7. 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 align the matchmarks on the ring gear and differential case and set the ring gear onto the differential case. Then 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, remove the 10 bolts. Then apply adhesive to the 10 bolts and install them.

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

Adhesive:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

8. 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

9. 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 shaft bearing retainer.

(b) Using SST and a press, press the bearing (outer race) into 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 the bearing (outer race) into the differential carrier assembly.

SST: 09950-60020

09951-00890

SST: 09950-70010

09951-07150

10. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING

(a) Using SST, install the bearing (outer race). SST: 09950-00020 09951-00810 09951-00890

11. 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: After installing the washer, check the tooth contact pattern. If necessary, replace the washer with one of a different thickness.

12. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

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

13. INSTALL FRONT DIFFERENTIAL UNION

(a) Install the front differential union to the differential carrier.

14. INSTALL FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Install the 2 bolts and oil deflector. Torque: 7.0 N·m (71 kgf·cm, 62 in·lbf)

15. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

16. INSTALL FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

17. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

(a) Install the differential cross shaft bearing retainer and differential support with the 14 bolts. Torque: 65 N·m (633 kgf·cm, 48 ft·lbf) Torque: 155 N·m (1581 kgf·cm, 114 ft·lbf)

18. 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

19. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

20. 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, hold the companion flange. SST: 09330-00021 09330-00030

(d) Tighten the nut until the standard preload is reached.

Torque: 451 N·m (4599 kgf·cm, 332 ft·lbf)

NOTICE:

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): Bearing Specified Condition New 3.0 to 3.5 N*m (31 to 35 kgf*cm, 27 to 50 in.*lbf) Reused 2.1 to 2.5 N*m (22 to 24 kgf*cm, 19 to 21 in.*lbf)

If necessary, disassemble and inspect the differential assembly.

21. 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 0.0106 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 differential case. Make sure that there is ring gear backlash. Standard Plate Washer Thickness: Specified Condition Specified Condition 1.49 to 1.51 mm (0.0587 to 0.0594 in.) 1.93 to 1.95 mm (0.0760 to 0.0768 in.) 1.51 to 1.53 mm (0.0594 to 0.0602 in.) 1.95 to 1.97 mm (0.0768 to 0.0776 in.) 1.53 to 1.55 mm (0.0602 to 0.0610 in.) 1.97 to 1.99 mm (0.0776 to 0.0783 in.) 1.55 to 1.57 mm (0.0610 to 0.0618 in.) 1.99 to 2.01 mm (0.0783 to 0.0791 in.) 1.57 to 1.59 mm (0.0618 to 0.0626 in.) 2.01 to 2.03 mm (0.0791 to 0.0799 in.) 1.59 to 1.61 mm (0.0626 to 0.0634 in.) 2.03 to 2.05 mm (0.0799 to 0.0807 in.) 1.61 to 1.63 mm (0.0634 to 0.0642 in.) 2.05 to 2.07 mm (0.0807 to 0.0815 in.) 1.63 to 1.65 mm (0.0642 to 0.0650 in.) 2.07 to 2.09 mm (0.0815 to 0.0823 in.) 1.65 to 1.67 mm (0.0650 to 0.0657 in.) 2.09 to 2.11 mm (0.0823 to 0.0831 in.) 1.67 to 1.69 mm (0.0657 to 0.0665 in.) 2.11 to 2.13 mm (0.0831 to 0.0839 in.) 1.69 to 1.71 mm (0.0665 to 0.0673 in.) 2.13 to 2.15 mm (0.0839 to 0.0846 in.) 1.71 to 1.73 mm (0.0673 to 0.0681 in.) 2.15 to 2.17 mm (0.0846 to 0.0854 in.) 1.73 to 1.75 mm (0.0681 to 0.0689 in.) 2.17 to 2.19 mm (0.0854 to 0.0862 in.) 1.75 to 1.77 mm (0.0689 to 0.0697 in.) 2.19 to 2.21 mm (0.0862 to 0.0870 in.) 1.77 to 1.79 mm (0.0697 to 0.0705 in.) 2.21 to 2.23 mm (0.0870 to 0.0878 in.) 1.79 to 1.81 mm (0.0705 to 0.0713 in.) 2.23 to 2.25 mm (0.0878 to 0.0886 in.) 1.81 to 1.83 mm (0.0713 to 0.0720 in.) 2.25 to 2.27 mm (0.0886 to 0.0894 in.) 1.83 to 1.85 mm (0.0720 to 0.0728 in.) 2.27 to 2.29 mm (0.0894 to 0.0902 in.) 1.85 to 1.87 mm (0.0728 to 0.0736 in.) 2.29 to 2.31 mm (0.0902 to 0.0909 in.) 1.87 to 1.89 mm (0.0736 to 0.0744 in.) 2.31 to 2.33 mm (0.0909 to 0.0917 in.) 1.89 to 1.91 mm (0.0744 to 0.0752 in.) 2.33 to 2.35 mm (0.0917 to 0.0925 in.) 1.91 to 1.93 mm (0.0752 to 0.0760 in.) -

22. 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): Bearing Specified Condition New Standard drive pinion preload plus 1.6 to 2.4 N*m (17 to 24 kgf*cm, 15 to 21 in.*lbf) Reused Standard drive pinion preload plus 1.3 to 2.1 N*m (14 to 21 kgf*cm, 12 to 18 in.*lbf)

If necessary, disassemble and inspect the differential.

23. 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. Torque: 65 N·m (633 kgf·cm, 48 ft·lbf) Torque: 155 N·m (1581 kgf·cm, 114 ft·lbf)

(e) Hold the companion flange firmly and rotate it in both directions.

(f) Remove the 14 bolts, differential case, shaft bearing retainer and front support.

(g) Inspect the tooth contact pattern.

If the teeth are not engaged properly, use the following chart to select the appropriate drive pinion washer for correction.

Standard Drive Pinion Washer Thickness:

25. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

29. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING

30. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new bearing spacer.

31. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

32. INSTALL FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

33. 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 shaft bearing retainer.

(b) Wipe off any residual FIPG material on the contact surface using gasoline or alcohol.

(c) Apply seal packing to the shaft bearing retainer as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Standard Seal Diameter (A): 2.0 to 3.0 mm (0.0788 to 0.118 in.) HINT: Install the shaft 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 new bolts (B). Torque: 65 N·m (633 kgf·cm, 48 ft·lbf) Torque: 155 N·m (1581 kgf·cm, 114 ft·lbf)

34. 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

35. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

36. 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.

37. 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

38. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST, 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 N·m (4599 kgf·cm, 332 ft·lbf)

(d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Standard Preload (at Starting): Bearing Specified Condition New 3.0 to 3.5 N*m (31 to 35 kgf*cm, 27 to 50 in.*lbf) Reused 2.1 to 2.5 N*m (22 to 24 kgf*cm, 19 to 21 in.*lbf)

If the preload is more than the specification, replace the bearing spacer.

If the preload is less than the specification, tighten 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 N·m (4599 kgf·cm, 332 ft·lbf)

If the maximum torque is exceeded while tightening the nut, replace the bearing spacer and repeat the preload procedure.

HINT:

Do not loosen the nut to reduce the preload.

39. 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): Bearing Specified Condition New Standard drive pinion preload plus 1.6 to 2.4 N*m (17 to 24 kgf*cm, 15 to 21 in.*lbf) Reused Standard drive pinion preload plus 1.3 to 2.1 N*m (14 to 21 kgf*cm, 12 to 18 in.*lbf)

40. 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.)

41. 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: Runout Specified Condition Vertical runout 0.10 mm (0.00394 in.) Lateral runout 0.10 mm (0.00394 in.)

If the runout is more than the maximum, replace the companion flange.

42. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

(a) Using a chisel and hammer, stake the nut.

43. 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 of the oil seal with MP grease.

Standard oil seal depth:

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

44. INSTALL DIFFERENTIAL EXTENSION FLANGE TUBE

(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) Wipe off any residual FIPG material on the contact surface 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 Standard Seal Diameter (A): 2.0 to 3.0 mm (0.0788 to 0.118 in.) HINT: Install the differential tube within 10 minutes of applying seal packing.

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

(e) Install 4 new bolts. Torque: 65 N·m (663 kgf·cm, 48 ft·lbf)