16. ADJUST BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

(a) Using SST and a dial indicator, measure the ring gear backlash. SST: 09564-34010 Standard backlash: 0.1 to 0.2 mm (0.00394 to 0.00787 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. Washer Thickness: Thickness Thickness 1.55 to 1.57 mm (0.0610 to 0.0618 in.) 1.91 to 1.93 mm (0.0752 to 0.0760 in.) 1.57 to 1.59 mm (0.0618 to 0.0626 in.) 1.93 to 1.95 mm (0.0760 to 0.0768 in.) 1.59 to 1.61 mm (0.0626 to 0.0634 in.) 1.95 to 1.97 mm (0.0768 to 0.0776 in.) 1.61 to 1.63 mm (0.0634 to 0.0642 in.) 1.97 to 1.99 mm (0.0776 to 0.0783 in.) 1.63 to 1.65 mm (0.0642 to 0.0650 in.) 1.99 to 2.01 mm (0.0783 to 0.0791 in.) 1.65 to 1.67 mm (0.0650 to 0.0657 in.) 2.01 to 2.03 mm (0.0791 to 0.0799 in.) 1.67 to 1.69 mm (0.0657 to 0.0665 in.) 2.03 to 2.05 mm (0.0799 to 0.0807 in.) 1.69 to 1.71 mm (0.0665 to 0.0673 in.) 2.05 to 2.07 mm (0.0807 to 0.0815 in.) 1.71 to 1.73 mm (0.0673 to 0.0681 in.) 2.07 to 2.09 mm (0.0815 to 0.0823 in.) 1.73 to 1.75 mm (0.0681 to 0.0689 in.) 2.09 to 2.11 mm (0.0823 to 0.0831 in.) 1.75 to 1.77 mm (0.0689 to 0.0697 in.) 2.11 to 2.13 mm (0.0831 to 0.0839 in.) 1.77 to 1.79 mm (0.0697 to 0.0705 in.) 2.13 to 2.15 mm (0.0839 to 0.0846 in.) 1.79 to 1.81 mm (0.0705 to 0.0713 in.) 2.15 to 2.17 mm (0.0846 to 0.0854 in.) 1.81 to 1.83 mm (0.0713 to 0.0720 in.) 2.17 to 2.19 mm (0.0854 to 0.0862 in.) 1.83 to 1.85 mm (0.0720 to 0.0728 in.) 2.19 to 2.21 mm (0.0862 to 0.0870 in.) 1.85 to 1.87 mm (0.0728 to 0.0736 in.) 2.21 to 2.23 mm (0.0870 to 0.0878 in.) 1.87 to 1.89 mm (0.0736 to 0.0744 in.) 2.23 to 2.25 mm (0.0878 to 0.0886 in.) 1.89 to 1.91 mm (0.0744 to 0.0752 in.) 2.25 to 2.27 mm (0.0886 to 0.0894 in.)

17. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Standard Preload (at Starting): Bearing Specified Condition New 2.33 to 4.47 N*m (24 to 46 kgf*cm, 21 to 40 in.*lbf) Reused 1.79 to 3.34 N*m (18 to 34 kgf*cm, 16 to 30 in.*lbf)

If necessary, disassemble and inspect the differential.

18. 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 rear differential side bearing retainer with the 12 bolts. HINT: Tighten the bolts gradually, skipping to the bolt on the opposite side. Torque: 70 N·m (714 kgf·cm, 52 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:

20. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

24. REMOVE REAR DRIVE PINION FRONT RADIAL BALL BEARING

25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new bearing spacer.

26. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

27. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY

28. INSTALL REAR DIFFERENTIAL SIDE 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 rear differential side bearing retainer with the 12 bolts. HINT: Tighten the bolts gradually, skipping to the bolt on the opposite side. Torque: 70 N·m (714 kgf·cm, 52 ft·lbf)

29. INSTALL REAR 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 09316-00011 SST: 09506-30012

30. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

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

31. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal. SST: 09223-56010 SST: 09527-17011 Standard oil seal depth: 0 to 0.1 mm (0 to 0.0394 in.)

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

32. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT

(a) Using SST, install the companion flange. HINT: Use the propeller shaft installation nuts when mounting SST on the flange. SST: 09950-30012 09951-03010 09953-03010 09954-03010 SST: 09955-03050

33. 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) Using a socket wrench (30mm). install the nut by tightening it until the standard preload is reached.

NOTICE:

Install nuts on the bolts to protect them, as shown in the illustration.

Torque: 441 N·m (4497 kgf·cm, 325 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 2.04 to 3.24 N*m (21 to 33 kgf*cm, 18 to 29 in.*lbf) Reused 1.52 to 2.23 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)

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

If the preload is less than the specification, retighten the nut with until the specified preload is reached.

Torque: 441 N·m (4497 kgf·cm, 325 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.

34. 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 Preload (at Starting): Bearing Specified Condition New 2.33 to 4.47 N*m (24 to 46 kgf*cm, 21 to 40 in.*lbf) Reused 1.79 to 3.34 N*m (18 to 34 kgf*cm, 16 to 30 in.*lbf)

35. INSPECT BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

(a) Using SST and a dial indicator, measure the ring gear backlash. SST: 09564-34010 Standard backlash: 0.1 to 0.2 mm (0.00394 to 0.00787 in.)

36. INSPECT RUNOUT OF REAR 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 0.1 mm (0.00394 in.) Lateral runout 0.1 mm (0.00394 in.)

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

37. STAKE REAR DRIVE PINION NUT

(a) Using a chisel and hammer, stake the nut. SST: 09930-00010

38. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Apply MP grease to 2 new oil seals.

(b) Using SST and a hammer, tap in the 2 oil seals.

SST: 09223-15020

SST: 09950-70010

09951-07150

NOTICE:

Make sure that the oil seal are installed in the proper locations.

Standard oil seal depth:

-0.50 to 0.50 mm (-0.0197 to 0.0197 in.)