Front Differential Carrier Assembly: Reassembly

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL DIFFERENTIAL RING GEAR
1. Clean the differential ring gear set bolt hole
2. Heat the ring gear to approximately 100°C (212°F) in boiling water.
  CAUTION: Use thick gloves to protect your hands as the ring gear is hot.
  
  Fig 1: Heating Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Carefully take the ring gear out of the boiling water
4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
  HINT.
  
  Align the matchmarks, differential case bolt holes and ring gear screw holes
  
  Fig 2: Identifying Ring Gear And Differential Case Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Hold the differential case in a vise between aluminum plates.
  NOTE: Do not overtighten the vise.
  
  Fig 3: Identifying Differential Case In Vise Between Aluminum Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply adhesive to the threads and flanges of 10 new ring gear set bolts.
  Torque: 97 N*m (989 kgf*cm, 72 ft.*lbf)
  
  Adhesive:
  
  Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
  NOTE:
  - Tighten the bolts after the ring gear has sufficiently cooled down.
  - Install the differential case bolts by tightening diametrically opposite pairs uniformly in several passes.
    
    Fig 4: Applying Adhesive To Ring Gear Set Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE
1. Using SST, a bolt, nut, and washer, install the bearing outer race to the differential carrier.
  SST 09950-60020(09951-00730,09951-00810)
  
  NOTE: Do not apply hypoid gear oil to a new bearing.
  
  HINT
  
  If there are not enough threads, add another SST accordingly.
  
  Fig 5: Installing Front Drive Pinion Rear Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE
1. Install the adjust shim to the differential carrier.
  HINT:
  
  Select a adjusting shim of the same thickness as the one removed.
2. Using SST, a bolt, nut, and washer, install the bearing outer race to the differential carrier.
  SST 09950-60020 (09951 -00730, 09951 -00810)
  
  NOTE: Do not apply hypoid gear oil to a new bearing.
  
  Fig 6: Installing Front Drive Pinion Front Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE
1. Using SST and a press, press in the front drive pinion front tapered roller bearing inner race to the drive pinion.
  SST 09309-14020
  
  NOTE: Do not apply hypoid gear oil to a new bearing.
  
  Fig 7: Installing Front Drive Pinion Front Tapered Roller Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE BEARING OUTER RACE LH
1. Remove the differential carrier from the overhaul attachment.
2. Install the differential case washer to the differential carrier.
  HINT:
  - If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential case washer first.
  - If the drive pinion, ring gear or differential case are reused, select and install a differential case washer with the same thickness as the one before the disassembly first
3. Using SST and a press, press in the case bearing outer race to the differential carrier.
  SST 09950-60020 (09951 -00680, 09951 -00790, 09952-06010), 09950-70010 (09951-07100)
  
  NOTE: Do not apply hypoid gear oil to a new bearing.
  
  Fig 8: Installing Front Differential Case Bearing Outer Race LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE BEARING OUTER RACE RH
1. Install the differential case washer to the differential carrier retainer.
  HINT:
  - If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential case washer first
  - If the drive pinion, ring gear or differential case are reused, select and install a differential case washer with the same thickness as the one before the disassembly first
2. Using SST and a press, press in the case bearing outer race to the differential carrier retainer.
  SST 09950-60020 (09951 -00790, 09951 -00890, 09952-06010), 09950-70010 (09951-07100)
  
  NOTE: Do not apply hypoid gear oil to a new bearing.
  
  Fig 9: Installing Front Differential Case Bearing Outer Race RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
1. Using SST and a press, insert a new dust deflector into the companion flange
  SST 09612-30012, 09950-70010 (09951 -07100)
  NOTE:
  - Slowly press in the dust deflector but not excessively.
  - If any burrs remain after pressing in the deflector, remove them.
    
    Fig 10: Installing Front Differential Dust Deflector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST DRIVE PINION PRELOAD
1. Fix the differential carrier with an attachment
2. Install the drive pinion to the differential carrier, and then install the bearing inner race and oil slinger while supporting the drive pinion by hand.
  NOTE:
  - Do not apply hypoid gear oil to a new bearing.
  - Do not drop the drive pinion.
  HINT:
  
  Install the spacer and oil seal after performing the ring gear tooth contact pattern inspection adjustment.
  
  Fig 11: Identifying Bearing Inner Race And Oil Slinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the companion flange.
  SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
  NOTE:
  - As a bearing spacer is not installed, if SST is tightened excessively, SST, the companion flange, and drive pinion will be damaged.
  - Support the drive pinion by hand until SST is installed.
  - Be careful not to drop the drive pinion.
  HINT:
  - Before using SST center bolt, apply hypoid gear oil to its threads and tip.
  - Install the companion flange so that there is some free play in the drive pinion.
4. Remove SST.
5. Using SST and a torque wrench, tighten the flange nut little by little until it reaches the specified preload.
  SST 09213-58013, 09330-00021, 09229-55010
  
  Maximum torque:
  
  490 N*m (4996 kgf*cm, 361 ft.*lbf)
  NOTE:
  - Tighten the nut with a force Of 100 N*m (1020 kgf*cm. 74 in.*lbf) while checking the starting torque of the drive pinion.
  - As the bearing spacer is not installed, tighten the flange nut little by little. Do not overtighten the nut.
  - Do not overtighten the nut, as the threads will become damaged.
  - Coat the threads the flange nut and drive pinion with hypoid gear oil LSD.
  - Perform the installment while supporting the overhaul attachment.
    
    Fig 13: Tightening Flange Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST and a torque wrench, measure the preload
  SST 09229-55010
  
  Standard drive pinion preload (at starting):
  
  New bearing:
  
  3.9 to 4.6 N*m (40 to 46 kgf cm, 35 to 40 in.*lbf)
  
  Reused bearing:
  
  2.7 to 3.2 N*m (28 to 32 kgf*cm, 24 to 28 in.*lbf)
  
  Fig 14: Measuring Drive Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: For a more accurate measurement, rotate the bearing forward and backward before the inspection.
  
  HINT.
  
  Record the preload for total preload measurement.
INSTALL DIFFERENTIAL CASE
1. Remove the differential carrier from the overhaul attachment.
2. Install the differential case to the differential carrier.
  NOTE: Do not damage the case bearing and ring gear.
  
  Fig 15: Identifying Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH

Install the retainer to the differential carrier with the 11 bolts.
Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf)

Fig 16: Locating Differential Carrier Retainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the differential carrier to the overhaul attachment

Fig 17: Identifying Differential Carrier On Overhaul Stand
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Set a lever probe to a dial indicator Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle

Fig 18: Inserting Probe Into Drain Plug Hole
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand
SST 09564-50010

Standard backlash:

0.13 to 0.23 mm (0.00512 to 0.00905 in.)

HINT
- Measure at 3 or more areas around the circumference of the ring gear.
- Record the measured value, as it is used to select the differential case washer
- If the result is outside of the standard range, replace the washer with one of a different thickness in accordance with the following procedure.
- Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.
  
  Fig 19: Measuring Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a washer from the table until the backlash measured value is in the standard range

Washer thickness (LH)

WASHER THICKNESS REFERENCE

Thickness mm (in)	Thickness mm (in)	Thickness mm (in.)
2.11 to 2.13 (0.0831 to 0 0839)	2.43 to 2.45 (0.0957 to 0.0965)	2.75 to 2.77 (0.1083 to 0.1091)
2.13 to 2.15 (0.0839 to 0.0846)	2.45 to 2.47 (0.0965 to 0 0972)	2.77 to 2.79 (0 1091 to 0.1098)
2.15 to 2 17 (0.0846 to 0.0854)	2.47 to 2.49 (0.0972 to 0 0980)	2.79 to 2.81 (0 1098 to 0.1106)
2.17 to 2.19 (0.0854 to 0.0862)	2.49 to 2.51 (0.0980 to 0 0988)	2.81 to 2.83 (0 1106 to 0.1114)
2.19 to 2.21 (0 0862 to 0.0870)	2.51 to 2.53 (0.0988 to 0.0996)	2.83 to 2.85 (0.1114 to 0.1122)
2 21 to 2.23 (0 0870 to 0 0878)	2 53 to 2 55 (0 0996 to 0.1004)	2.85 to 2.87 (0.1122 to 0.1130)
2.23 to 2.25 (0.0878 to 0.0886)	2.55 to 2 57 (0.1004 to 0.1012)	2 87 to 2.89 (0.1130 to 0 1138)
2.25 to 2 27 (0 0886 to 0.0894)	2.57 to 2 59 (0 1012 to 0.1020)	2 89 to 2 91 (0.1138 to 0 1146)
2.27 to 2.29 (0.0894 to 0.0902)	2.59 to 2.61 (0.1020 to 0.1028)	2.91 to 2.93 (0 1146 to 0.1154)
2.29 to 2 31 (0 0902 to 0.0909)	2.61 to 2.63 (0.1028 to 0.1035)	2.93 to 2.95 (0.1154 to 0.1161)
2.31 to 2.33 (0.0909 to 0 0917)	2.63 to 2.65 (0.1035 to 0 1043)	2.95 to 2 97 (01161 to 0.1169)
2.33 to 2.35 (0 0917 to 0 0925)	2.65 to 2.67 (0 1043 to 0 1051)	2 97 to 2.99 (0.1169 to 0.1177)
2.35 to 2.37 (0.0925 to 0.0933)	2.67 to 2.69 (0.1051 to 0.1059)	2.99 to 3.01 (0 1177 to 0.1185)
2.37 to 2 39 (0.0933 to 0.0941)	2 69 to 2.71 (0.1059 to 0.1067)	3.01 to 3.03 (0.1185 to 0.1193)
2.39 to 2 41 (0.0941 to 0 0949)	2 71 to 2.73 (0.1067 to 0 1075)	3 03 to 3 05 (01193 to 01201)
2.41 to 2.43 (0 0949 to 0.0957)	2.73 to 2.75 (0.1075 to 0.1083)	-

Washer thickness (RH)

WASHER THICKNESS REFERENCE

Thickness mm (in.)	Thickness mm (in.)	Thickness mm (in.)
2 09 to 2.11 (0 0823 to 0 0831)	2 43 to 2.45 (0.0957 to 0.0965)	2.77 to 2 79 (0.1091 to 0 1098)
2.11 to 2.13 (0.0831 to 0.0839)	2.45 to 2.47 (0 0965 to 0.0972)	2 79 to 2.81 (0.1098 to 0 1106)
2.13 to 2 15 (0.0839 to 0.0847)	2 47 to 2 49 (0.0972 to 0.0980)	2.81 to 2 83 (0.1106 to 0.1114)
2.15 to 2.17 (0 0847 to 0.0854)	2.49 to 2.51 (0.0980 to 0.0988)	2.83 to 2.85 (0.1114 to 0.1122)
2.17 to 2.19 (0.0854 to 0 0862)	2.51 to 2.53 (0.0988 to 0.0996)	2.85 to 2.87 (0.1122 to 0.1130)
2 19 to 2.21 (0.0862 to 0.0870)	2 53 to 2.55 (0.0996 to 0 1004)	2.87 to 2.89 (0.1130 to 0.1138)
2 21 to 2.23 (0.0870 to 0.0878)	2.55 to 2.57 (0.1004 to 0.1012)	2.89 to 2.91 (0.1138 to 0.1146)
2.23 to 2 25 (0.0878 to 0.0886)	2.57 to 2.59 (0.1012 to 0.1020)	2.91 to 2.93 (0.1146 to 0.1154)
2.25 to 2.27 (0.0886 to 0.0894)	2.59 to 2.61 (0.1020 to 0.1028)	2.93 to 2.95 (0 1155 to 0.1161)
2.27 to 2.29 (0.0894 to 0.0902)	2.61 to 2 63 (0.1028 to 0.1035)	2.95 to 2.97 (0.1161 to 0.1169)
2.29 to 2.31 (0 0902 to 0 0909)	2.63 to 2.65 (0.1035 to 0.1043)	2.97 to 2.99 (0.1169 to 0.1177)
2.31 to 2.33 (0.0909 to 0.0917)	2.65 to 2.67 (0.1043 to 0 1051)	2.99 to 3.01 (0 1177 to 0 1185)
2.33 to 2 35 (0.0917 to 0 0925)	2.67 to 2.69 (0.1051 to 0.1059)	3.01 to 3 03 (0.1185 to 0.11929)
2 35 to 2.37 (0 0925 to 0 0933)	2.69 to 2.71 (0 1059 to 0 1067)	3 03 to 3 05 (01193 to 01201)
2.37 to 2.39 (0 0933 to 0 0941)	2 71 to 2.73 (0.1067 to 0.1075)	3.05 to 3.07 (0.1201 to 0.1209)
2 39 to 2.41 (0.0941 to 0.0949)	2.73 to 2 75 (0.1075 to 0.1083)	-
2.41 to 2.43 (0.0949 to 0.0957)	2.75 to 2.77 (0.1083 to 0 1091)	-

HINT

Make sure to increase the thickness of the LH and RH differential case washer by the same amount each time until the backlash is in the standard range
Perform the tooth contact pattern inspection for the differential ring gear and drive pinion The results will be used as a reference for selecting the differential case washer LH and RH.
When adjusting the backlash, adjust to within 0 18 mm (0 00709 in) of the average of the measurements

INSPECT AND ADJUST TOTAL PRELOAD
1. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
  SST 09229-55010
  
  Standard total preload:
  
  New bearing:
  
  Drive pinion preload plus 0.7 to 0.9 N*m (7 to 9 kgf*cm, 6 to 7 in.*lbf)
  
  Reused bearing:
  
  Drive pinion preload plus 0.5 to 0.6 N*m (5 to 6 kgf*cm, 4 to 5 in.*lbf)
  
  Fig 20: Measuring Drive Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - When the value is outside the standard range, adjust using the differential case washer on the ring gear tooth side
  - When the value is less than the lower limit of the standard range, replace the differential case washer with a thicker one.
  - When the value is more than the upper limit of the standard range, replace the differential case washer with a thinner one.
  - For reassembly purposes, record the measured value.
2. Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle
  
  Fig 21: Inserting Probe Into Drain Plug Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand
  SST 09564-50010
  
  Standard backlash:
  
  0.13 to 0.23 mm (0.00512 to 0.00905 in.)
  
  HINT
  - Measure at 3 or more areas around the circumference of the ring gear.
  - If the backlash is not in the standard range, increase the LH and RH differential case washer by the same amount until the backlash is in the standard range.
  - Record the measured value and use it when selecting the differential case washer
    
    Fig 22: Measuring Ring Gear Backlash
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Perform the tooth contact pattern inspection for the differential ring gear and drive pinion The results will be used as a reference for selecting the differential case washer LH and RH.
  - When adjusting the backlash, adjust to within 0.18 mm (0.00709 in.) of the average of the measurements.
4. Recheck the total preload.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Remove the differential carrier from the overhaul attachment.
Remove the 11 bolts and retainer from the differential carrier

Fig 23: Locating Differential Carrier Retainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the differential case from the differential carrier.
NOTE: Do not damage the case bearing and ring gear.

Fig 24: Identifying Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

Fig 25: Applying Coat Of Prussian Blue On Differential Ring Gear Teeth
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the differential case to the differential carrier.
NOTE: Do not damage the case bearing and ring gear.

Fig 26: Identifying Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the retainer to the differential carrier with the 11 bolts.
Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf)

Fig 27: Locating Differential Carrier Retainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Rotate the companion flange several times in the forward and backward rotation directions.

Fig 28: Rotating Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 11 bolts and retainer from the differential carrier

Fig 29: Locating Differential Carrier Retainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the differential case from the differential carrier
NOTE: Do not damage the case bearing and ring gear.

Fig 30: Identifying Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect the tooth contact pattern.

Fig 31: Identifying Tooth Contact Pattern
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The patterns indicated by the Prussian blue are the tooth contact locations

NOTE: Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.

If the tooth contact is not proper, select a drive pinion spacer adjust shim from the table and perform the tooth contact pattern inspection again.

NOTE:

It is possible for the backlash to be adjusted within the standard range in instances of face contact and flank contact.
If the thickness of the drive pinion spacer adjust shim changes, perform the backlash adjustment and inspect the total preload.

Fig 32: Identifying Adjust Shim
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Adjust shim thickness

SHIM THICKNESS REFERENCE

Thickness mm (in.)	Thickness mm (in)	Thickness mm (in.)
0.09 to 1.01 (0.0354 to 0 0398)	1.17 to 1.19 (0.0461 to 0.0469)	1.35 to 1.37 (0.0531 to 0.0539)
1.01 to 1.03 (0.0398 to 0.0406)	1.19 to 1.21 (0.0469 to 0.0476)	1.37 to 1.39 (0.0539 to 0.0547)
1.03 to 1 05 (0.0406 to 0.0413)	1.21 to 1.23 (0.0476 to 0.0484)	1 39 to 1.41 (0.0547 to 0.0555)
1.05 to 1.07 (0.0413 to 0.0421)	1.23 to 1.25 (0 0484 to 0.0492)	1.41 to 1.43 (0.0555 to 0.0563)
1.07 to 1 09 (0.0421 to 0 0429)	1.25 to 1.27 (0.0492 to 0.0500)	1.43 to 1.45 (0.0563 to 0.0571)
1.09 to 1.11 (0 0429 to 0.0437)	1.27 to 1.29 (0.0500 to 0.0508)	1.45 to 1.47 (0.0571 to 0.0579)
1.11 to 1 13 (0.0437 to 0 0445)	1 29 to 1.31 (0 0508 to 0.0516)	1 47 to 1.49 (0.0579 to 0.0587)
1.13 to 1.15 (0.0445 to 0.0453)	1 31 to 1.33 (0 0516 to 0.0524)	-
1.15 to 1 17 (0 0453 to 0.0461)	1.33 to 1 35 (0.0524 to 0 0531)	-

REMOVE DIFFERENTIAL CASE
1. Remove the 11 bolts and retainer from the differential carrier.
  
  Fig 33: Locating Differential Carrier Retainer Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the differential case from the differential carrier
  NOTE: Do not damage the case bearing and ring gear.
  
  Fig 34: Identifying Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
1. Install the differential carrier to the overhaul attachment
2. Using SST to hold the flange, remove the flange nut.
  SST 09213-58013, 09330-00021, 09229-55010
  
  NOTE: Perform the removal while supporting the overhaul attachment.
  
  Fig 35: Removing Flange Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY
1. Using SST, remove the companion flange from the differential carrier.
  SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
  
  HINT:
  
  Before using SST center bolt, apply hypoid gear oil to its threads and tip.
  
  Fig 36: Removing Companion Flange From Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Remove the oil slinger from the differential carrier.
  
  Fig 37: Identifying Front Differential Drive Pinion Oil Slinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL DRIVE PINION
1. Remove the differential carrier together with the overhaul attachment from the engine stand.
  
  Fig 38: Identifying Differential Carrier With Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the differential carrier to an overhaul stand, etc., as shown in the illustration.
  
  Fig 39: Identifying Differential Carrier Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a press, press out the drive pinion and bearing inner race.
  NOTE: Do not drop the drive pinion and bearing inner race.
  
  Fig 40: Removing Drive Pinion And Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the differential carrier to the overhaul attachment as it was installed previously
5. Install the differential carrier together with overhaul attachment to the engine stand.
INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Install a new drive pinion bearing spacer to the drive pinion.
  
  Fig 42: Identifying Front Differential Drive Pinion Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE
1. Using SST and the companion flange, press the bearing inner race into the differential carrier
  SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
  NOTE:
  - As the drive pinion is supported by hand until SST is installed, be careful not to drop the drive pinion.
  - Apply grease to the threads and tip of SST center bolt before use.
2. Using SST, remove the companion flange from the differential carrier
  HINT:
  
  Before using SST center bolt, apply hypoid gear oil to its threads and tip.
  
  Fig 43: Installing Front Drive Pinion Rear Tapered Roller Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Install the oil slinger to the differential carrier.
  
  Fig 44: Identifying Front Differential Drive Pinion Oil Slinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
1. Using SST and a hammer, tap in a new oil seal
  SST 09309-36010,09502-24010
  
  Standard depth:
  
  6.2 to 7.2 mm (0.244 to 0.283 in.)
  NOTE:
  - Using a vernier caliper, measure the depth of the oil seal.
  - Measure at 3 or more areas around the circumference of the oil seal.
  - Make sure the difference between the maximum and minimum measured values is less than 0.75 mm (0.0295 in.), as a greater difference may lead to oil leaks.
  - Tap the oil seal uniformly so that the oil seal is straight.
  - Do not excessively tap the oil seal.
    
    Fig 45: Installing Front Differential Carrier Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  HINT:
  
  First, uniformly tap in the oil seal until it is flush with the edge of the carrier, then tap it little by little until the depth is within the standard range.
2. Apply MP grease to the lip of the oil seal.
INSTALL FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Install the oil deflector to the differential carrier with the 2 bolts
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 46: Locating Front Differential Breather Plug Oil Deflector Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY
1. Using SST, install the companion flange to the drive pinion
  SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
  
  NOTE: Do not insert the companion flange excessively as the preload will be adjusted in the following procedure.
  
  HINT.
  
  Before using SST center bolt, apply hypoid gear oil to its threads and tip
  
  Fig 47: Installing Companion Flange To Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE PINION PRELOAD
1. Coat the threads of a new drive pinion companion flange front nut with hypoid gear oil LSD
2. Using SST and a torque wrench, tighten the drive pinion companion flange front nut while checking the preload.
  SST 09213-58013, 09330-00021, 09229-55010
  
  Maximum torque:
  
  490 N*m (4996 kgf*cm, 361 ft.*lbf)
  NOTE:
  - Tighten the flange nut little by little to reach the specified preload, being careful not to exceed the maximum torque.
  - Do not overtighten the nut, as the threads will become damaged.
  - Measure the preload after rotating the companion flange several times in the forward and backward directions to make sure the bearing is operating correctly.
  - Perform the installation while supporting the overhaul attachment.
    
    Fig 48: Tightening Flange Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a torque wrench, measure the drive pinion preload.
  SST 09229-55010
  
  HINT.
  
  Record the drive pinion preload for the total preload inspection.
  
  Fig 49: Measuring Drive Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard drive pinion preload (at starting):
  
  New bearing:
  
  3.9 to 4.6 N*m (40 to 46 kgf*cm, 35 to 40 in.*lbf)
  
  Reused bearing:
  
  2.7 to 3.2 N*m (28 to 32 kgf*cm, 24 to 28 in.*lbf)
  
  NOTE: The bearing spacer is made of plastic and changes shape when used. If the starting torque of the drive pinion is exceeded by mistake, make sure to replace the bearing spacer with a new one.
  
  HINT:
  - If the preload is insufficient, tighten the nut 5 to 10° at a time until the preload is in the standard range.
  - If the tightening torque of the flange nut exceeds the specified torque but the preload is still insufficient, loosen the flange nut. Then check if the flange nut and drive pinion threads are damaged.
  - If there are no problems, replace the bearing spacer, apply hypoid gear oil LSD to the threads of the drive pinion companion flange front nut and repeat the procedure above.
INSTALL NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY
1. Remove the differential carrier from the overhaul attachment.
2. Install the differential case to the differential carrier.
  NOTE: Do not damage the case bearing and ring gear.
  
  Fig 50: Identifying Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY
1. Remove the seal packing attached on the differential carrier and side bearing retainer using a scraper and wire brush
  NOTE: Do not scratch the fitting surface.
2. Check that there is no foreign matter or damage on the installation surface of the side bearing retainer.
3. Apply seal packing to the differential carrier as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent
  
  Fig 51: Applying Seal Packing To Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
  - Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.
  - Install the differential carrier cover within 3 minutes of application.
4. Install the retainer with the 11 bolts.
  Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf)
  
  NOTE: Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.
  
  Fig 52: Locating Differential Carrier Retainer Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Set the differential carrier to an overhaul stand as shown in the illustration.
  
  Fig 53: Identifying Differential Carrier On Overhaul Stand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL BREATHER PLUG
1. Install the breather plug to the differential carrier
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 54: Locating Front Differential Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TOTAL PRELOAD
1. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact
  SST 09229-55010
  
  Standard total preload:
  
  New bearing:
  
  Drive pinion preload plus 0.7 to 0.9 N*m (7 to 9 kgf*cm, 6 to 7 in.*lbf)
  
  Reused bearing:
  
  Drive pinion preload plus 0.5 to 0.6 N*m (5 to 6 kgf*cm, 4 to 5 in.*lbf)
  
  Fig 55: Measuring Drive Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.
  
  Fig 56: Inserting Probe Into Drain Plug Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
  SST 09564-50010
  
  Standard backlash:
  
  0.13 to 0.23 mm (0.00512 to 0.00905 in.)
  
  HINT.
  
  Measure at 3 or more areas around the circumference of the ring gear
  
  Fig 57: Measuring Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY
1. Wipe the inside surface of the companion flange with a cloth or equivalent and remove dirt and foreign matter.
2. Perform the vertical runout inspection.
  1. Set a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the companion flange.
  2. Measure the vertical runout of the companion flange.
    Maximum runout:
    
    0.12 mm (0.00472 in.)
    
    Fig 58: Measuring Runout Of Front Drive Pinion Companion Flange Front Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Perform the horizontal runout inspection.
  1. Set a dial indicator at a right angle to the surface of the companion flange as shown in the illustration.
  2. Measure the horizontal runout of the companion flange
    Maximum runout:
    
    0.08 mm (0.00314 in.)
STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
1. Using SST and a hammer, stake the flange nut.
  SST 09930-00010
  
  Fig 59: Staking Flange Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE OIL SEAL
1. LH:
  1. Using SST and a hammer, install a new oil seal LH.
    SST 09950-60010 (09951 -00570), 09950-70010 (09951-07100)
    
    Standard depth:
    
    -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)
    NOTE:
    Tap the oil seal uniformly so that the oil seal is straight.
    
    Do not excessively tap the oil seal.
    
    Make sure the difference between the maximum and minimum measured values is less than 0.57 mm (0.0224 in.), as a greater difference may lead to oil leaks.
    
    Fig 60: Installing Differential Case Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Apply MP grease to the lips of the oil seal.
2. RH:
  1. Using SST and a hammer, install a new oil seal RH.
    SST 09608-32010, 09950-70010 (09951 - 07100)
    
    Standard depth:
    
    1.0 to 2.0 mm (0.0394 to 0.0787 in.)
    NOTE:
    Tap the oil seal uniformly so that the oil seal is straight.
    
    Do not excessively tap the oil seal.
    
    Make sure the difference between the maximum and minimum measured values is less than 0.47 mm (0.0185 in.), as a greater difference may lead to oil leaks.
    
    Fig 61: Installing RH Differential Case Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Apply MP grease to the lips of the oil seal.
INSTALL FRONT DIFFERENTIAL FILLER PLUG
HINT

Perform this procedure as necessary
1. Using a 10 mm socket hexagon wrench, install a new gasket and filler plug to the differential carrier.
  Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
INSTALL FRONT DIFFERENTIAL DRAIN PLUG
HINT

Perform this procedure as necessary.
1. Using a 10 mm socket hexagon wrench, install a new gasket and drain plug to the differential carrier.
  Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY FROM OVERHAUL STAND
1. Remove the differential carrier from the overhaul attachment stand's.
  
  Fig 62: Identifying Differential Carrier On Overhaul Attachment Stand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002