DIFFERENTIAL – REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL DF–7

REMOVAL
1. DRAIN DIFFERENTIAL OIL (See page DF-10)
2. REMOVE TAILPIPE ASSEMBLY
(a) Remove the tailpipe (see page EX-2).
3. REMOVE CENTER EXHAUST ASSEMBLY
(a) Remove the center pipe (see page EX-2).
4. REMOVE PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-3)
5. REMOVE REAR DIFFERENTIAL CARRIER SUB-
ASSEMBLY (See page DF-18)
6. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT
OIL SEAL
(a) Using a SST, tap out the 2 oil seals. DF
SST 09308-00010

SST
C109016E01

SST INSTALLATION
1. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT
OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new
rear differential side gear shaft oil seal.
(b) Using SST and a hammer, tap the 2 rear differential
side gear shaft oil seals into the rear differential
A carrier and differential side bearing retainer
C109017E01
according to the specification.
SST 09223-00010
Standard oil seal tapping amount (A value):
7.2 +-0.5 mm (0.28 +-0.02 in.)
2. INSTALL REAR DIFFERENTIAL CARRIER
ASSEMBLY (See page DF-44)
3. TEMPORARILY INSTALL PROPELLER WITH
CENTER BEARING SHAFT ASSEMBLY (See page
PR-5)
4. TIGHTEN PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-6)
5. INSPECT AND ADJUST JOINT ANGLE (See page PR-
4)
6. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Install the center pipe (see page EX-5).
7. INSTALL TAILPIPE ASSEMBLY
(a) Install the tailpipe (see page EX-6).
8. ADD DIFFERENTIAL OIL
(a) Add differential oil (see page DF-3).
 DF–8 DIFFERENTIAL – REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

9. CHECK FOR DIFFERENTIAL OIL LEAKAGE

10. CHECK FOR EXHAUST GAS LEAKAGE
If gas is leaking, tighten the areas necessary to stop the
leak. Replace damaged parts as necessary.

DF
 DF–18 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL
1. DRAIN DIFFERENTIAL OIL
2. REMOVE REAR WHEEL
3. REMOVE TAILPIPE ASSEMBLY
(a) Remove the tailpipe (see page EX-2).
4. REMOVE CENTER EXHAUST PIPE ASSEMBLY
(a) Remove the center pipe (see page EX-2).
5. REMOVE PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-3)
6. REMOVE REAR SUSPENSION MEMBER BRACE LH
(a) Remove the 2 bolts and brace from the suspension
member.
DF 7. REMOVE REAR SUSPENSION MEMBER BRACE RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE REAR DIFFERENTIAL CARRIER SUB-
ASSEMBLY
C127572 (a) Disconnect the harness clamp.
(b) Remove the breather tube.
(c) Disconnect the connector.

C127575
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–19

(d) Support the rear differential carrier with a

transmission jack or equivalent.
Bolt A (e) Fix the nuts in place and remove bolt A, bolt B and
bolt C.
NOTICE:
Do not loosen the nuts. Loosen the bolts.

DF

Bolt A Bolt B

C129479E01

(f) Slowly lower the jack and then tilt the rear
differential carrier.

C129480

(g) Set the tip of the tire lever to the position on the rear
drive shaft inboard joint shown in the illustration.
Then, using the ribbed part of the rear differential
carrier as a fulcrum, disconnect the left and right
rear drive shafts.
NOTICE:
Do not scratch the rear drive shaft dust cover.

C129481
 DF–20 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

9. REMOVE REAR DIFFERENTIAL NO. 1 AND NO. 2

SUPPORT
(a) Remove the 4 bolts and differential No. 1 and No. 2
supports from the differential carrier.

C127578

10. REMOVE REAR DIFFERENTIAL SUPPORT

(a) Remove the 4 bolts and differential support from the
differential carrier.

DF

C127579
DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–21

DISASSEMBLY
1. FIX DIFFERENTIAL CARRIER SUB-ASSEMBLY
(a) Fix the rear differential carrier in place with the
overhaul attachment.
2. REMOVE STUD BOLT
(a) Remove the 4 stud bolts from the transmission
coupling.
3. REMOVE DIFFERENTIAL DRAIN PLUG
(a) Using a 10 mm socket hexagon wrench, remove the
rear differential drain plug and gasket.

DF
C110127

4. REMOVE DIFFERENTIAL FILLER PLUG

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

C110128

5. REMOVE DIFFERENTIAL CARRIER COVER PLUG

(a) Using an 8 mm socket hexagon wrench, remove
rear differential carrier cover plug.
6. REMOVE DIFFERENTIAL CARRIER COVER
BREATHER PLUG
(a) Using a chisel and hammer, slightly lift up the rear
differential carrier cover breather plug.

C110129

(b) Using a screwdriver, lightly pry up and remove the

rear differential carrier cover breather plug.

C110130
 DF–22 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

7. INSPECT RUNOUT OF TRANSMISSION COUPLING

Vertical Runout Lateral Runout ASSEMBLY
(a) Install a dial gauge so that it is perpendicular to the
inner side of the transmission coupling.
(b) Using SST, rotate the transmission coupling
assembly forward and backward and measure the
vertical runout.
SST 09564-32011
Maximum vertical runout :
0.06 mm (0.0024 in.)
(c) Install a dial gauge perpendicularly onto the
transmission coupling assembly, as shown in the
illustration.
(d) Using SST, rotate the transmission coupling
assembly forward and backward and measure the
DF lateral runout.
SST SST 09564-32011
Maximum lateral runout:
0.07 mm (0.0028)

C110131E01

8. REMOVE ELECTROMAGNETIC COUPLING

(a) Remove the 4 bolts and, using a plastic-faced
hammer, lightly tap the rear differential carrier cover
to remove it from the rear differential carrier.
NOTICE:
Set the brass bar on the ribbed part of the rear
differential carrier cover.

C110132

9. REMOVE 4WD LINEAR SOLENOID

(a) Using a snap ring expander, remove the snap ring.

C129932

(b) Remove the solenoid from the yoke.

(c) Remove the O-ring from the solenoid.

C129931
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–23

10. REMOVE YOKE

(a) Using a 5 mm socket hexagon wrench, remove the
3 bolts and yoke from the differential carrier.

C129930

11. REMOVE TRANSMISSION COUPLING CONICAL

Transmission Coupling SPRING WASHER
Conical Spring Washer
(a) Remove the spring washer from the differential
carrier.
DF

C109021E01

12. REMOVE TRANSMISSION COUPLING SHIM

Transmission (a) Remove the shim from the differential carrier.
Coupling Shim

C109022E01

13. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial gauge through the rear differential
carrier cover plug hole, and set it perpendicular to
the ring gear tooth surface's tip.
(b) Using SST, fix the drive pinion in place.
SST 09556-16011
SST
(c) Using SST, rotate the rear differential case forward
and backward, and measure the backlash.
SST 09564-32011
Standard backlash:
0.09 to 0.16 mm (0.0034 to 0.0063 in.)
NOTICE:
Measure at 3 or more areas around the
circumference of the ring gear.

SST

C110134E01
 DF–24 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

14. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST and a torque wrench, inspect the preload
SST (starting torque) within the differential drive pinion
and differential ring gear backlash area.
SST 09556-16011
Standard drive pinion preload:
0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3 in.*lbf)
NOTICE:
For a more accurate measurement, rotate the
C110135E01 case bearing forward and backward before
measuring.
15. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, inspect the preload
SST (starting torque) with the teeth of the differential
drive pinion and differential ring gear in contact.
DF SST 09556-16011
Standard total preload:
Standard drive pinion preload plus 0.99 to 1.63
N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)
NOTICE:
C110135E01 For a more accurate measurement, rotate the
case bearing forward and backward before
measuring.
16. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL
SEAL
(a) Using SST, tap out the 2 rear differential side shaft
gear oil seals from the rear differential carrier.
SST 09308-00010

SST
C110136E01

17. REMOVE DIAPHRAGM OIL SEAL

SST (a) Using SST, remove the diaphragm oil seal from the
rear differential carrier.
SST 09308-10010

Oil Seal
C110140E01
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–25

18. REMOVE DRIVE PINION NUT

(a) Using SST and a hammer, unstake the rear drive
pinion nut.
SST SST 09930-00010
NOTICE:
• Use SST with the tapered part against the
shaft side.
• Do not modify the SST tip with a grinder or
equivalent.
C110138E01 • Fully unstake the rear drive pinion nut

(b) Using SST, fix the differential drive pinion in place

and remove the rear drive pinion nut from the
SST differential drive pinion.
SST 09556-16011, 09564-16020
SST
DF

C110139E01

19. REMOVE REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
SST (a) Using SST, remove the rear drive pinion tapered
roller bearing front (inner race) from the rear
differential carrier.
SST 09556-30010

C110141E01

20. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

(a) Remove the 8 bolts.

C110142

(b) Using a brass bar and hammer, lightly tap out the
differential side bearing retainer.
NOTICE:
Set the brass bar on the ribbed part of the
differential side bearing retainer.

C110143
 DF–26 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

21. REMOVE DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Remove the rear differential case from the rear
differential carrier.

C110144

22. REMOVE DIFFERENTIAL DRIVE PINION

(a) Remove the differential drive pinion from the rear
differential carrier.

DF

C110145

23. REMOVE DIFFERENTIAL DRIVE PINION BEARING

SPACER
(a) Remove the rear differential drive pinion bearing
spacer from the differential drive pinion.

C110146

24. REMOVE REAR DRIVE PINION REAR TAPERED

ROLLER BEARING
(a) Using SST and a press, press out the rear drive
SST pinion tapered roller bearing rear (inner race) from
the differential drive pinion.
SST 09950-00020
NOTICE:
If the rear differential drive pinion or differential
ring gear is damaged, replace them both.
C110147E01 (b) Remove the rear differential drive pinion washer.

25. REMOVE REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
(a) Using SST, remove the rear drive pinion tapered
roller bearing front (outer race) from the rear
SST differential carrier.
SST 09612-65014 (09612-01020, 09612-01050)

C110148E01
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–27

26. REMOVE REAR DRIVE PINION REAR TAPERED

ROLLER BEARING
(a) Using a brass bar and hammer, lightly and uniformly
tap out the rear drive pinion tapered roller bearing
rear (outer race).
NOTICE:
Set the brass bar on the notch.

C110149

27. REMOVE DIFFERENTIAL CASE BEARING

SST 09950-60010 (09951-00460), 09950-70010
(09951-07100), 09649-17010 (09951-00510)
SST (a) Using SST and a press, press out the rear
differential case bearing RH (outer race) and rear DF
differential side gear shaft plate washer from the
rear differential carrier.
SST 09950-60010, 09950-70010 (09951-07100)

C110150E01

(b) Using SST and a press, press out the rear

differential case bearing LH (outer race) and rear
SST
differential side gear shaft plate washer from the
differential side bearing retainer.
SST 09950-60010 (09951-00460), 09950-70010
(09951-07100), 09649-17010

SST
C110151E01

28. REMOVE DIFFERENTIAL CASE BEARING

(a) Using SST, remove the rear differential case bearing
RH (inner race) from the rear differential case.
SST 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04061,
09957-04010, 09958-04011), 09950-60010
SST (09951-00320, 09955-04071)
NOTICE:
Before using SST center bolt (09953-04020),
C110153E01 apply hypoid gear oil to its threads and tip.

(b) Using SST, remove the rear differential case bearing

LH (inner race) from the rear differential case.
SST 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04071,
09957-04010, 09958-04011), 09950-60010
(09951-00320)
SST NOTICE:
Before using SST center bolt (09953-04020),
apply hypoid gear oil to its threads and tip.
C110154E01
 DF–28 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

HINT:
If the race is remains on the rear differential case,
repeat the step above to remove the race.
29. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on the rear differential case and
differential ring gear.
(b) Remove the 10 bolts.
(c) Using a plastic-faced hammer, lightly tap the outer
circumference of the differential ring gear to remove
it from the rear differential case.

Matchmark
C110155E01

30. REMOVE DIFFERENTIAL BREATHER PLUG OIL

DF DEFLECTOR
(a) Using a 5 mm socket hexagon wrench, remove the
2 bolts and rear differential breather plug oil
deflector.
31. REMOVE STRAIGHT PIN

C110156

C110152

(a) Using pliers, remove the 4 straight pins from the

rear differential carrier.
32. REMOVE ELBOW TUBE
33. REMOVE WIRING HARNESS CLAMP BRACKET
(a) Remove the bolt and bracket.
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–29

REASSEMBLY
1. INSTALL WIRING HARNESS CLAMP BRACKET
(a) Install the bracket with the bolt.
2. INSTALL ELBOW TUBE
3. INSTALL STRAIGHT PIN

8.0 to 9.0 mm
(0.31 to 0.35 in.)

DF
8.0 to 9.0 mm
(0.31 to 0.35 in.)

C110158E02

(a) Using a plastic hammer, install the 4 straight pins to

the rear differential carrier.
(b) Thoroughly clean oil and water from the surface of
the rear differential case that will face the differential
ring gear.
4. INSTALL DIFFERENTIAL BREATHER PLUG OIL
Arrow Mark
DEFLECTOR
(a) Using a 5 mm socket hexagon wrench, install the
rear differential breather plug oil deflector with the 2
bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
NOTICE:
Install it so that the arrow mark faces the front
(transmission coupling side) of the vehicle.
C110156E01

5. INSTALL DIFFERENTIAL RING GEAR

(a) Align the matchmarks on the rear differential case
and differential ring gear, and install the differential
ring gear.
(b) Install 10 new differential case bolts.
Torque: 90 N*m (918 kgf*cm, 66 ft.*lbf)
NOTICE:
• The new bolts are coated with heat resistant
Matchmark oil. Do not wash it off.
C110155E01 • Install the rear differential case bolts by
tightening diametrically opposite bolts
uniformly in several passes.
 DF–30 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

6. INSTALL DIFFERENTIAL CASE BEARING

(a) Using SST and a press, press-fit the rear differential
case bearing RH (inner race) to the rear differential
SST case.
SST 09223-50010
NOTICE:
If the rear differential case bearing inner race is
damaged, replace it with a new one.

C110159E01

(b) Using SST and a press, press-fit the rear differential

case bearing LH (inner race) to the rear differential
case.
SST SST 09223-50010
DF NOTICE:
If the rear differential case bearing inner race is
damaged, replace it with a new one.

C110160E01

7. INSTALL DIFFERENTIAL CASE BEARING

(a) Using SST and a press, press-fit the rear differential
side gear shaft washer and rear differential case
SST bearing LH (outer race) to the differential side
bearing retainer.
SST 09950-60010 (09951-00510, 09951-00620,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
• Install each rear differential side gear shaft
C110161E01 washer to the place it was removed from.
• When replacing a bearing, replace the inner
and outer races as a set.
• Install the rear differential side gear shaft oil
seal after performing the teeth contact
inspection and backlash adjustment.
(b) Using SST and a press, press-fit the rear differential
side gear shaft washer and rear differential case
SST
bearing RH (outer race) to the rear differential
carrier.
SST 09950-60010 (09951-00510, 09951-00620,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
• Install each rear differential side gear shaft
washer to the place it was removed from.
C110162E01 • When replacing a bearing, replace the inner
and outer races as a set.
• Install the rear differential side gear shaft oil
seal after performing the teeth contact
inspection and backlash adjustment.
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–31

8. INSTALL REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
SST (a) Using SST and a press, press-fit the rear drive
pinion tapered roller bearing front (outer race) to the
rear differential carrier.
SST 09950-60010 (09951-00550), 09950-60020
(09951-00680), 09950-70010 (09951-07100)

C110307E01

9. INSTALL REAR DRIVE PINION REAR TAPERED

ROLLER BEARING
(a) Using SST, bolts, nuts and washers, install the rear
drive pinion tapered roller bearing rear (outer race)
to the rear differential carrier. DF
SST 09950-60010 (09951-00600), 09950-60020
(09951-00680, 09951-00750)
HINT:
Use M12 x P1.25 bolts with shaft lengths of 186 mm
(part No. 90101-12159) and M12 x P1.25 nuts (part
No. 90179-12051) for the installation.
10. INSTALL REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
SST (a) Install the rear differential drive pinion washer to the
differential drive pinion.
NOTICE:
Install each rear differential drive pinion washer
to the place it was removed from.
SST

C110308E01

(b) Using SST and a press, press-fit the tapered roller

rear (inner race) to the differential drive pinion.
SST 09506-30012
11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the differential drive pinion (with rear drive
pinion tapered roller bearing rear inner race) to the
SST
rear differential carrier.
(b) Install the rear drive pinion tapered roller bearing
front inner race and a new rear drive pinion nut to
C110309E01
the differential drive pinion.
NOTICE:
• New bearings are coated with anti-rust oil. If
using new bearings, do not wash it off.
• If reusing a bearing, coat it with hypoid gear
oil SX.
 DF–32 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

(c) Using SST, tighten a new rear drive pinion nut a little
at a time until the specified preload is reached. Do
SST not exceed the torque limit shown below.
SST 09556-16011, 09564-16020
Torque: 245 N*m (2,500 kgf*cm, 181 ft.*lbf) for
SST use without SST
223 N*m (2,273 kgf*cm, 164 in.*lbf) for
use with SST
HINT:
C110310E01 Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
(d) Using SST and a torque wrench, measure the
starting torque of the differential drive pinion.
SST 09556-16011
Standard drive pinion preload (start torque)
DF Bearing Preload
SST
New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12
to 19 in.*lbf)
Reused bearing 0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3
in.*lbf)
C110311E01
NOTICE:
• For a more accurate measurement, rotate the
bearing forward and backward before
inspecting.
• Record the preload measurement for use with
the total preload inspection.
12. INSTALL DIFFERENTIAL CASE
(a) Install the rear differential case to the rear
differential carrier.
13. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
(a) Using a scraper and wire brush, clean the seal
packing from the rear differential carrier and
differential side bearing retainer.
NOTICE:
Do not scratch the installation area.
C110144

(b) Install the differential side bearing retainer to the

rear differential carrier with the 8 bolts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)

C110142
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–33

14. ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial gauge through the rear differential
carrier cover plug hole, and set it perpendicular to
the ring gear tooth surface's tip.
(b) Using SST, fix the drive pinion in place.
SST 09556-16011
SST
(c) Using SST, rotate the rear differential case forward
and backward, and measure the backlash.
SST 09564-16020
NOTICE:
Measure at 3 or more areas around the
circumference of the ring gear.
(d) If the result is not within the specified range, select
washers that are thicker or thinner as necessary,
where the thickness for the left and right side is the
same. Then perform the rear differential case DF
bearing outer race installation.
SST HINT:
• If the backlash is small, select a thick washer for
the RH side and a thin washer for the LH side.
C110134E02 • If the backlash is large, select a thin washer for
the RH side and a thick washer for the LH side.
Rear differential side gear shaft washer
Part No. Thickness mm (in.) Identifying Mark Part No. Thickness mm (in.) Identifying Mark
90564-37022 1.59 to 1.61 (0.0625 A0 90564-37040 2.13 to 2.15 (0.0839 B8
to 0.0633) to 0.0846)
90564-37023 1.62 to 1.64 (0.0637 A1 90564-37041 2.16 to 2.18 (0.0850 B9
to 0.0649) to 0.0858)
90564-37024 1.65 to 1.67 (0.0650 A2 90564-37042 2.19 to 2.21 (0.0862 C0
to 0.0657) to 0.0870)
90564-37025 1.68 to 1.70 (0.0661 A3 90564-37043 2.22 to 2.24 (0.0874 C1
to 0.0669) to 0.0882)
90564-37026 1.71 to 1.73 (0.0673 A4 90564-37044 2.25 to 2.27 (0.0886 C2
to 0.0681) to 0.0894)
90564-37027 1.74 to 1.76 (0.0685 A5 90564-37045 2.28 to 2.30 (0.0898 C3
to 0.0693) to 0.0906)
90564-37028 1.77 to 1.79 (0.0697 A6 90564-37046 2.31 to 2.33 (0.0909 C4
to 0.0705) to 0.0917)
90564-37029 1.80 to 1.82 (0.0709 A7 90564-37047 2.34 to 2.36 (0.0921 C5
to 0.0717) to 0.0929)
90564-37030 1.83 to 1.85 (0.0720 A8 90564-37048 2.37 to 2.39 (0.0930 C6
to 0.0728) to 0.0941)
90564-37031 1.86 to 1.88 (0.0732 A9 90564-37049 2.40 to 2.42 (0.0945 C7
to 0.0740) to 0.0953)
90564-37032 1.89 to 1.91 (0.0744 B0 90564-37050 2.43 to 2.45 (0.0957 C8
to 0.0752) to 0.0965)
90564-37033 1.92 to 1.94 (0.0756 B1 90564-37051 2.46 to 2.48 (0.0969 C9
to 0.0764) to 0.0976)
90564-37034 1.95 to 1.97 (0.0768 B2 90564-37052 2.49 to 2.51 (0.0980 D0
to 0.0776) to 0.0988)
90564-37035 1.98 to 2.00 (0.0780 B3 90564-37053 2.52 to 2.54 (0.0992 D1
to 0.0787) to 0.1000)
90564-37036 2.02 to 2.04 (0.0795 B4 90564-37054 2.55 to 2.57 (0.1004 D2
to 0.0803) to 0.1012)
90564-37037 2.04 to 2.06 (0.0803 B5 90564-37055 2.58 to 2.60 (0.1016 D3
to 0.0811) to 0.1024)
 DF–34 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

Part No. Thickness mm (in.) Identifying Mark Part No. Thickness mm (in.) Identifying Mark
90564-37038 2.07 to 2.09 (0.0815 B6 90564-37056 2.61 to 2.63 (1.1028 D4
to 823) to 0.1035)
90564-37039 2.10 to 2.12 (0.0827 B7 90564-37057 2.64 to 2.66 (0.1039 D5
to 0.0835) to 0.1047)

15. INSPECT TOOTH CONTACT BETWEEN RING GEAR

AND DRIVE PINION
(a) Remove the 8 bolts and differential side bearing
retainer from the rear differential carrier.
(b) Remove the rear differential carrier case.
(c) Uniformly apply a light coat of prussian blue on both
sides of the differential ring gear teeth.
(d) Install the rear differential case.
(e) Temporarily install the differential side bearing
retainer to the differential carrier with the 8 bolts.
DF (f) Rotate the differential side pinion several times.
(g) Remove the 8 bolts and rear differential side
bearing retainer from the differential carrier.
(h) Check the tooth contact pattern of the differential
drive pinion and differential ring gear.

Heel Contact Face Contact

Proper Contact

Select an adjusting washer that will bring the drive pinion closer to the ring gear.

Toe Contact Flank Contact

Select an adjusting washer that will shift the drive pinion away from the ring gear
ZK03673E02

NOTICE:
Check the tooth contact pattern at 2 or more
positions around circumference of the
differential ring gear.
(i) Perform the following procedures for face or flank
contact.
(1) Select washers that are thicker or thinner as
necessary, where the thickness for the left and
right side is the same. Then install the rear
differential case bearing outer race.(*1)
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–35

(2) Repeat the differential ring gear and differential

drive pinion tooth contact pattern inspection.
HINT:
If the tooth contact pattern is not correct,
repeat*1.
(3) Repeat the differential ring gear and differential
drive pinion backlash inspection.
HINT:
If the differential ring gear and differential drive
pinion backlash is not as specified, replace the
differential ring gear and differential drive pinion
with new ones.
(j) Perform the following procedures for heel or toe
contact.
(1) Select a drive pinion washer again and perform
the rear drive pinion tapered roller bearing rear DF
installation.
Rear differential drive pinion washer
Part No. Thickness (mm) Identifying Mark Part No. Thickness (mm) Identifying Mark
90564-35041 1.695 to 1.705 41 90564-35071 1.955 to 1.965 71
(0.0667 to 0.0671) (0.0770 to 0.0774)
90564-35042 1.705 to 1.715 42 90564-35072 1.965 to 1.975 72
(0.0671 to 0.0675) (0.0774 to 0.0778)
90564-35043 1.715 to 1.725 43 90564-35073 1.975 to 1.985 73
(0.0675 to 0.0679) (0.0778 to 0.0781)
90564-35044 1.725 to 1.735 44 90564-35074 1.985 to 1.995 74
(0.0679 to 0.0683) (0.0781 to 0.0785)
90564-35045 1.735 to 1.745 45 90564-35075 1.995 to 2.005 75
(0.0683 to 0.0687) (0.0785 to 0.0789)
90564-35046 1.745 to 1.755 46 90564-35076 2.005 to 2.015 76
(0.0687 to 0.0690) (0.0789 to 0.0793)
90564-35047 1.755 to 1.765 47 90564-35077 2.015 to 2.025 77
(0.0690 to 0.0695) (0.0793 to 0.0797)
90564-35048 1.765 to 1.775 48 90564-35078 2.025 to 2.035 78
(0.0695 to 0.0699) (0.0797 to 0.0801)
90564-35049 1.775 to 1.785 49 90564-35079 2.035 to 2.045 79
(0.0699 to 0.0703) (0.0801 to 0.0805)
90564-35050 1.785 to 1.795 50 90564-35080 2.045 to 2.055 80
(0.0703 to 0.0707) (0.0805 to 0.0809)
90564-35051 1.795 to 1.805 51 90564-35081 2.055 to 2.065 81
(0.0707 to 0.0711) (0.0809 to 0.0813)
90564-35052 1.805 to 1.815 52 90564-35082 2.065 to 2.075 82
(0.0707 to 0.0715) (0.0813 to 0.0817)
90564-35053 1.815 to 1.825 53 90564-35083 2.075 to 2.085 83
(0.0715 to 0.0719) (0.0817 to 0.0821)
90564-35054 1.825 to 1.835 54 90564-35084 2.085 to 2.095 84
(0.0719 to 0.0720) (0.0821 to 0.0825)
90564-35055 1.835 to 1.845 55 90564-35085 2.095 to 2.105 85
(0.0719 to 0.0726) (0.0825 to 0.0829)
90564-35056 1.845 to 1.855 56 90564-35086 2.105 to 2.115 86
(0.0726 to 0.0730) (0.0829 to 0.0833)
90564-35057 1.855 to 1.865 57 90564-35087 2.115 to 2.125 87
(0.0730 to 0.0734) (0.0833 to 0.0837)
90564-35058 1.865 to 1.875 58 90564-35088 2.125 to 2.135 88
(0.0734 to 0.0738) (0.0837 to 0.0841)
90564-35059 1.875 to 1.885 59 90564-35089 2.135 to 2.145 89
(0.0734 to 0.0742) (0.0841 to 0.0844)
 DF–36 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

Part No. Thickness (mm) Identifying Mark Part No. Thickness (mm) Identifying Mark
90564-35060 1.885 to 1.895 60 90564-35090 2.145 to 2.155 90
(0.0742 to 0.0746) (0.0844 to 0.0848)
90564-35061 1.895 to 1.905 61 90564-35091 2.155 to 2.165 91
(0.0746 to 0.0750) (0.0848 to 0.0852)
90564-35062 1.905 to 1.915 62 90564-35092 2.165 to 2.175 92
(0.0750 to 0.0754) (0.0852 to 0.0856)
90564-35063 1.915 to 1.925 63 90564-35093 2.175 to 2.185 93
(0.0754 to 0.0758) (0.0856 to 0.0860)
90564-35064 1.925 to 1.935 64 90564-35094 2.185 to 2.195 94
(0.0758 to 0.0762 (0.0860 to 0.0864)
90564-35065 1.935 to 1.945 65 90564-35095 2.195 to 2.205 95
(0.0762 to 0.0766) (0.0864 to 0.0868)
90564-35070 1.945 to 1.955 70 - - -
(0.0766 to 0.0770)

DF 16. INSPECT TOTAL PRELOAD

(a) Using SST and a torque wrench, measure the
SST starting torque with the teeth of the differential drive
pinion and differential ring gear in contact.
SST 09556-16011
Standard total preload:
Standard drive pinion preload plus
Bearing Preload
New bearing 1.18 to 1.63 N*m (12 to 17 kgf*cm, 10
C110135E01 to 14 in.*lbf)
Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9
to 14 in.*lbf)

NOTICE:
For a more accurate measurement, rotate the
case bearing forward and backward before
measuring.
(b) If the results are not within the specification, perform
the procedures below.
(1) Select a side gear shaft washer for the RH side
again, and then perform the rear differential
case bearing outer race installation (RH side
only).
(2) Repeat the total preload inspection.
(3) Repeat the ring gear backlash inspection.
(4) Repeat the differential ring gear and drive
pinion tooth contact pattern inspection.
17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove the 8 bolts and differential side bearing
retainer from the rear differential carrier.
18. REMOVE DIFFERENTIAL CASE
(a) Remove the rear differential case from the rear
differential carrier.
19. REMOVE DIFFERENTIAL DRIVE PINION
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–37

20. INSTALL DIFFERENTIAL DRIVE PINION BEARING

SPACER
(a) Install a new rear differential drive pinion bearing
spacer to the differential drive pinion.

C110146

21. INSTALL DIFFERENTIAL DRIVE PINION

(a) Install the differential drive pinion to the rear
differential carrier.
22. INSTALL REAR DRIVE PINION NUT
(a) Apply hypoid gear oil LSD to the threads of the rear
DF
drive pinion nut.

C110145

(b) Install a new rear drive pinion nut to the differential

drive pinion. Using SST, tighten the nut while
SST confirming the preload.
SST 09556-16011, 09564-16020
SST 09564-16020
SST Torque: 245 N*m (2,500 kgf*cm, 181 ft.*lbf) for
use without SST
223 N*m (2,273 kgf*cm, 164 ft.*lbf) for
use with SST
C110310E01 HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
23. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST and a torque wrench, inspect the starting
torque.
SST 09556-16011
Standard drive pinion preload
SST
Bearing Preload
New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12
to 19 in.*lbf)
Reused bearing 0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3
C110311E01 in.*lbf)

NOTICE:
• For a more accurate measurement, rotate the
bearing forward and backward before
adjusting.
• Adjust it so that it matches the drive pinion
temporary adjustment starting torque.
 DF–38 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

(b) If the preload is insufficient, use SST to tighten the

drive pinion nut 5 to 10° at a time. Measure the
SST starting torque and repeat the adjustment as
necessary until the preload matches the specified
torque.
SST SST 09564-16020
(c) If the tightening torque of the rear drive pinion nut
exceeds 245 N*m { 2500 kgf*cm } but the preload is
still insufficient, loosen the rear drive pinion nut.
C110310E01 Then check if the rear drive pinion nut and
differential drive pinion screw threads are damaged.
(d) If there is no defect, replace the rear drive
differential drive pinion bearing spacer, apply hypoid
gear oil LSD to its threads and repeat the procedure
above.
DF 24. INSTALL DIFFERENTIAL CASE
25. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
(a) Install the differential side bearing retainer to the
rear differential carrier with the 8 bolts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
26. INSPECT DIFFERENTIAL RING GEAR BACKLASH
27. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the
SST starting torque with the teeth of the differential drive
pinion and differential ring gear in contact.
SST 09556-16011
Standard total preload:
Standard drive pinion preload plus
Bearing Preload
New bearing 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10
C110135E01 to 17 in.*lbf)
Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9
to 14 in.*lbf)

NOTICE:
For a more accurate measurement, rotate the
case bearing forward and backward before
measuring.
(b) If the results are not within the specified range,
select a rear differential side gear shaft washer for
the RH side again, and then perform the rear
differential case bearing outer race installation (RH
side only).
NOTICE:
If using a different rear differential side gear
shaft washer, adjust the ring gear backlash.
Then adjust the total preload.
28. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove the 8 bolts and side bearing retainer from
the rear differential carrier.
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–39

29. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

(a) Using white gasoline, remove grease and oil from
the alignment surfaces of the rear differential carrier
and differential side bearing retainer.
(b) Apply seal packing to the areas indicated in the
a: 6 mm (0.24 in.)
b: 3 mm (0.12 in.) illustration of the differential side bearing retainer.
Seal Packing:
a
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or equivalent
NOTICE:
b • Apply seal packing in a continuous line 2 to 3
a mm (0.08 to 0.12 in.) in diameter.
a a • Perform the installation with 3 minutes of
C110312E01 applying seal packing.

(c) Install the differential side bearing retainer to the DF

rear differential carrier with the 8 bolts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
NOTICE:
After installing the cover, do not add oil or drive
the vehicle, and leave it alone for 1 hour or
more. Also, avoid sudden acceleration and
deceleration for 12 hours or more.

C110142

30. INSPECT TOTAL PRELOAD

(a) Using SST and a torque wrench, inspect the starting
SST torque with the teeth of the differential drive pinion
and differential ring gear in contact.
SST 09556-16011
Standard total preload:
Standard drive pinion preload plus
Bearing Preload
New bearing 1.18 to 1.90 N*m (12 to 19 kgf*cm, 10
C110135E01 to 17 in.*lbf)
Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9
to 14 in.*lbf)

NOTICE:
For a more accurate measurement, rotate the
case bearing forward and backward before
inspecting.
 DF–40 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

31. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial gauge through the rear differential
carrier cover plug hole, and set it perpendicular to
the ring gear tooth surface's tip.
(b) Using SST, fix the drive pinion in place.
SST 09556-16011
SST
(c) Using SST, rotate the rear differential case forward
and backward, and inspect the backlash.
SST 09564-16020
Standard backlash:
0.09 to 0.16 mm (0.0004 to 0.006 in.)
NOTICE:
Inspect at 3 or more areas around the
circumference of the ring gear.

DF 32. INSTALL REAR DRIVE PINION NUT

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

C110134E01

33. INSTALL DIAPHRAGM OIL SEAL

(a) Apply a light coat of MP grease No. 2 to the lip of a
new diaphragm oil seal.
SST (b) Using SST and a hammer, tap the diaphragm oil
seal into the rear differential carrier according to the
specification.
SST 09710-30021 (09710-03121), 09950-60010
(09951-00570), 09950-70010 (09951-07100)
Distance Standard distance:
C110313E01 7.0 +-0.5 mm (0.28 +-0.02 in.)
34. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL
SEAL
(a) Apply a light coat of MP grease No. 2 to the lip of a
new rear differential side gear shaft oil seal.
(b) Using SST and a hammer, tap the 2 rear differential
side gear shaft oil seals into the rear differential
carrier and differential side bearing retainer
SST
according to the specification.
SST 09223-00010
Distance
Standard distance:
7.2 +-0.5 mm (0.28 +-0.02 in.)

C110314E01
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–41

35. INSTALL TRANSMISSION COUPLING SHIM

(a) Measure each of the dimensions.
HINT:
• Dimension A: Bearing axis distance
• Dimension B: Drive pinion axis distance
(b) Select a transmission coupling shim based on the
difference between dimensions A and B, and install
the shim.
A B
C110318E01

Transmission coupling shim

Difference of dimension A and Part No. Thickness mm (in.) Identifying Mark
B mm (in.)
3.96 to 4.01 (0.148 to 0.154) 90564-25024 1.98 to 2.02 (0.078 to 0.080) 1
4.26 to 4.31 (0.161 to 0.168) 90564-25025 2.28 to 2.32 (0.090 to 0.091) 2 DF
4.56 to 4.61 (0.174 to 0.181) 90564-25026 2.58 to 2.62 (0.102 to 0.103) 3
3.81 to 3.86 (0.141 to 0.148) 90564-25027 1.83 to 1.87 (0.072 to 0.074) 4
4.11 to 4.16 (0.154 to 0.161) 90564-25028 2.13 to 2.17 (0.084 to 0.085) 5
4.41 to 4.16 (0.168 to 0.174) 90564-25029 2.43 to 2.47 (0.096 to 0.097) 6
3.71 to 3.76 (0.146 to 0.148) 90564-25031 1.73 to 1.77 (0.068 to 0.700) 8
3.76 to 3.81 (0.148 to 0.150) 90564-25032 1.78 to 1.82 (0.070 to 0.072) 9
3.86 to 3.91 (0.151 to 0.154) 90564-25033 1.88 to 1.92 (0.074 to 0.076) 10
3.91 to 3.96 (0.154 to 0.156) 90564-25034 1.93 to 1.97 (0.076 to 0.078) 11
4.01 to 4.06 (0.158 to 0.160) 90564-25035 2.03 to 2.07 (0.080 to 0.081) 12
4.06 to 4.11 (0.160 to 0.162) 90564-25036 2.08 to 2.12 (0.082 to 0.083) 13
4.16 to 4.21 (0.164 to 0.166) 90564-25037 2.18 to 2.22 (0.086 to 0.087) 14
4.21 to 4.26 (0.166 to 0.168) 90564-25038 2.23 to 2.27 (0.088 to 0.089) 15
4.31 to 4.36 (0.170 to 0.172) 90564-25039 2.33 to 2.37 (0.092 to 0.093) 16
4.36 to 4.41 (0.172 to 0.174) 90564-25040 2.38 to 2.42 (0.094 to 0.095) 17
4.46 to 4.51 (0.176 to 0.178) 90564-25041 2.48 to 2.52 (0.098 to 0.099) 18
4.51 to 4.56 (0.178 to 0.180) 90564-25042 2.53 to 2.57 (0.100 to 0.101) 19
4.61 to 4.66 (0.181 to 0.183) 90564-25043 2.63 to 2.67 (0.104 to 0.105) 20
4.66 to 4.71 (0.183 to 0.185) 90564-25044 2.68 to 2.72 (0.106 to 0.107) 21

36. REMOVE TRANSMISSION COUPLING CONICAL

Transmission Coupling SPRING WASHER
Conical Spring Washer
(a) Install the transmission coupling conical spring
washer to the rear differential carrier.
NOTICE:
Install the transmission coupling conical spring
washer so that the green marking (protruding
part) is facing the front of the vehicle (coupling
side).
C109021E01
37. INSTALL YOKE
(a) Using a 5 mm socket hexagon wrench, install the
yoke with the 3 bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
38. INSTALL 4WD LINEAR SOLENOID
(a) Install a new O-ring to the solenoid.
NOTICE:
Do not damage or twist the O-ring.
(b) Install the solenoid to the yoke.
 DF–42 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

(c) Install the snap ring.

39. INSTALL ELECTROMAGNETIC COUPLING
(a) Using white gasoline, remove grease and oil from
the alignment surfaces of the rear differential carrier
and transmission coupling.
(b) Apply seal packing 1281 to the areas indicated in
Seal Packing
the illustration of the transmission coupling.
Seal Packing:
2 to 3 mm Toyota Genuine Seal Packing 1281, Three
(0.08 to 0.12 in) Bond 1281 or equivalent
NOTICE:
• Apply seal packing 1281 in a continuous line
2 to 3 mm (0.08 to 0.12 in.) in diameter.
• Perform the installation with 3 minutes of
DF C130565E01 applying seal packing 1281.

(c) Install the rear differential carrier cover to the rear

differential carrier assembly with the 4 bolts.
Torque: 19.6 N*m (200 kgf*cm, 14 ft.*lbf)

C110132

40. INSTALL DIFFERENTIAL CARRIER COVER

BREATHER PLUG
(a) Using a plastic-faced hammer, tap in the breather
plug.
SST 09612-07010 (09612-10061)
SST

C110319E01

41. INSTALL DIFFERENTIAL CARRIER COVER PLUG

(a) Using an 8 mm socket hexagon wrench, install a
new rear differential carrier cover plug.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

C110129
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–43

42. INSTALL DIFFERENTIAL FILLER PLUG

(a) Install a new gasket to the rear differential filler plug.
(b) Using a 10 mm socket hexagon wrench, install the
rear differential filler plug.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

C110128

43. INSTALL DIFFERENTIAL DRAIN PLUG

(a) Install a new gasket to the rear differential drain
plug.
(b) Using a 10 mm socket hexagon wrench, install the
rear differential drain plug. DF
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

C110127

44. INSPECT RUNOUT OF TRANSMISSION COUPLING

Vertical Runout Lateral Runout ASSEMBLY
(a) Install a dial gauge so that it is perpendicular to the
inner side of the transmission coupling.
(b) Using SST, rotate the transmission coupling forward
and backward and measure the vertical runout.
SST 09564-16020
Maximum vertical runout:
0.06 mm (0.0024 in.)
(c) Install a dial gauge perpendicularly onto the
transmission coupling, as shown in the illustration.
(d) Using SST, rotate the transmission coupling forward
and backward and measure the lateral runout.
SST 09564-16020
Maximum lateral runout:
0.07 mm (0.0028 in.)
SST

C110131E01

45. INSTALL STUD BOLT

(a) Install the differential support assembly rear with the
12.2 mm (0.480 in.) 26.3 mm (1.035 in.) 4 bolts.
Torque: 8 N*m (82 kgf*cm, 71 in.*lbf)

Propeller Shaft Side Coupling Side

C110326E01
 DF–44 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

INSTALLATION
1. INSTALL REAR DIFFERENTIAL SUPPORT
(a) Install the differential support to the differential
carrier with the 4 bolts.
Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf)

C127579

2. INSTALL REAR DIFFERENTIAL NO. 1 AND NO. 2

SUPPORT
(a) Install the differential No. 1 and No. 2 supports with
the 4 bolts to the differential carrier.
DF Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf)
3. INSTALL REAR DIFFERENTIAL CARRIER SUB-
ASSEMBLY
(a) Support the rear differential carrier with a
transmission jack or equivalent
C127578
(b) Apply hypoid gear oil to the splines of the left and
right rear drive shaft inboard joints.
(c) Align the splines of the rear drive shaft inboard joints
and, using a brass bar and hammer, tap in the left
and right rear drive shafts.
NOTICE:
• Face the cutout section of the snap ring
downward.
• Do not damage the oil seal during the
insertion.
• Do not strike the tip of the outboard joint with
C129504 the hammer.
HINT:
Determine whether or not the rear drive shaft is
completely tapped in by checking for changes in
sound or the reaction force of the brass bar.
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–45

(d) Slowly raise the transmission jack, fix the nuts in

place and install the 3 bolts.
Bolt A Torque: 86 N*m (877 kgf*cm, 63 ft.*lbf) for bolt A
140 N*m (1,428 kgf*cm, 103 ft.*lbf) for
bolt B
NOTICE:
Tighten the bolts, not the nuts.

DF

Bolt A Bolt B

C129479E01

(e) Connect the connector.

(f) Install the breather tube.
(g) Connect the harness clamp.
4. INSTALL REAR SUSPENSION MEMBER BRACE LH
(a) Install the member brace to the suspension member
with the 2 bolts.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
5. INSTALL REAR SUSPENSION MEMBER BRACE RH
C127575 HINT:
Use the same procedures described for the LH side.
6. TEMPORARILY INSTALL PROPELLER WITH
CENTER BEARING SHAFT ASSEMBLY (See page
PR-5)
7. TIGHTEN PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-6)
8. INSPECT JOINT ANGLE (See page PR-4)
9. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See
page EX-5)
10. INSTALL TAILPIPE ASSEMBLY (See page EX-6)
11. INSTALL REAR WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
12. ADD DIFFERENTIAL OIL
(a) Add differential oil (see page DF-3).
13. CHECK FOR DIFFERENTIAL OIL LEAKAGE
14. CHECK FOR EXHAUST GAS LEAKAGE
If gas is leaking, tighten the areas necessary to stop the
leak. Replace damaged parts as necessary.
DIFFERENTIAL – DIFFERENTIAL SYSTEM DF–1

DIFFERENTIAL SYSTEM
PRECAUTION
1. Before disassembling the differential assembly,
thoroughly clean it by removing any sand, mud or
foreign matter. This will help prevent contamination
during disassembly and reassembly.
2. When removing the rear differential carrier cover or
any other light alloy part, do not pry it off with a
screwdriver or other tool that may cause damage.
Instead, tap the part with a plastic-faced hammer.
3. Always arrange disassembled parts in the order they
were removed and protect them from foreign matter.
4. Before installation of each part, thoroughly clean
and dry it. Then apply hypoid gear oil SX to it. Do not
DF
use alkaline chemicals to clean aluminum parts,
rubber parts or ring gear set bolts. Also, do not use
white gasoline or other cleaning oils to clean Orings,
oil seals or rubber parts.
5. Coat any sliding surface and rotating parts with
hypoid gear oil SX.
6. Do not directly fix a part in a vise. Place aluminum
plates between the part and vise.
7. Be careful not to damage the contact surfaces of the
case. Such damage may cause oil leakage.
8. Before applying sealant, remove deposited oil
sealant and clean the part to be sealed using white
gasoline.
9. After sealing parts, do not allow oil to contact the
seal for at least an hour.
10. Do not allow scratches on a part's contact surface
with an oil seal, O-ring or gasket. Scratches may
lead to oil leakage.
11. When press-fitting an oil seal, be careful not to
damage the lip of the oil seal and its outside
periphery.
12. When replacing a bearing, replace the inner and
outer races as a set.
 DF–2 DIFFERENTIAL – DIFFERENTIAL SYSTEM

PROBLEM SYMPTOMS TABLE

HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected area" column of
the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Differential system
Symptom Suspected area See page
1. Oil (Level low or wrong grade) DF-3
2. Ring gear or drive pinion (Worn or chipped) DF-20
3. Backlash adjustment (Defective) DF-20
Noise in rear differential
4. Preload adjustment (Defective) DF-20
DF 5. Tooth contact between ring gear and drive pinion (Defective) DF-34
6. Bearing (Worn) DF-20
1. Oil (Level too high or wrong grade) DF-3
Oil leak from rear differential 2. Side gear shaft oil seal (Worn or damaged) DF-6
3. Seal packing (Damaged) DF-28
 DIFFERENTIAL – DIFFERENTIAL OIL DF–3

DIFFERENTIAL OIL
ON-VEHICLE INSPECTION
1. CHECK DIFFERENTIAL OIL
(a) Stop the vehicle on a level surface.
(b) Using a 10 mm socket hexagon wrench, remove the
rear differential filler plug and gasket.

C109015
DF
(c) Check that the oil level is between 0 to 5 mm (0 to
0.20 in.) from the bottom lip of the differential filler
plug hole.
0 to 5 mm NOTICE:
(0 to 0.20 in.) • After changing the oil seal, drive the vehicle
and then check the oil level again.
• Too much or too little oil will lead to
differential problems.
HINT:
C082139E01 If necessary, fill the differential carrier assembly with
hypoid gear oil.
Recommended viscosity:
SAE 90
Standard oil grade:
Hypoid gear oil SX API GL-5
Standard differential oil capacity:
0.45 to 0.55 liters (0.48 to 0.58 US qts., 0.40 to
0.48 Imp. qts.)
(d) Using a 10 mm socket hexagon wrench, install a
new gasket and the rear differential filler plug.
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
 DF–4 DIFFERENTIAL – REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

DRIVE LINE
DIFFERENTIAL

COMPONENTS
HEATED OXYGEN SENSOR CONNECTOR
EXHAUST MANIFOLD
HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

FRONT EXHAUST PIPE ASSEMBLY

GASKET

DF GASKET 44 (449, 33)

EXHAUST PIPE
SUPPORT
43 (440, 32)
COMPRESSION SPRING

EXHAUST PIPE SUPPORT

GASKET

CENTER EXHAUST PIPE ASSEMBLY

43 (440, 32)

EXHAUST PIPE
SUPPORT

TAILPIPE ASSEMBLY

EXHAUST PIPE
SUPPORT
N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part COMPRESSION SPRING 43 (440, 32)

A126829E05
 DIFFERENTIAL – REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL DF–5

35 (357, 26) DF
ADJUSTING WASHER

35 (357, 26)

36.8 (375, 27)

PROPELLER SHAFT WITH CENTER BEARING SHAFT ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

C129508E01
 DF–6 DIFFERENTIAL – REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

REAR DRIVE SHAFT ASSEMBLY LH

FRONT DRIVE SHAFT HOLE SNAP RING RH

REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

DIFFERENTIAL CARRIER SUB-ASSEMBLY

DF NUT
REAR DIFFERENTIAL NO. 1
MOUNT CUSHION

140 (1,428, 103)

86 (877, 63)

86 (877, 63)

NUT

REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

FRONT DRIVE SHAFT HOLE SNAP RING LH

REAR DRIVE SHAFT ASSEMBLY LH

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

Apply MP grease
C127376E06
 DIFFERENTIAL – DIAPHRAGM OIL SEAL DF–9

DIAPHRAGM OIL SEAL

DRIVE LINE
DIFFERENTIAL

COMPONENTS

35 (357, 26)

35 (357, 26)

DF

36.8 (375, 27)

PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

ELECTROMAGNETIC COUPLING

TRANSMISSION COUPLING
CONICAL SPRING WASHER

TRANSMISSION COUPLING SHIM

DIAPHRAGM OIL SEAL

5.0 (51, 44 in.*lbf)

8.0 (82, 71 in.*lbf)

O-RING
19.6 (200, 14)

YOKE DRAIN PLUG

GASKET
SNAP RING 5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque

4WD LINEAR SOLENOID

Non-reusable part

Apply MP grease DIFFERENTIAL CARRIER ASSEMBLY

C127374E03
 DF–10 DIFFERENTIAL – DIAPHRAGM OIL SEAL

REMOVAL
1. DRAIN DIFFERENTIAL OIL
(a) Using a 10 mm socket hexagon wrench, remove the
rear differential drain plug and gasket, and drain the
oil.
(b) Install a new gasket to the rear differential drain
plug.
(c) Using a 10 mm socket hexagon wrench, install the
C109019
rear differential drain plug and gasket.
2. REMOVE PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-3)
3. REMOVE ELECTROMAGNETIC COUPLING (See
page DF-21)
DF 4. REMOVE 4WD LINEAR SOLENOID (See page DF-22)
5. REMOVE YOKE (See page DF-22)
6. REMOVE TRANSMISSION COUPLING CONICAL
SPRING WASHER (See page DF-22)
7. REMOVE TRANSMISSION COUPLING SHIM (See
page DF-22)
8. REMOVE DIAPHRAGM OIL SEAL
SST (a) Using SST, remove the oil seal from the rear
differential carrier.
SST 09308-10010

C109023E01

Distance
INSTALLATION
1. INSTALL DIAPHRAGM OIL SEAL
(a) Apply a light coat of MP grease No. 2 to the lip of a
new diaphragm oil seal.
(b) Using SST and a hammer, tap the diaphragm oil
seal into the rear differential carrier according to the
specification.
SST 09710-30021 (09710-03121), 09950-60010
SST (09951-00570), 09950-70010 (09951-07100)
C109024E01
Standard distance:
7.0 +-0.5 mm (0.28 +-0.02 in.)
2. INSTALL TRANSMISSION COUPLING SHIM (See
page DF-41)
3. INSTALL TRANSMISSION COUPLING CONICAL
SPRING WASHER (See page DF-41)
4. INSTALL YOKE (See page DF-41)
5. INSTALL 4WD LINEAR SOLENOID (See page DF-41)
DIFFERENTIAL – DIAPHRAGM OIL SEAL DF–11

6. INSTALL ELECTROMAGNETIC COUPLING (See page

DF-42)
7. TEMPORARILY INSTALL PROPELLER WITH
CENTER BEARING SHAFT ASSEMBLY (See page
PR-5)
8. FULLY TIGHTEN PROPELLER WITH CENTER
BEARING SHAFT ASSEMBLY (See page PR-6)
9. INSPECT AND ADJUST JOINT ANGLE (See page PR-
4)
10. ADD DIFFERENTIAL OIL
(a) Add differential oil (see page DF-3).
11. CHECK FOR DIFFERENTIAL OIL LEAKAGE
If gas is leaking, tighten the areas necessary to stop the
leak. Replace damaged parts as necessary. DF
 DF–12 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

REAR DIFFERENTIAL CARRIER ASSEMBLY

DRIVE LINE
DIFFERENTIAL

COMPONENTS
HEATED OXYGEN SENSOR CONNECTOR
EXHAUST MANIFOLD
HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

FRONT EXHAUST PIPE ASSEMBLY

GASKET

DF GASKET 44 (449, 33)

EXHAUST PIPE
SUPPORT
43 (440, 32)
COMPRESSION SPRING

EXHAUST PIPE SUPPORT

GASKET

CENTER EXHAUST PIPE ASSEMBLY

43 (440, 32)

EXHAUST PIPE
SUPPORT

TAILPIPE ASSEMBLY

EXHAUST PIPE
SUPPORT
N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part COMPRESSION SPRING 43 (440, 32)

A126829E06
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–13

35 (357, 26) DF
ADJUSTING WASHER

35 (357, 26)

36.8 (375, 27)

PROPELLER SHAFT WITH CENTER BEARING SHAFT ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

C129508E01
 DF–14 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

REAR DRIVE SHAFT ASSEMBLY LH

FRONT DRIVE SHAFT HOLE SNAP RING RH

DIFFERENTIAL CASE SUB-ASSEMBLY

NUT REAR DIFFERENTIAL NO. 1

DF MOUNT CUSHION

140 (1,428, 103)

86 (877, 63)

86 (877, 63)

NUT

FRONT DRIVE SHAFT HOLE SNAP RING LH

REAR DRIVE SHAFT ASSEMBLY LH

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
C127376E07
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–15

DIFFERENTIAL CARRIER SUB-ASSEMBLY

REAR DIFFERENTIAL
SUPPORT

DF
98 (999, 72)

55 (561, 41)

REAR DIFFERENTIAL NO. 2 SUPPORT

55 (561, 41)

REAR DIFFERENTIAL NO. 1 SUPPORT

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
C127377E03
 DF–16 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY

TRANSMISSION COUPLING
CONICAL SPRING WASHER

TRANSMISSION COUPLING SHIM

8.0 (82, 71 in.*lbf)
STUD BOLT

19.6 (200, 14)

ELECTROMAGNETIC COUPLING

DF DIFFERENTIAL CARRIER COVER PLUG

39 (398, 29)
DIFFERENTIAL FILLER PLUG
GASKET

DIFFERENTIAL CARRIER COVER

BREATHER PLUG

DIFFERENTIAL SIDE
5.0 (51, 44 in. ) GEAR SHAFT OIL SEAL

O-RING

REAR DRIVE PINION FRONT

TAPERED ROLLER BEARING
5.0 (51, 44 in.*lbf) 245 (2,498, 181)
DRIVE PINION NUT
YOKE

4WD LINEAR SOLENOID

DIAPHRAGM OIL SEAL x8
34.3 (350, 25)
SNAP RING
DIFFERENTIAL SIDE BEARING RETAINER

N*m (kgf*cm, ft.*lbf) : Specified torque DIFFERENTIAL SIDE GEAR

SHAFT OIL SEAL
Non-reusable part

Apply hypoid gear oil LSD GASKET

39 (398, 29)
Apply MP grease DIFFERENTIAL DRAIN PLUG
C127378E03
 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–17

DIFFERENTIAL BREATHER PLUG

OIL DEFLECTOR

STRAIGHT PIN

5.0 (51, 44 in.*lbf)

DF
DIFFERENTIAL CASE BEARING

DIFFERENTIAL RING GEAR

STRAIGHT PIN STRAIGHT PIN

REAR DIFFERENTIAL SIDE GEAR WASHER

90 (918, 66)
DIFFERENTIAL DRIVE PINION
x 10

REAR DIFFERENTIAL
DRIVE PINION WASHER

DIFFERENTIAL CASE SUB-ASSEMBLY

REAR DRIVE PINION REAR
TAPERED ROLLER BEARING

DIFFERENTIAL DRIVE PINION

BEARING SPACER

DIFFERENTIAL CASE BEARING

REAR DIFFERENTIAL SIDE GEAR WASHER

N*m (kgf*cm, ft.*lbf) : Specified torque

DIFFERENTIAL SIDE BEARING RETAINER
Non-reusable part
C127379E03