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Reassembly

DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 2UZ-FE)

COMPONENTS (Part 1):




COMPONENTS (Part 2):




COMPONENTS (Part 3):








REASSEMBLY





1. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck)
(a) Install the washer and dynamic damper with the bolt.
Torque: 17 Nm (168 kgf-cm, 12 ft. lbs.)





2. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST, a press and steel plate, press in the dust deflector.
SST 09523-36010

NOTICE: Be careful not to damage the dust deflector.

3. INSTALL DIFFERENTIAL CASE ASSEMBLY





(a) Install the 2 side gear thrust washers to 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.
^ Apply hypoid gear oil to each sliding surface and rotating part.





(c) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Standard backlash: 0.05 to 0.20 mm (0.00197 to 0.00788 inch)
If the backlash is not within the specified value, replace the side gear thrust washer with an appropriate thickness.

HINT: Refer to the following table to select thrust washers which will ensure that the backlash is within the specified value.

Washer thickness:








(d) Using a pin punch and hammer, tap 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.





4. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press in the 2 bearings.
SST 09950-60010 (09951-00480, 09951-00640), 09950-70010 (09951-07150)

5. 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 set the ring gear onto the differential case.

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





(e) After the ring gear cools down sufficiently, apply thread lock adhesive to the bolts and install them.
Thread lock: Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
Torque: 137 Nm (1397 kgf-cm, 101 ft. lbs.)

6. 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.
(c) Install the 2 adjusting nut locks with the 2 bolts.
(d) Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.05 mm (0.00197 inch)
If the runout is greater than the maximum, replace the ring gear.
(e) Remove the 2 bolts and adjusting nut locks.
(f) Remove the 2 bearing caps, 2 adjusting nuts and differential case assembly.





7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, press in the bearing (outer race).
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)





8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press in the bearing (outer race).
SST 09950-60020 (09951-00910), 09950-70010 (09951-07150)





9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the plate washer onto the drive pinion.

HINT: First fit a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

(b) Using SST and a press, press in the rear bearing (inner race).
SST 09506-35010

10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD





(a) Install the drive pinion, front bearing (inner race) 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, 09956-03050)





(c) Using SST to hold the companion flange.
SST 09330-00021 (09330-00030)
(d) Coat the threads of the nut with hypoid gear oil.
(e) Install the nut by tightening it until the standard preload is reached.
Torque: 441 Nm (4497 kgf-cm, 325 ft. lbs.) or less

NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





(f) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard preload (at starting):





HINT: Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth.





11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY
(a) Place the 2 bearing outer races on their respective bearings.

HINT: Do not interchange the right and left race.





12. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT
(a) Install the 2 adjusting nuts onto the carrier, making sure the nuts are threaded properly.

13. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH





(a) Align the matchmarks on the bearing cap and carrier.





(b) Install the right and left bearing caps with the 4 bolts.
Torque: 103 Nm (1050 kgf-cm, 76 ft. lbs.)
If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.





(c) Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned using SST.
SST 09504-00011
(d) Using SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.00788 inch).

Pinion Side:





(e) While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side.
SST 09504-00011
(f) Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.





(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification.
SST 09504-00011
Standard backlash: 0.10 to 0.20 mm (0.00394 to 0.00788 inch)

HINT:
^ The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.
^ Perform the measurement at 3 or more positions around the circumference of the ring gear.





(h) Tighten the bearing cap bolts.
Torque: 103 Nm (1050 kgf-cm, 76 ft. lbs.)





14. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Standard total preload (at starting): Standard drive pinion preload plus 0.24 to 0.46 Nm (2.4 to 4.7 kgf-cm, 2.1 to 4.1 inch lbs.)

15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.





(b) Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.





If the teeth are not contacting properly, use the following table to select a proper washer for correction.

Washer thickness (Part 1):




Washer thickness (Part 2):








16. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the companion flange, remove the nut.
SST 09330-00021 (09330-00030)

17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER





19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the bearing (inner race).
SST 09556-22010





20. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new spacer onto the drive pinion.

21. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING





(a) Install the drive pinion, front bearing (inner race) and oil slinger.





(b) Using SST and the companion flange, install the bearing (inner race) and then remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050)






22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end.
SST 09316-12010, 09649-17010
Standard oil seal depth: 0.05 to 0.95 mm (0.0020 to 0.0374 inch)

HINT: Connect 2 SST with vinyl tape.

(b) Coat the lip of the oil seal with MP grease.





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

24. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Coat the threads of a new nut with hypoid gear oil.





(b) Using SST to hold the companion flange.
SST 09330-00021 (09330-00030)
(c) Tighten the nut until the standard preload is reached.
Torque: 441 Nm (4497 kgf-cm, 325 ft. lbs.) or less





(d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard 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 Nm (130 kgf-cm, 9 ft. lbs.) of torque at a time until the specified preload is reached.
Torque: 441 Nm (4497 kgf-cm, 325 ft. lbs.) 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.





25. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Standard total preload (at starting): Standard drive pinion preload plus 0.24 to 0.46 Nm (2.4 to 4.7 kgf-cm, 2.1 to 4.1 inch lbs.)





26. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, check the backlash of the ring gear.
Standard backlash: 0.10 to 0.20 mm (0.00394 to 0.00788 inch)
If the backlash is not as specified, adjust the side bearing preload or repair as necessary.

HINT: Perform the measurements at 3 or more positions around the circumference of the ring gear.





27. INSPECT RUNOUT OF REAR 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.





28. STAKE REAR DRIVE PINION NUT
(a) Using a chisel and hammer, stake the nut.





29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
(a) Install 2 new adjusting locks onto the bearing caps with the 2 bolts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(b) Bend the nut locks.
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