the shaft into the differential tube.
(b) Using needle nose pliers, install the snap ring.
HINT: Install the snap ring securely.





3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
Oil seal depth:
4.8 to 5.8 mm (0.189 to 0.229 in.)
(b) Using SST and a plastic-faced hammer, tap in the oil seal.
SST: 09223-15020






4. INSTALL DIFFERENTIAL CLUTCH HUB
(a) Install the clutch hub onto the side gear inter shaft.
(b) Using snap ring pliers, install the snap ring.
HINT: Install the snap ring securely.
NOTE: Install the differential clutch hub in the correct direction.





5. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING
(a) Using SST and a press, press in 2 new bearings.
SST: 09950-60010
09951-00380
Needle roller bearing depth:
1.4 to 2.0 mm (0.055 to 0.079 in.)
6. ASSEMBLE DIFFERENTIAL CASE





(a) Install the 2 thrust washers onto the 2 side gears.
HINT: Using the table below, select 2 thrust washers which will ensure that the backlash is within the specifications.

Thrust washer thickness:










(b) Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion thrust washers and pinion shaft into the differential case.
HINT: Align the holes of the differential case and pinion shaft.





(c) Measure the side gear backlash.
(1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Backlash:
0.15 mm (0.0059 in.) or less
- If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.





(d) Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.
(e) Stake the differential case.
7. INSTALL DIFFERENTIAL RING GEAR





(a) Clean the contact surface of the differential case and ring gear.
(b) Heat the ring gear in water that is approximately 100 °C (212 °F).
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.






(e) Align the matchmarks on the ring gear with those of the differential case.
(f) After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.
Thread lock:
THREE BOND 1360K or the equivalent.
Torque: 115 Nm (1,173 kgf-cm, 85 ft-lbf)






8. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press the bearing into the differential case.
SST: 09950-60010
09951-00520
09951-00610
SST: 09950-70010
09951-07150
9. INSTALL FRONT DIFFERENTIAL CASE BEARING





HINT: When replacing the 3 differential case bearings, fit the 2 thinnest new washers onto each bearing. When reusing the bearings, fit the new washers into the same places they were removed from.

(a) Using SST and a press, press the case bearing (outer race) into the differential case bearing retainer.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07150






(b) Using SST and a press, press the case bearing (outer) into the differential carrier.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07150






10. INSTALL BEARING OUTER RACE
(a) Using SST, install the outer race front.
SST: 09950-00020
09951-00890
09951-00680
(b) Using a brass bar and hammer, tap in the oil storage ring.
(c) Using SST, install the outer race rear.
SST: 09950-00020
09951-00890
09951-00680






11. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the washer onto the drive pinion.
HINT: First fit a washer that has the same thickness as the removed washer. After checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

(b) Using SST and a press, press the front bearing onto the drive pinion.
SST: 09506-30012
12. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD





(a) Install the drive pinion and oil slinger.
HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.





(b) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
NOTE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.





(c) Adjust the drive pinion preload by tightening the companion flange nut.
(d) Using SST to hold the flange in place, tighten the nut.
Torque: 370 Nm (3,770 kgf-cm, 273 ft-lbf)or less
NOTICE:
- As there is no spacer, tighten the nut a little at a time. Be careful not to overtighten it.
- Apply hypoid gear oil to the nut.





(e) Using a torque wrench, measure the preload.
Preload (at starting):





NOTE: For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

13. INSTALL DIFFERENTIAL CASE ASSEMBLY
14. ADJUST DIFFERENTIAL RING GEAR BACKLASH
(a) Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)






(b) Using SST and a dial indicator, measure the ring gear backlash.
SST: 09564-32011
Backlash:
0.11 to 0.21 mm (0.0043 to 0.0083 in.)
If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.
HINT: There should be no clearance between the plate washer and case. Make sure that the ring gear has backlash.

Washer thickness:










15. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
HINT: Bolts without torque specifications are shown in the service data Service Data.
- If necessary, disassemble and inspect the differential.

16. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Remove the differential case bearing retainer and differential case.






(b) Coat 3 or 4 teeth at 3 different positions on the ring gear with prussian blue.
(c) Install the differential case and differential case bearing retainer.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
(d) Hold the companion flange firmly in place and rotate the ring gear in both directions.
(e) Remove the differential case bearing retainer and differential case.
(f) Inspect the tooth contact pattern.









(g) If the teeth are not contacting properly, use the following chart to select an appropriate washer.
Washer thickness:






17. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT Disassembly

18. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Disassembly

19. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Disassembly







21. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer onto the drive pinion.






22. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
23. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER






24. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, tap in the oil seal.
SST: 09554-22010
Oil seal depth:
3.9 to 4.8 mm (0.154 to 0.189 in.)






25. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
(a) Using a steel plate and a press, press in a new dust deflector.
NOTE: Do not damage the dust deflector.

26. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY





(a) Place the companion flange on the drive pinion.
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
NOTE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.





(d) Using SST to hold the companion flange in place, tighten the nut to the correct torque.
SST: 09330-00021
09330-00030
Torque: 370 Nm (3,770 kgf-cm, 273 ft-lbf)






27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove any old FIPG material from the side bearing retainer.
NOTE: Do not drop oil on the contact surfaces of the differential carrier and side bearing retainer.

(b) Clean residual FIPG material from the contact surface using gasoline or alcohol.
(c) Apply FIPG to the side bearing retainer, as shown.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
HINT: Install the side bearing retainer within 10 minutes of applying FIPG.

(d) Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)






28. INSPECT DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):





- If the preload is greater than the maximum, replace the bearing spacer.
- If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

Torque: 370 Nm (3,770 kgf-cm, 273 ft-lbf)or less
- If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.
HINT: Do not loosen the pinion nut to reduce the preload.





29. 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) - Torque: 0.22 to 0.88 Nm (6 to 9 kgf-cm, 1.9 to 8.8 in-lbf)drive pinion preload plus
HINT: Bolts without torque specifications are shown in the service data Service Data.
- If necessary, disassemble and inspect the differential.





30. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using SST and a dial indicator, measure the ring gear backlash.
SST: 09564-32011
Backlash:
0.11 to 0.21 mm (0.0043 to 0.0083 in.)
- If the backlash is not within the specification, adjust the side bearing preload.





31. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.
Maximum runout:





- If the runout is greater than the maximum, replace the companion flange.





32. STAKE DRIVE PINION COMPANION FLANGE NUT
(a) Using a chisel and hammer, stake the drive pinion nut.






33. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a plastic-faced hammer, tap in the oil seal until its surface is flush with the differential carrier end.
SST: 09608-32010
Oil seal depth:
-0.45 to 0.45 mm (-0.018 to 0.018 in.)






34. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
(a) Using a brass bar and hammer, tap in the side bearing retainer deflector.
NOTE: Install the side bearing retainer deflector in the correct direction.





35. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY
(a) Install a new snap ring onto the side gear inter shaft.
(b) Using a plastic-faced hammer, tap the side gear inter shaft into the differential case.
(c) Check that there is 2 to 3 mm (0.08 to 0.12 in.) of axial play.
(d) Check that the side gear inter shaft cannot be completely pulled out by hand.
36. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY





(a) Remove any old FIPG material from the contact surfaces of the differential and clutch case.
NOTE: Do not drop oil on the contact surfaces of the differential and clutch case.

(b) Clean residual FIPG material from the contact surface using gasoline or alcohol.
(c) Apply FIPG to the differential as shown.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
HINT: Install the differential tube within 10 minutes of applying FIPG.

(d) Install the differential tube onto the differential.






(e) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(f) Apply adhesive to 2 or 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
(g) Install the 4 bolts.
Torque: 110 Nm (1,120 kgf-cm, 81 ft-lbf)
37. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR





(a) Remove any FIPG material from the contact surface of the differential and clutch case. Also, do not drop oil on the contact surfaces.
(b) Clean residual FIPG material from the contact surfaces using gasoline or alcohol.
(c) Apply FIPG to the differential tube as shown.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
HINT: Install the actuator within 10 minutes of applying FIPG.





(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 or 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
(g) Install the 4 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft-lbf)