Differential Reassembly

1. Install the front differential side gear needle roller bearings.

Using the SST and a press press in 2 NEW bearings into the NEW differential case.

SST: 09950-60010 (09951-00420)

Standard Bearing Depth:
1.2 to 1.8 mm (0.0472 to 0.0709 in.)

2. Install the differential ring gear.

A. Clean the contact surfaces of the differential case and ring gear.

B. Heat the ring gear to about 212°F (100°C) in boiling water.

CAUTION

Do NOT use flame directly on gear.

HINT

^ Heating the ring gear allows easier installation onto the differential case.

^ Placing the differential case into a freezer the night before will also aid installation.

C. After the moisture on the ring gear has completely evaporated quickly set the ring gear onto the differential case.

D. Temporarily install the 12 bolts so that the bolt holes in the ring gear and differential case are aligned.

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: 137 N*m (1397 kgf*cm, 101 ft*lbf)





3. Install the front differential case bearings.

Using the SST and a press press on the two bearings.

SST: 09316-20011-01; 09309-36010-01

NOTE

Re-use the bearings removed from the old differential case.





4. Assemble the differential housing with the new differential case.

A. Carefully set the NEW differential case into the housing.

B. Torque bolts A and B.

Bolt A:

Torque: 65 N*m (633 kgf*cm, 48 ft*lbf)

Bolt B:

Torque: 155 N*m (1581 kgf*cm, 114ft*lbf)

NOTICE

Rotate the pinion gear while tightening the bolts to be sure the original washers are NOT too large. Washers that are too large could cause the ring gear to bind and damage the housing. Reduce washer thickness if binding occurs.

5. Inspect backlash between the differential ring gear and pinion gear.

A. Mount the dial indicator to the differential case.





B. Measure backlash from the pinion gear flange as shown in Figure 13.

Specification: 0.36 to 0.52 mm (0.014 to 0.020 in.)

^ The dial indicator must be at a 90 degree angle to the stud.

^ Be sure the ring gear does NOT move during backlash inspection.





6. Using the SST measure the total pre-load.

SST: 00002-02955

Standard Total Pre-load (at starting):

3.47 to 4.58 N*m (36 to 45 kgf*cm, 31 to 39 in*lbf)

NOTE

Total pre-load measurement is the amount of force required to start the rotation of the pinion gear (highest reading before pinion gear starts to rotate). Do NOT use traditional rotating force measurement.

^ If backlash or total pre-load is NOT within specification, proceed to the next step.

^ If NO adjustment is required, proceed to step 13.

7. Determine washer thickness adjustment.





Using the chart along with pre-load and backlash measurements determine the required washer adjustment.

8. Remove the bearing race(s) from the bearing retainer and/or differential carrier.





A. Using the SST and a press press out the bearing race and washer from the bearing retainer.

SST: 09950-60020 (09951-00680); 09950-70010
(09951-07150)





B. Using the SST and a press press out the race
and washer from the differential carrier.
SST: 09950-60020 (09951-00680); 09950-70010
(09951-07150)

NOTE

If the washer needs to be changed on ONE side only, removal of the bearing race on the opposite side is NOT required.

9. Install the bearing race(s) and NEW washer(s).





A. Insert the NEW washer(s) into the bearing retainer and/or differential carrier.





B. Using the SST and a press press the bearing race into the differential bearing retainer.

SST: 09950-60020 (09951-00890); 09950-70010
(09951-07150)





C. Using the SST and a press press the bearing race into the differential carrier assembly.

SST: 09950-60020 (09951-00890); 09950-70010 (09951-07150)





10. Assemble the differential housing.

A. Carefully set the differential case into the housing.

B. Torque bolts A and B.

Bolt A:

Torque: 65 N*m (633 kgf*cm, 48 ft*lbf)

Bolt B:

Torque: 155 N*m (1581 kgf*cm, 114 ft*lbf)

11. Inspect backlash between the differential ring gear and pinion gear.

A. Mount the dial indicator to the differential case.





B. Measure backlash from the pinion gear flange as shown in Figure 22.

Specification: 0.36 to 0.52 mm (0.014 to 0.020 in.)

NOTE

^ The dial indicator must be at a 90 degree angle to the stud.

^ Be sure the ring gear does NOT move during backlash inspection.

12. Measure the total pre-load.





A. Using the SST measure the total pre-load.

SST: 00002-02955

Standard Total Pre-load (at starting):

3.47 to 4.58 N*m (36 to 45 kgf*cm, 31 to 39 in*lbf)

B. Repeat steps 7 - 12 until backlash and pre-load are within specification.

NOTE

Multiple washer changes and inspections may be required. Changing the washers can be a trial and error process until the backlash and pre-load are correct.

13. Separate the differential housing and apply seal packing.

A. Be sure contact surfaces are clean.





B. Apply seal packing to the differential housing contact surfaces as shown.

Adhesive:

Toyota Genuine Adhesive 1281, Three Bond 1281, or equivalent

Install the other half of the differential housing within 10 minutes of applying seal packing.





C. Reinstall the differential bearing retainer

housing with 11 bolts A and 3 bolts B.

Bolt A:

Torque: 65 N*m (633 kgf*cm, 48 ft*lbf)

Bolt B:

Torque: 155 N*m (1581 kgf*cm, 114 ft*lbf)

14. Install the differential side gear intermediate shaft sub-assembly.





A. Install a NEW C-ring onto the side gear intermediate shaft.

B. Using a plastic-faced hammer install the side gear intermediate shaft.

C. Check that there is 2 to 3 mm (0.0788 to 0.118 in.) end play in the axial direction.

D. Check that the side gear intermediate shaft does NOT come out when trying to pull on it by hand.





15. Install the axle shaft seal.

A. Using the SST and plastic-faced hammer tap in a new oil seal until its surface is flush with the differential housing.

SST: 09608-32010

B. Coat the lip of the oil seal with grease.

Standard Oil Seal Depth:

-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

16. Install the front differential tube assembly.

A. Remove any old sealant and FIPG.





B. Clean contact surface and apply seal packing.

Adhesive:

Toyota Genuine Adhesive 1281, Three Bond 1281, or equivalent

Install the differential tube within 10 minutes of applying seal packing.





C. Align the ADD collar spines and install 4 NEW bolts.

Torque: 65 N*m (663 kgf*cm, 48 ft*lbf)

17. Install the front differential carrier assembly.

Refer to TIS 2007 or 2008 model year Tundra Repair Manual:
or Tundra Drivetrain - Axle/Differential - "Differential: Front Differential Carrier Assembly (for 4WD): Installation"

18. Add differential oil.





A. Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom of the differential filler plug hole.

Do NOT add oil immediately after assembling the differential carrier.

Wait at LEAST 1 hour for the adhesive to dry.

Oil Type and Viscosity:

Toyota Genuine Differential Gear Oil LT 75W-85
GL-5 or equivalent

B. Using a 10 mm hexagon wrench install a new gasket and the filler plug.

Torque: 39 N*m (398 kgf*cm, 29 ft*lbf)

19. Test drive the vehicle and confirm the noise is eliminated.

20. Re-check oil level and confirm NO leaks are present.