Reassembly

DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 3UR-FE):

REASSEMBLY

1. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck)





(a) Install the dynamic damper and washer with the bolt.
Torque: 17 Nm (168 kgf-cm, 12 ft-lbf)
2. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR





(a) Using SST, a press and steel plate, press in the dust deflector.
SST: 09523-36010

NOTE: 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 straight pin holes of 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:
0.15 mm (0.00591 in.) or less
If the backlash is not within the specification, replace the side gear thrust washer with one of an appropriate thickness.

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

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
09951-00500
09951-00630
SST: 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 adhesive to the bolts and install them.
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
Torque: 197 Nm (2008 kgf-cm, 145 ft-lbf)
6. INSTALL DIFFERENTIAL OIL STORAGE RING





(a) Using SST and a press, press in the oil storage ring to the differential carrier.
SST: 09950-70010
09951-07150
SST: 09950-60020
09951-00750
7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING





(a) Using SST and a press, press in the bearing (outer race).
SST: 09950-60020
09951-00810
SST: 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
09951-01030
SST: 09950-70010
09951-07360
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 bearing.
SST: 09630-24014
09620-24051
10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (with Shim Pairing Table)
(a) Install the bearing spacer onto the drive pinion.





(b) Install the 2 preload adjusting shims.





(c) Install the front bearing (inner race) and oil slinger.

HINT: Install the oil seal after adjusting the gear contact pattern.





(d) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09956-03050
SST: 09955-03050
(e) Coat the threads of the nut with hypoid gear oil.





(f) Using SST to hold the companion flange, install the nut by tightening it until the standard preload is reached.
SST: 09330-00021
09330-00030
Torque: 304 Nm (3100 kgf-cm, 224 ft-lbf)





(g) Using a torque wrench, measure the preload.
Standard preload (at starting):





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

If the preload is not within the specification, adjust the preload until it is within the specification by performing the following procedures.
(h) Refer to the table below and choose a combination of 2 shims.
Preload adjustment shim:









(i) Calculate the B measurement.
B measurement:
Shim A + Shim B + Spacer = B measurement
Spacer:





Preload adjustment shim pairing table (Reference):





(j) Measure the preload.
(k) Change the shims so that the B measurement changes by 0.01 mm (0.000394 in.), and measure the preload.
Standard preload (at starting):





HINT: Repeat the above procedure until the preload is as specified.

11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY





(a) Place the 2 bearing outer races on their corresponding bearings.
(b) Install the differential case assembly in the differential carrier assembly.

HINT: Do not interchange the right and left race.

12. ADJUST RING GEAR BACKLASH





(a) Install the plate washer on the ring gear back side.

NOTE: Make sure that the ring gear has backlash.





(b) Tap on the ring gear with a plastic-faced hammer so that the washer fits to the bearing.





(c) Using a dial indicator, while holding the companion flange, measure the ring gear backlash.
Standard backlash (reference):
0.10 to 0.20 mm (0.00394 to 0.00788 in.)





(d) Select a ring gear back side plate washer 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 case.
(f) Remove the 2 plate washers and differential case.
(g) Install the plate washer on the ring gear back side.





(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-faced hammer so that the washers fit to the bearing.





(j) Using a dial indicator, while holding the companion flange, measure the ring gear backlash.
Standard backlash:
0.10 to 0.20 mm (0.00394 to 0.00788 in.)
If the backlash is not within the specification values, 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 ring gear backlash.

13. ADJUST SIDE BEARING PRELOAD





(a) Remove the ring gear teeth side plate washer and using a micrometer, measure the thickness.
(b) Install the selected plate washer.
(c) Using the backlash as a reference, tap a new washer that is 0.05 to 0.20 mm (0.00197 to 0.00787 in.) thicker than the removed washer so that it fits to the bearing.

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

(d) Using a plastic-faced hammer, install the plate washer.





(e) Recheck the ring gear backlash.
Standard backlash:
0.10 to 0.20 mm (0.00394 to 0.00788 in.)
If the backlash is not within the specification, 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 (0.000787 in.), corresponding to a 0.03 mm (0.00118 in.) change in the plate washer.

Washer thickness:





14. INSTALL BEARING CAP





(a) Align the matchmarks on the cap and carrier.
(b) Install the 4 bolts.
Torque: 205 Nm (2090 kgf-cm, 151 ft-lbf)

HINT: After rotating the ring gear 5 times or more, recheck the backlash.

15. INSPECT DIFFERENTIAL RING GEAR RUNOUT





(a) Using a dial indicator, measure the runout of the ring gear.
Standard runout:
0.05 mm (0.00197 in.)
If the runout is not within the specification, replace the ring gear.
16. 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):





17. 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:





18. REMOVE REAR DRIVE PINION NUT





(a) Using SST to hold the companion flange, remove the nut.
SST: 09330-00021
09330-00030
19. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (Disassembly)

20. 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
SST: 09649-17010
Standard oil seal depth:
-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

HINT: Connect 2 SST with vinyl tape.

(b) Coat the lip of the oil seal with MP grease.
21. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY





(a) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09956-03030
SST: 09955-03050
(b) Coat the threads of a new nut with hypoid gear oil.





(c) Using SST to hold the flange, install the nut.
SST: 09330-00021
09330-00030
Torque: 304 Nm (3100 kgf-cm, 224 ft-lbf)





22. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) 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 not within the specification, refer to the tables in the "INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (with Shim Pairing Table)" procedure to change the combination of the 2 shims.
23. 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):









24. 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 in.)

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

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





25. 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.





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