Toyota Highlander manuals

Toyota Highlander Service Manual: Differential carrier ASSY rear (4WD)

Toyota Highlander Service Manual / Differential / Differential carrier ASSY rear (4WD)

OVERHAUL

HINT:

1. REMOVE REAR WHEEL

2. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) SST 09325-20010

3. REMOVE EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 )

4. REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 )

5. REMOVE REAR DIFFERENTIAL FILLER PLUG

(a) Using a hexagon wrench (10 mm), remove the filler plug and gasket.

6. REMOVE REAR DIFFERENTIAL DRAIN PLUG

(a) Using a hexagon wrench (10 mm), remove the drain plug and gasket, and drain the oil.

7. SEPARATE SPEED SENSOR REAR LH (SEE PAGE 30-45 )

8. SEPARATE SPEED SENSOR REAR RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

9. REMOVE REAR AXLE SHAFT LH NUT (SEE PAGE 30-45 ) SST 09930-00010

10. REMOVE REAR AXLE SHAFT RH NUT SST 09930-00010

HINT: Removal procedure of the RH side is the same as that of the LH side.

11. SEPARATE STRUT ROD ASSY REAR (SEE PAGE 27-13 )

12. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 )

13. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

14. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-18 )

15. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

16. REMOVE REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 )

17. REMOVE REAR DRIVE SHAFT ASSY RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

18. REMOVE REAR SUSPENSION MEMBER SUB-ASSY (SEE PAGE 27-18 )

19. REMOVE DIFFERENTIAL CARRIER ASSY REAR

REMOVE DIFFERENTIAL CARRIER ASSY REAR


(a) Support the differential carrier assy rear with a jack.

(b) Remove the 2 bolts and 2 lock nuts, and separate the rear differential support No.1 from the rear suspension member sub-assy.

REMOVE DIFFERENTIAL CARRIER ASSY REAR


(c) Remove the 3 bolts and differential carrier sub-assy rear from the rear suspension member sub-assy.

NOTICE: Be careful not to drop the differential carrier assy rear.

20. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.1

REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.1


HINT: Perform this operation only when the rear differential mount cushion No.1 is damaged.

(a) Using SST, remove the rear differential mount cushion No.1.

SST 09570-24010, 09316-12010

NOTICE:

21. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.2

REMOVE REAR DIFFERENTIAL MOUNT CUSHION


HINT: Perform this operation only when the rear differential mount cushion No.2 is damaged.

(a) Using SST, remove the rear differential mount cushion No.2.

SST 09570-24010, 09316-12010

NOTICE:

22. REMOVE REAR DIFFERENTIAL SUPPORT NO.1

REMOVE REAR DIFFERENTIAL SUPPORT NO.1


(a) Remove the 2 bolts, 2 lock nuts and rear differential support No.1 from the differential carrier sub-assy rear.

23. REMOVE REAR DIFFERENTIAL CARRIER COVER

 REMOVE REAR DIFFERENTIAL CARRIER COVER


(a) Remove the 8 bolts from the carrier cover.

(b) Using a brass bar and a hammer, separate the carrier cover from differential carrier sub-assy.

(c) Remove the breather plug from the differential carrier cover.

24. FIX DIFFERENTIAL CARRIER ASSY REAR

FIX DIFFERENTIAL CARRIER ASSY REAR


25. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


(a) Using a dial indicator, check the runout of the ring gear.

Maximum runout: 0.07 mm (0.0028 in.)

If the runout is greater than the maximum, replace the ring gear with a new one

26. INSPECT DIFFERENTIAL RING GEAR BACKLASH

 INSPECT DIFFERENTIAL RING GEAR BACKLASH


(a) Using a dial indicator, check the backlash of the ring gear.

Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.)

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

27. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

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 contact pattern.

If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.

28. INSPECT DIFFERENTIAL PINION AND SIDE GEAR BACKLASH

INSPECT DIFFERENTIAL PINION AND SIDE GEAR BACKLASH


(a) Using a dial indicator, check the backlash of the side gear while holding 1 pinion gear toward the differential case.

Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness (See step 52).

HINT: Measure the backlash of the side gear with the side gear shaft installed.

29. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR

INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR


(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

Maximum runout: 0.10 mm (0.0039 in.)

If the runout is greater than the maximum, replace the rear drive pinion companion flange sub-assy rear.

30. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


(a) Using a torque wrench, measure the preload of the drive pinion.

Preload (at starting): 0.6 to 0.9 N*m (6 to 9 kgf*cm, 5.2 to 7.8 in.*lbf)

If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.

HINT: This preload is within the backlash between the drive pinion and ring gear.

31. INSPECT TOTAL PRELOAD

 INSPECT TOTAL PRELOAD


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

Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf) If the total preload is not within the specification, adjust the total preload or repair as necessary.

HINT: Disassemble and inspect the differential as necessary.

32. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL

REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL


(a) Using SST, remove the 2 oil seals from the housing.

SST 09308-00010

33. REMOVE REAR DRIVE PINION NUT

REMOVE REAR DRIVE PINION NUT


(a) Using SST and a hammer, unstake the staked part of the nut.

SST 09930-00010

REMOVE REAR DRIVE PINION NUT


(b) Using SST to hold the flange, remove the nut.

SST 09330-00021

34. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR

 REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR


(a) Using SST, remove the companion flange.

SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020)

35. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


(a) Using SST and a press, remove the dust deflector.

SST 09950- 60010 (09951- 00360), 09950- 70010 (09951-07150), 09950-00020

36. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


(a) Using SST, remove the oil seal from the differential carrier.

SST 09308-10010

37. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

38. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


(a) Using SST, remove the front bearing from the drive pinion.

SST 09556-22010

39. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

40. REMOVE DIFFERENTIAL CASE ASSY

REMOVE DIFFERENTIAL CASE ASSY


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

(b) Remove the 4 bolts and 2 bearing caps.

REMOVE DIFFERENTIAL CASE ASSY


(c) Using SST and a hammer, remove the 2 plate washers.

SST 09504-2201 1

HINT: Measure the thickness of the plate washers and note it down.


(d) Remove the differential case assy and the 2 bearing outer races from the differential carrier.

HINT: Tag the 2 bearing outer races to show the location for reassembly.

41. REMOVE DIFFERENTIAL DRIVE PINION

42. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


(a) Using SST and a press, remove the rear bearing from the drive pinion.

SST 09950-00020

HINT: If either the drive pinion or ring gear is damaged, replace both as a set.

(b) Remove the plate washer.

43. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

 REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


(a) Using a brass bar and a hammer, remove the front bearing (outer race) from the carrier.

44. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


(a) Using a brass bar and a hammer, remove the rear bearing (outer race) from the carrier.

45. REMOVE DIFFERENTIAL RING GEAR

REMOVE DIFFERENTIAL RING GEAR


(a) Align matchmarks on the ring gear and differential case.

(b) Using a screwdriver and a hammer, unstake the 4 lock plates.

(c) Remove the 8 ring gear set bolts and 4 lock plates.

(d) Using a plastic hammer, tap on the ring gear to separate it from the differential case.

46. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSY

INSPECT RUNOUT OF DIFFERENTIAL CASE ASSY


(a) Install the differential case to the differential carrier.

(b) Install the right and left bearing caps with the 4 bolts.

Torque: 79 NVm (800 kgfVcm, 58 ftVlbf) (c) Using a dial indicator, measure the differential case runout.

Maximum case runout: 0.07 mm (0.0028 in.)

If the runout is greater than the maximum, replace the differential case assy with a new one.

(d) Remove the differential case.

47. REMOVE REAR DIFFERENTIAL CASE BEARING

REMOVE REAR DIFFERENTIAL CASE BEARING


(a) Using SST, remove the case bearing (LH) from the differential case.

SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04030, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00360)

48. REMOVE REAR DIFFERENTIAL CASE BEARING

REMOVE REAR DIFFERENTIAL CASE BEARING


(a) Using SST, remove the case bearing (RH) from the differential case.

SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04030, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00360)

49. REMOVE REAR DIFFERENTIAL PINION SHAFT

REMOVE REAR DIFFERENTIAL PINION SHAFT


(a) Using a pin punch (5 mm) and a hammer, remove the straight pin.

REMOVE REAR DIFFERENTIAL PINION SHAFT


(b) Remove the differential pinion shaft. [A] (c) Remove the 2 differential pinion gears. [B] (d) Remove the 2 differential pinion thrust washers. [C] (e) Remove the 2 side gears. [D] (f) Remove the 2 side gear thrust washers. [E]

50. INSPECT DIFFERENTIAL PINION AND SIDE GEAR

(a) Check that there is no damage to the differential pinion gear and side gear.

If the differential pinion gear and/or side gear is damaged, replace them with new ones.

51. INSPECT DIFFERENTIAL CASE

(a) Check that there is no damage to the differential case.

If the differential case is damaged, replace it.

52. INSTALL REAR DIFFERENTIAL PINION SHAFT

INSTALL REAR DIFFERENTIAL PINION SHAFT


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

(b) Install the 2 side gears, 2 differential pinion gears, 2 differential pinion thrust washers and differential pinion shaft to the differential case.

HINT: Align the holes of the differential case and differential pinion shaft.

53. ADJUST DIFFERENTIAL PINION GEAR BACKLASH

ADJUST DIFFERENTIAL PINION GEAR BACKLASH


(a) Measure the side gear backlash while holding 1 pinion gear toward the differential case.

Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.)

If the backlash is not within the specification, install the 2 side gear thrust washers of different thicknesses.

HINT: Refer to the following table to select 2 thrust washers.

Thrust washer thickness:

ADJUST DIFFERENTIAL PINION GEAR BACKLASH


ADJUST DIFFERENTIAL PINION GEAR BACKLASH


(b) Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.

(c) Using a chisel and a hammer, stake the outside of the differential case pin hole.

54. INSTALL DIFFERENTIAL RING GEAR

INSTALL DIFFERENTIAL RING GEAR


(a) Clean the contact surfaces of the differential case and ring gear.

(b) Heat the ring gear to approx. 100C (212F) 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.

INSTALL DIFFERENTIAL RING GEAR


(e) Align the matchmarks on the ring gear and differential case.

(f) Temporarily install 4 new lock plates and 8 bolts.

(g) After the ring gear cools down enough, torque the 8 bolts uniformly.

Torque: 97 N*m (989 kgf*cm, 71 ft*lbf)

HINT: Tighten the bolts, in diagonal order, a little at a time until they are all tightened.

INSTALL DIFFERENTIAL RING GEAR


(h) Using a chisel and a hammer, stake the 4 lock plates.

  1.  Stake one claw so that it is flush against the flat surface of the bolt.
  2.  As for the other claw, stake it against the surface of the bolt head so as to act as a stopper if the bolt starts to loosen.

55. INSTALL REAR DIFFERENTIAL CASE BEARING

INSTALL REAR DIFFERENTIAL CASE BEARING


(a) Using SST and a press, install the case bearing (RH) to the differential case.

SST 09636-20010

56. INSTALL REAR DIFFERENTIAL CASE BEARING

INSTALL REAR DIFFERENTIAL CASE BEARING


(a) Using SST and a press, install the case bearing (LH) to the differential case.

SST 09636-20010

57. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

 INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


(a) Install the differential case to the carrier, and install the 2 plate washers so that there is no play in the bearing.

(b) Install the 2 bearing caps with the 4 bolts.

Torque: 79 N*m (800 kgf*cm, 58 ft*lbf) (c) Using a dial indicator, measure the runout of the ring gear.

Maximum runout: 0.07 mm (0.0028 in.)

If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.

(d) Remove the 2 bearing caps, 2 plate washers and differential carrier.

58. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


(a) Using SST and a press, install the front bearing (outer race) to the carrier.

SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150)

59. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


(a) Using SST and a press, install the rear bearing (outer race) to the carrier.

SST 09950- 60020 (09951- 00710), 09950- 70010 (09951-07150)

60. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


(a) Install the removed plate washer to the drive pinion.

(b) Using SST and a press, install the rear bearing to the drive pinion.

SST 09506-30012

61. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

 ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


(a) Install the drive pinion and front bearing.

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

 ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


(b) Install the rear differential drive pinion oil slinger to the drive pinion.

 ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


(c) Using SST, install the companion flange.

SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020)

(d) Coat the threads of the nut with hypoid gear oil LSD.

 ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


(e) Using SST to hold the flange, torque the nut.

SST 09330-00021 Torque: 108 N*m (1,100 kgf*cm, 80 ft*lbf)

NOTICE:

 ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


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

Drive pinion preload (at starting):

New bearing: 1.1 to 1.7 N*m (11 to 17 kgf*cm, 9.6 to 14.8 in.*lbf) Reused bearing: 0.6 to 0.9 N*m (6 to 9 kgf*cm, 5.2 to 7.8 in.*lbf)

If the preload is not within the specification, adjust the differential drive pinion preload or repair as necessary.

62. INSTALL DIFFERENTIAL CASE ASSY

(a) Place the 2 bearing outer races on their respective bearings. Make sure the right and left races are not interchanged.

63. ADJUST DIFFERENTIAL RING GEAR BACKLASH

ADJUST DIFFERENTIAL RING GEAR BACKLASH


(a) Install the right and left bearing caps with the 4 bolts.

Torque: 79 N*m (800 kgf*cm, 58 ft*lbf)

HINT:

(b) Make snug the differential case bearing and thrust shim by tapping on the ring gear with a plastic hammer.

(c) Set the dial indicator perpendicular to the end of the ring gear face.

(d) While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.)

NOTICE: Measure it at 3 points or more on the ring gear periphery.

If the measured value is out of the specified value, select a proper thrust shim so that the backlash of the differential ring gear is within the value, and install it to the ring gear back side.

Washer thickness:

ADJUST DIFFERENTIAL RING GEAR BACKLASH


64. ADJUST TOTAL PRELOAD

(a) After adjusting the backlash of the differential ring gear, remove the teeth side thrust shim.

(b) Using a micrometer, measure the thickness of the removed thrust shim.

(c) Select a new thrust shim 0.06 to 0.09 mm (0.0024 to 0.0035 in.) which is thicker than the removed one.

HINT: Select a thrust shim which can be pressed in 2/3 rds of the way by finger.

ADJUST TOTAL PRELOAD


(d) Using SST and a plastic hammer, drive in the thrust shim.

SST 09504-2201 1

ADJUST TOTAL PRELOAD


(e) Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

NOTICE: Make sure the right and left bearing caps are not interchanged. (f) Tighten both bearing caps with the 4 bolts.

Torque: 79 N*m (800 kgf*cm, 58 ft*lbf)

ADJUST TOTAL PRELOAD


(g) Set the dial indicator to the end of the differential ring gear face.

(h) While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.

Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) (i) If the measured value is out of the specified value, adjust it by increasing or decreasing the thickness of both right and left thrust shims equally.

SST 09504-2201 1

ADJUST TOTAL PRELOAD


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

Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)

If the preload is not within the specification, adjust the total preload or repair as necessary.

65. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

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.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


(c) Inspect the tooth contact pattern.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


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

Washer thickness:

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


66. REMOVE REAR DRIVE PINION NUT (SEE STEP 33) SST 09330-00021

67. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (SEE STEP 34) SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

68. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

69. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (SEE STEP 38) SST 09556-22010

70. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new bearing spacer.

71. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


(a) Install the rear drive pinion front tapered roller bearing to the drive pinion.

72. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

v


(a) Install the rear differential drive pinion oil slinger to the drive pinion.

73. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


(a) Using SST and a hammer, install a new oil seal.

SST 09554-22010 Oil seal drive in depth: 2.0 0.3 mm (0.079 0.012 in.) (b) Apply MP grease to the oil seal lip.

74. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


(a) Using SST and a press, install a new dust deflector.

SST 09223-00010

NOTICE: Be careful not to damage the dust deflector.

75. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR

INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR


(a) Using SST, install the companion flange to the drive pinion.

SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020) (b) Coat the threads of a new nut with hypoid gear oil LSD.

INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR


(c) Using SST to hold the flange, torque the nut.

SST 09330-00021

Torque: 108 NVm (1,100 kgfVcm, 80 ftVlbf)

76. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


(a) Using a torque wrench, measure the preload of the drive pinion.

Preload (at starting): New bearing: 1.1 to 1.7 N*m (11 to 17 kgf*cm, 9.6 to 14.8 in.*lbf) Reused bearing: 0.6 to 0.9 N*m (6 to 9 kgf*cm, 5.2 to 7.8 in.*lbf)

Torque: 108 to 235 N*m (1,100 to 2,400 kgf*cm, 80 to 174 ftVlbf)

NOTICE: Do not loosen the pinion nut to reduce the preload.

HINT: This preload is within the backlash between the drive pinion and ring gear.

77. INSPECT TOTAL PRELOAD

INSPECT TOTAL PRELOAD


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

Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)

If the total preload is not within the specification, adjust the total preload or repair as necessary.

78. INSPECT DIFFERENTIAL RING GEAR BACKLASH

INSPECT DIFFERENTIAL RING GEAR BACKLASH


(a) Using a dial indicator, check the backlash of the ring gear.

Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.)

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

79. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR

INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR


(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

Maximum runout: 0.10 mm (0.0039 in.)

If the runout is greater than the maximum, replace the rear drive pinion companion flange sub-assy rear.

80. INSTALL REAR DRIVE PINION NUT

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

81. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL

INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL


(a) Using SST and a hammer, install 2 new oil seals.

SST 09550-00032, 09950-70010 (09951-07200)

Oil seal drive in depth: 0 0.5 mm (0 0.019 in.)

(b) Apply MP grease to the oil seal lip.

82. INSTALL REAR DIFFERENTIAL CARRIER COVER

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

Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)

(b) Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.

 INSTALL REAR DIFFERENTIAL CARRIER COVER


(c) Apply FIPG to the carrier.

FIPG: 08826-00090, THREE BOND 1281 or equivalent

HINT:

 INSTALL REAR DIFFERENTIAL CARRIER COVER


(d) Install the carrier cover with the 8 bolts.

Torque: 47 NVm (475 kgfVcm, 34 ftVlbf)

83. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO.1

v


(a) Using SST, install a new rear differential mount cushion No.1.

SST 09570-24010

NOTICE: Do not set the SST in the wrong direction.

HINT: Perform this operation only when the rear differential mount cushion No.1 replaced.

84. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO.2

INSTALL REAR DIFFERENTIAL MOUNT CUSHION


(a) Using SST, install a new rear differential mount cushion No.2.

SST 09570-24010

NOTICE: Do not set the SST in the wrong direction.

HINT: Perform this operation only when the rear differential mount cushion No.2 replaced.

85. INSTALL REAR DIFFERENTIAL SUPPORT NO.1

INSTALL REAR DIFFERENTIAL SUPPORT NO.1


(a) Install the rear differential support No.1 to the differential carrier assy rear with the 2 bolts and 2 lock nuts.

Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)

86. INSTALL DIFFERENTIAL CARRIER ASSY REAR

INSTALL DIFFERENTIAL CARRIER ASSY REAR


(a) Jack up the differential carrier assy rear and rear suspension member with a jack.

(b) Connect the rear differential support No.1 to the rear suspension member with 2 bolts and 2 lock nuts.

Torque: 137 NVm (1,400 kgfVcm, 101 ftVlbf)

INSTALL DIFFERENTIAL CARRIER ASSY REAR


(c) Install the differential carrier assy rear to the rear suspension member sub-assy with the 3 bolts.

Torque: 95 NVm (970 kgfVcm, 70 ftVlbf)

87. INSTALL REAR SUSPENSION MEMBER SUB-ASSY (SEE PAGE 27-18 )

88. INSTALL REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 )

89. INSTALL REAR DRIVE SHAFT ASSY RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

90. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-18 )

91. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

92. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 )

93. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

94. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 )

95. INSTALL REAR AXLE SHAFT LH NUT (SEE PAGE 30-45 ) SST 09930-00010

96. INSTALL REAR AXLE SHAFT RH NUT SST 09930-00010

HINT: Installation procedure of the RH side is the same as that of the LH side.

97. INSTALL SPEED SENSOR REAR LH (SEE PAGE 30-45 )

98. INSTALL SPEED SENSOR REAR RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

99. STABILIZE SUSPENSION (SEE PAGE 27-13 )

100. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 )

101. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-18 )

102. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

103. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 )

104. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH

HINT: Installation procedure of the RH side is the same as that of the LH side.

105. INSTALL EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 )

106. INSTALL EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 )

107. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 )

108. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) SST 09370-50010

109. INSTALL REAR DIFFERENTIAL DRAIN PLUG

(a) Using a hexagon wrench (10 mm), install the drain plug with a new gasket.

Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

110. ADD DIFFERENTIAL OIL

(a) Fill the rear differential carrier assy with hypoid gear oil.

Oil grade: Hypoid gear oil API GL-5

Recommended oil viscosity: Above -18C (0F) SAE 90 Below -18C (0F) SAE 80W or 80W-90 Capacity: 0.9 +- 0.05 liters (0.95 +- 0.05 US qts, 0.79 +- 0.04 lmp. qts)

111. INSPECT DIFFERENTIAL OIL (SEE PAGE 29-5 )

112. INSTALL REAR DIFFERENTIAL FILLER PLUG

(a) Using a hexagon wrench (10 mm), install the filler plug with a new gasket.

Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

113. INSTALL REAR WHEEL

Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)

114. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 )

115. CHECK FOR EXHAUST GAS LEAKS

116. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-763 )

Differential carrier assy rear (4wd)
REPLACEMENT HINT: Differential components (See page 29-3 ) Rear drive shaft components (See page 30-4 ) Replace the RH side following the same procedures as with the LH side. 1. REMOVE ...

Drive shaft / propeller shaft
...

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Your vehicle includes a variety of electronic features that can be personalized to your preferences. The settings of these features can be changed by the meter control switches, on the audio system screen or at your toyota dealer. Customizing vehicle features (audio system screen) Audio system ...

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