Reassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REASSEMBLY

REASSEMBLY

1. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in the straight pins until their protrusion amounts are at the specified values shown in the illustration below.





Standard:






2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING






(a) Using SST and a press, press in the bearing.
SST: 09223-00010






(b) Using a snap ring expander, install a new snap ring.
3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH






(a) Install the side gear shaft into the differential tube.
(b) Using snap ring pliers, install a new snap ring.
4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL






(a) Using SST and a plastic-faced hammer, tap in a new oil seal.
SST: 09608-32010
Standard oil seal depth:
4.8 to 5.8 mm (0.189 to 0.228 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL DIFFERENTIAL CLUTCH HUB






(a) Install the clutch hub onto the side gear inter shaft.






(b) Using snap ring pliers, install a new snap ring.
NOTE: Be sure to install the differential clutch hub in the correct direction.

6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING






(a) Using SST and a press, press in 2 new bearings.
SST: 09950-60010
09951-00420
Standard bearing depth:
1.2 to 1.8 mm (0.0472 to 0.0709 in.)
7. INSTALL FRONT DIFFERENTIAL CASE






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

Washer thickness:






(b) Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly.
HINT:
- Align the holes of the differential case assembly and pinion shaft.
- Apply hypoid gear oil to each sliding surface and rotating part.

(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 assembly.
Standard backlash:
0 to 0.15 mm (0 to 0.00591 in.)
If the backlash is not within the specification, install a side gear thrust washer with a different thickness.






(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.
8. INSTALL DIFFERENTIAL RING GEAR






(a) Clean the contact surfaces of the differential case and ring gear.
(b) Heat the ring gear to about 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.
- Temporarily install the 10 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.
Torque: 137 Nm (1397 kgf-cm, 101 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
9. INSTALL FRONT DIFFERENTIAL CASE BEARING






(a) Using SST and a press, press in the 2 bearings (inner race).
SST: 09316-20011
SST: 09316-60011
09316-00041
10. INSTALL FRONT DIFFERENTIAL CASE BEARING
HINT: When replacing the 2 differential case bearings, fit the thinnest washer to each bearing. When reusing the bearings, fit a washer of the same thickness as the one removed to each bearing.





(a) Install a new plate washer to the side bearing retainer.
(b) Using SST and a press, install the bearing (outer race) onto the differential case bearing retainer.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150






(c) Install a new plate washer onto the differential carrier.
(d) Using SST and a press, press in the bearing (outer race) onto the differential carrier assembly.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150
11. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING






(a) Using SST, install the bearing (outer race).
SST: 09950-00020
09951-00810
09951-00890
12. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING






(a) Using SST, install the washer and bearing (outer race).
SST: 09950-00020
09951-00890
09951-01030
HINT: First, fit a washer of the same thickness as the removed washer, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

13. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING






(a) Using SST and a press, press in the bearing (inner race).
SST: 09506-35010
14. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION
15. INSTALL FRONT DIFFERENTIAL CASE
16. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER






(a) Install the differential cross shaft bearing retainer and differential support with the 14 bolts.
for bolt A - Torque: 65 Nm (633 kgf-cm, 48 ft-lbf)
for bolt B - Torque: 155 Nm (1581 kgf-cm, 114 ft-lbf)
17. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING






(a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it.
SST: 09316-60011
09316-00041
18. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
19. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD






(a) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
(b) Coat the threads of the nut with hypoid gear oil.






(c) Using SST to hold the companion flange.
SST: 09330-00021
09330-00030
(d) Tighten the nut until the standard preload is reached.
Torque: 451 Nm (4599 kgf-cm, 332 ft-lbf) or less
NOTE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





(e) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Standard preload (at starting):





If necessary, disassemble and inspect the differential assembly.
20. ADJUST BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION






(a) Using SST and a dial indicator, measure the ring gear backlash.
SST: 09564-33010
Standard backlash:
0.17 to 0.27 mm (0.00670 to 0.01064 in.)
If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount.
- There should be no clearance between the plate washer and differential case.
- Make sure that there is ring gear backlash.

Washer thickness:






21. 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 0.20 to 0.63 N*m (3 to 6 kgf*cm, 2 to 5 in.*lbf)
If necessary, disassemble and inspect the differential.
22. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Remove the 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 to the differential carrier.






(d) Install the differential cross shaft bearing retainer and front differential front support assembly LH with the 14 bolts.
for bolt A - Torque: 65 Nm (633 kgf-cm, 48 ft-lbf)
for bolt B - Torque: 155 Nm (1581 kgf-cm, 114 ft-lbf)
(e) Hold the companion flange firmly and rotate the ring gear in both directions.
(f) Remove the differential case, side bearing retainer and differential case.
(g) Inspect the tooth contact pattern.





If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction.
Washer thickness:






23. REMOVE FRONT DRIVE PINION FRONT COMPANION FLANGE SUB-ASSEMBLY

24. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
25. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

26. REMOVE FRONT DIFFERENTIAL CASE

27. REMOVE DIFFERENTIAL DRIVE PINION

28. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING
29. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer.
30. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION
31. INSTALL FRONT DIFFERENTIAL CASE
32. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER






(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the side bearing retainer as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT: Install the side bearing retainer within 10 minutes of applying seal packing.





(d) Install the front differential cross shaft bearing retainer and front differential front support assembly LH with the 11 bolts (A), and 3 bolts (B).
for bolt A - Torque: 65 Nm (633 kgf-cm, 48 ft-lbf)
for bolt B - Torque: 155 Nm (1581 kgf-cm, 114 ft-lbf)
33. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING






(a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it.
SST: 09316-60011
09316-00041
34. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
35. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL






(a) Using SST and a hammer, tap in a new oil seal.
SST: 09502-12010
SST: 09316-60011
09316-00041
Standard oil seal depth:
5.6 to 6.6 mm (0.221 to 0.260 in.)
(b) Coat the lip of the oil seal with MP grease.
36. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT






(a) Using SST, install the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
37. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD






(a) Using SST to hold the companion flange.
SST: 09330-00021
09330-00030
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Install the nut by tightening it until the standard preload is reached.
Torque: 451 Nm (4599 kgf-cm, 332 ft-lbf) 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 specification, replace the bearing spacer.
If the preload is less than the specification, 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: 451 Nm (4599 kgf-cm, 332 ft-lbf)
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
HINT: Do not loosen the nut to reduce the preload.

38. INSPECT TOTAL PRELOAD






(a) With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure the total preload.
Standard total preload (at starting):
Standard drive pinion preload plus 1.33 to 2.13 N*m (14 to 21 kgf*cm 12 to 18 in.*lbf)
39. INSPECT BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION






(a) Using SST and a dial indicator, measure the ring gear backlash.
SST: 09564-33010
Standard backlash:
0.17 to 0.27 mm (0.00670 to 0.0106 in.)
40. INSPECT RUNOUT OF 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.
41. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT






(a) Using a chisel and hammer, stake the nut.
42. INSTALL DIFFERENTIAL SIDE GEAR SHAFT 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: 09608-32010
(b) Coat the lip ofl the oil seal with MP grease.
Standard oil seal depth:
-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)
43. 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, install the side gear inter shaft onto the differential case.
(c) Check that there is 2 to 3 mm (0.0788 to 0.118 in.) of play in the axial direction.
(d) Check that the side gear inter shaft does not come out when trying to pull it out by hand.
44. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY






(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and bearing retainer.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the bearing retainer as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT: Install the differential tube within 10 minutes of applying seal packing.

(d) Install the differential tube onto the bearing retainer.






(e) Clean the threads of 4 new bolts and the retainer bolt holes with toluene or trichloroethylene.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf) or less
45. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR






(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT: Install the actuator within 10 minutes of applying seal packing.





(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 to 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)