Assembly

1. Temporarily adjust drive pinion preload as follows:
a. Install drive pinion and front bearing.
b. Install companion flange using tool No. 09557-22022.
c. Retain companion flange using tool No. 09330-0021, then adjust drive pinion preload to 10.4-16.5 inch lbs. for new bearings or 5.2-8.7 inch lbs. for used bearings.
2. Place bearing outer races on their respective bearings, then insert differential case into carrier.
3. Install plate washer on back of ring gear, then ensure ring gear has backlash.
4. Tap on ring gear, using a suitable mallet to snug down washer and bearing, then retain side bearing boss on tooth surface and measure backlash. Backlash should be .0039 inch.
5. Select ring gear back plate washer, using backlash as reference.
6. Select ring gear teeth side washer with a thickness that will eliminate clearance between outer race and case.
7. Remove plate washers and differential case, then install plate washer into lower part of carrier.
8. Place second plate washer onto differential case with outer race, then insert differential case and outer race into carrier.
9. Snug down washer and bearing, by tapping on ring gear, using a suitable mallet.
10. Measure ring gear backlash, using a suitable dial indicator. Backlash should be .0051-.0071 inch. If backlash is not as specified, adjust number of washers on both sides an equal amount.
11. Adjust side bearing preload as follows:
a. Remove ring gear teeth plate washer, then measure and record thickness.
b. Install a new washer approximately .0024-.0035 inch thicker, then install and check ring gear backlash.

Fig. 19 Ring gear plate washer selection chart. 1986-88 Pickup & 4Runner:

c. If backlash is not as specified, select a suitable washer from chart, Fig. 19,to bring backlash to within specifications.
12. Align matchmarks on cap and carrier, then install side bearing caps and torque to 58 ft. lbs.
13. Measure total preload. Preload should be 3.5-5.2 inch lbs., with a preload of .0051-.0071 inch.

Fig. 4 Ring gear and pinion tooth contact inspection:

Fig. 20 Drive pinion plate washer selection chart. 1986-88 Pickup & 4Runner:

14. Inspect gear tooth contact as shown, Fig. 4. If contacting pattern is not correct, select a suitable shim from chart, Fig. 20, that will ensure proper contact.
15. Install new bearing spacer and front bearing.
16. Install oil slinger, then drive in new oil seal to a depth of .059 inch.
17. Install companion flange, using tool No. 09557-22022, then apply a suitable lubricant to new nut. Retain companion flange, using tool No. 09330-00020, then install nut and torque to 80 ft. lbs.
18. Check drive pinion preload. Drive pinion preload should be 5.2-8.7 inch lbs.
19. If preload is greater than specified, replace bearing spacer. If preload is less that specified, torque nut 9 ft. lbs. at a time until specified preload is obtained. If a maximum torque to 174 ft. lbs. is exceeded during tightening procedure, replace bearing spacer and repeat preload adjustment.
20. Check companion flange deviation. Deviation in any direction should not exceed .0039 inch.
21. Stake drive pinion nut.
22. Apply a suitable lubricant to new side gear shaft oil seal, then drive in new oil seal using tool No. 09550-22011, until flush with carrier end surface.
23. Assemble differential side tube to carrier, then insert 4 attaching bolts and torque to 65 ft. lbs.
24. Reverse removal procedure to install differential carrier.