REASSEMBLY

1. ASSEMBLE DIFFERENTIAL CASE

(a) Install the 2 side gear thrust washers to the side gears.

(b) Install the 2 side gears to the RH case.

(c) Install the 4 pinion gears and pinion gear thrust washers to the spider.

(d) Install the pinion gears with the spider to the RH case.

(e) Using a dial indicator, holding the side gear and spider, measure the side gear backlash. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) HINT: Measure at all 4 locations. Measure the backlash at the specification, and install a thrust washer of a different thickness. Standard thrust washer thickness: Thickness mm (in.) Thickness mm (in.) 0.9 (0.035) 1.2 (0.047) 1.0 (0.039) 1.3 (0.051) 1.1 (0.043) -

(f) Align the matchmarks on the LH and RH cases.

(g) Torque the 8 bolts uniformly a little at a time.

Torque:

47 N·m {480 kgf·cm, 35ft·lbf}

2. 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 install the ring gear to the differential case.

HINT:

Align the matchmarks on the ring gear and differential case.

(e) Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential cases are not misaligned.

(f) After the ring gear has cooled sufficiently, torque the 10 ring gear set bolts.

Torque:

97 N·m {985 kgf·cm, 71ft·lbf}

(g) Using a chisel and hammer, stake the 5 lock plates. HINT: Stake the claws of the lock plates to fix the bolts. For the claw contacting the protruding portion of the bolt in place, stake only the half of it along the tightening direction.

3. INSTALL FRONT DIFFERENTIAL CASE BEARING (a) Using SST and a press, install the 2 side bearings to the differential case. SST: 09223-15020 SST: 09950-60010 09951-00480

4. INSPECT RING GEAR RUNOUT

(a) Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.

(b) Install the assembled plate washers onto the side gear bearing.

(c) Install the differential case in the differential carrier.

HINT:

If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one.

(d) Align matchmarks on the bearing cap and differential carrier.

(e) Install and uniformly tighten the 4 bolts a little at a time.

(f) Using a dial indicator, measure the ring gear runout. Maximum runout: 0.07 mm (0.0028 in.)

(g) Remove the differential carrier.

5. INSTALL BEARING OUTER RACE (a) Using SST and a press, install the front bearing outer race. SST: 09950-60020 09951-00780 SST: 09950-70010 09951-07150 (b) Using SST and a press, install the rear bearing outer race. SST: 09950-60020 09951-00710 SST: 09950-70010 09951-07150

6. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Install the washer on the drive pinion.

HINT:

First fit a washer with the same thickness as the washer that was removed. Then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

(b) Using SST and a press, install the front bearing onto the drive pinion. SST: 09506-30012

7. TEMPORARILY ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Install the drive pinion and rear bearing.

HINT:

Assemble the spacer and oil seal after adjusting the gear contact pattern.

(b) Install the oil slinger.

(c) Using SST, install the companion flange. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 09956-03020

(d) Use SST to hold the flange and adjust the drive pinion preload by tightening the nut. SST: 09330-00021 NOTICE: Coat the nut and threads of the drive pinion with gear oil. 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. Standard preload (at start of torque): Bearing Preload New bearing 1.1 to 1.6 N*m (11 to 16 kgf*cm, 9.7 to 13.9 in.*lbf) Reused bearing 0.6 to 0.9 N*m (6 to 9 kgf*cm, 5.3 to 8.0 in.*lbf) HINT: Measure the total preload after turning the bearing clockwise and counterclockwise several times to make the bearing smooth.

8. INSTALL FRONT DIFFERENTIAL CASE

(a) Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.

(b) Install the differential case in the differential carrier.

9. ADJUST RING GEAR BACKLASH

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

HINT:

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, measure the side gear backlash while holding one pinion gear toward the differential case.

Standard backlash (reference):

0.13 mm (0.0051 in.)

(d) Select a plate washer for the back side ring gear, using the backlash as reference.

Standard side plate washer thickness:

(e) Select a ring gear teeth side plate washer so that there is no clearance between the outer race and case.

(f) Remove the plate washers and differential case.

(g) Install the plate washer into the ring gear back side of the carrier.

(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, measure the ring gear backlash. Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0070 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. HINT: There should be no clearance between the plate washer and case. Make sure that there is ring gear backlash.

10. ADJUST FRONT DIFFERENTIAL CASE BEARING

(a) Remove the ring gear teeth side plate washer and measure the thickness.

(b) Using the backlash as a reference, install a new washer that is 0.06 to 0.09 mm (0.0024 to 0.0035 in.) thicker than the washer removed. HINT: Select a washer which can be pressed in 2/3 of the way with your finger.

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

(d) Align matchmarks on the bearing cap and differential carrier.

(e) Tighten the 4 bolts.

Torque:

85 N·m {870 kgf·cm, 63ft·lbf}

HINT:

Turn the ring gear several times to make the side bearings smooth.

(f) Using a dial indicator, adjust the ring gear backlash until it is within the specification. Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0070 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. HINT: The backlash will change by about 0.02 mm (0.0008 in.) corresponding to a 0.03 mm (0.0012 in.) change in the plate washer.

11. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the total preload.

Torque:

Standard total preload (at start of torque) -

0.4 to 0.6 N·m {4 to 6 kgf·cm, 3.5 to 5.2in·lbf} + drive pinion preload

12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

(b) Hold the companion flange firmly and rotate the ring gear in both directions.

(c) Inspect the tooth contact pattern.

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

  Standard washer thickness:

  Thickness mm (in.)	Thickness mm (in.)
  1.70 (0.0669)	2.03 (0.0799)
  1.73 (0.0681)	2.06 (0.0811)
  1.76 (0.0693)	2.09 (0.0822)
  1.79 (0.0704)	2.12 (0.0835)
  1.82 (0.0717)	2.15 (0.0847)
  1.85 (0.0729)	2.18 (0.0858)
  1.88 (0.0740)	2.21 (0.0870)
  1.91 (0.0752)	2.24 (0.0882)
  1.94 (0.0764)	2.27 (0.0894)
  1.97 (0.0776)	2.30 (0.0906)
  2.00 (0.0787)	2.33 (0.0918)

13. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

14. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

16. REMOVE BEARING OUTER RACE

17. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new bearing spacer.

18. INSTALL FRONT DIFFERENTIAL OIL STORAGE RING (a) Using SST and a hammer, install a new oil storage ring. SST: 09316-60011 09316-00011 SST: 09506-35010

19. INSTALL BEARING OUTER RACE (a) Using SST and a hammer, install the bearing outer race. SST: 09316-60011 09316-00011 SST: 09506-35010

20. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

21. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

22. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL

(a) Coat a new oil seal periphery with hypoid gear oil.

(b) Using SST and a hammer, install a new oil seal. SST: 09554-30011 Standard depth: 1.5 mm (0.0059 in.)

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

23. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, install the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

(b) Coat the threads of a new with hypoid gear oil LSD.

(c) Using SST to hold the flange, tighten the nut. SST: 09330-00021 Torque: 108 N·m {1,100 kgf·cm, 80ft·lbf}

24. ADJUST DRIVE PINION PRELOAD

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

Standard preload (at start of torque):

(b) If the preload is less than the specification, retighten the nut with a force of 13 N*m (130 kgf*cm, 9 ft.*lbf) at a time until the specified preload is reached. SST: 09330-00021 Torque: 370 N·m {3,773 kgf·cm, 273ft·lbf} or less If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not loosen the pinion nut to reduce the preload.

25. INSPECT TOTAL PRELOAD

26. INSPECT RING GEAR BACKLASH

27. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

28. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

29. STAKE DRIVE PINION NUT

30. INSTALL DIFFERENTIAL SIDE GEAR SHAFT BEARING (a) Using SST and a press, install the bearing to the side gear shaft. SST: 09502-12010 SST: 09950-60020 09951-00730 SST: 09950-70010 09951-07100

31. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY

(a) Clean surfaces with seal packing material attached to using gasoline or alcohol.

(b) Apply seal packing to the differential tube.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

HINT:

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

(c) Install the differential tube to the differential tube the with 4 bolts.

Torque:

105 N·m {1,070 kgf·cm, 77ft·lbf}

(d) Install the side gear shaft.

(e) Install a snap ring expander, install the snap ring.

(f) Using SST, install the snap ring. SST: 09350-30020 09350-07060

32. INSTALL SIDE GEAR SHAFT OIL SEAL

(a) Coat a new oil seal periphery with hypoid gear oil.

(b) SST and a hammer, install 2 new oil seals. SST: 09550-00032 SST: 09950-70010 09951-07150

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

33. INSTALL FRONT DIFFERENTIAL CARRIER COVER

(a) Install the oil seal deflector to the carrier cover with the 2 bolts.

Torque:

7.3 N·m {74 kgf·cm, 64in·lbf}

(b) Install the breather plug to the carrier cover.

(c) Remove any oil seal packing material and be careful not to drop oil on the contact surfaces of the differential carrier and carrier cover.

(d) Clean the contacting surfaces of any seal packing material using gasoline or alcohol.

(e) Apply seal packing to the carrier cover, as shown. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent HINT: Install the carrier cover within 10 minutes after applying seal packing.

(f) Install the differential carrier cover with the 9 bolts.

Torque:

47 N·m {475 kgf·cm, 34ft·lbf}