Toyota Tundra Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL DIFFERENTIAL CASE ASSEMBLY

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

(b) Install the 2 side gears with the thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft.

HINT:

  • Align the holes for the straight pin in the differential case and pinion shaft.
  • Apply hypoid gear oil to each sliding surface and rotating part.

(c) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.

Standard backlash:

0.15 mm (0.00591 in.) or less

If the backlash is not as specified, replace the side gear thrust washer with an appropriate thickness.

HINT:

Refer to the following table to select thrust washers which will ensure that the backlash is as specified.

Washer thickness:

Thickness

Thickness

1.53 to 1.57 mm (0.0603 to 0.0618 in.)

1.78 to 1.82 mm (0.0701 to 0.0176 in.)

1.58 to 1.62 mm (0.0622 to 0.0637 in.)

1.83 to 1.87 mm (0.0721 to 0.0736 in.)

1.63 to 1.67 mm (0.0642 to 0.0657 in.)

1.88 to 1.92 mm (0.0741 to 0.0755 in.)

1.68 to 1.72 mm (0.0662 to 0.0677 in.)

1.93 to 1.97 mm (0.0760 to 0.0775 in.)

1.73 to 1.77 mm (0.0682 to 0.0696 in.)

-

(d) Using a pin punch and hammer, tap the straight pin through the holes in the differential case and pinion shaft.

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

2. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, press in the 2 bearings.

SST: 09710-30050

SST: 09950-60010

09951-00480

SST: 09950-70010

09951-07150

3. INSTALL DIFFERENTIAL RING GEAR

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

(b) Heat the ring gear to approximately 100°C (212°F) in boiling water.

(c) Carefully take the ring gear out of the boiling water.

(d) After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the differential case.

Text in Illustration

*1

Adhesive

*a

Matchmark

HINT:

Align the matchmarks on the ring gear and differential case.

(e) After the ring gear cools down sufficiently, apply adhesive to the bolts and install them.

Adhesive:

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

Torque:

137 N·m {1397 kgf·cm, 101 ft·lbf}

4. INSPECT DIFFERENTIAL RING GEAR RUNOUT

(a) Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.

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

(c) Install the 2 adjusting nut locks with the 2 bolts.

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

Maximum runout:

0.05 mm (0.00197 in.)

If the runout is more than the maximum, replace the ring gear.

(e) Remove the 2 bolts and adjusting nut locks.

(f) Remove the 2 bearing caps, 2 adjusting nuts and differential case assembly.

5. INSTALL REAR DRIVE PINION FRONT BEARING

(a) Using SST and a press, press in the bearing (outer race).

SST: 09950-60020

09951-00710

SST: 09950-70010

09951-07150

6. INSTALL REAR DRIVE PINION REAR BEARING

(a) Using SST and a press, press in the bearing (outer race).

SST: 09950-60020

09951-00890

SST: 09950-70010

09951-07150

7. INSTALL REAR DRIVE PINION REAR BEARING

(a) Install the plate washer onto the drive pinion.

Text in Illustration

*1

Plate Washer

HINT:

First fit a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

(b) Using SST and a press, press in the rear bearing (inner race).

SST: 09506-35010

8. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Install the drive pinion, front bearing (inner race) and oil slinger.

HINT:

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

(b) Using SST, install the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09956-03050

SST: 09955-03050

(c) Using SST to hold the companion flange.

SST: 09330-00021

09330-00030

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

(e) Install the nut by tightening it until the standard preload is reached.

Torque:

441 N·m {4497 kgf·cm, 325 ft·lbf}

or less

NOTICE:

As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.

(f) 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

1.04 to 1.69 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)

Reused

0.85 to 1.37 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)

HINT:

Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth.

9. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY

(a) Place the 2 bearing outer races on their respective bearings.

NOTICE:

Do not interchange the right and left race.

10. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT

(a) Install the 2 adjusting nuts onto the carrier, making sure the nuts are threaded properly.

11. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH

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

Text in Illustration

*a

Matchmark

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

Torque:

103 N·m {1049 kgf·cm, 76 ft·lbf}

  • If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.

(c) Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned using SST.

SST: 09504-00011

(d) Using SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.00788 in.).

(e) While turning the ring gear, using SST to tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side.

SST: 09504-00011

Text in Illustration

*a

Pinion Side

(f) Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification.

SST: 09504-00011

Standard backlash:

0.10 to 0.20 mm (0.00394 to 0.00787 in.)

HINT:

  • The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.
  • Perform the measurement at 3 or more positions around the circumference of the ring gear.

(h) Tighten the bearing cap bolts.

Torque:

103 N·m {1049 kgf·cm, 76 ft·lbf}

Text in Illustration

*a

Matchmark

12. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Standard total preload (at starting):

Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

(b) Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.

Text in Illustration

*a

Proper Contact

*b

Heel Contact

*c

Face Contact

*d

Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)

*e

Toe Contact

*f

Flank Contact

*g

Select an adjusting washer that will shift the drive pinion away from the ring gear (*e, *f)

-

-

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

    *1

    Plate Washer

    Washer thickness:

    Thickness

    Thickness

    1.040 to 1.060 mm (0.0410 to 0.0417 in.)

    1.315 to 1.335 mm (0.0518 to 0.0525 in.)

    1.065 to 1.085 mm (0.0420 to 0.0427 in.)

    1.340 to 1.360 mm (0.0528 to 0.0535 in.)

    1.090 to 1.110 mm (0.0430 to 0.0437 in.)

    1.365 to 1.385 mm (0.0538 to 0.0545 in.)

    1.115 to 1.135 mm (0.0439 to 0.0446 in.)

    1.390 to 1.410 mm (0.0548 to 0.0555 in.)

    1.140 to 1.160 mm (0.0449 to 0.0456 in.)

    1.415 to 1.435 mm (0.0557 to 0.0564 in.)

    1.165 to 1.185 mm (0.0459 to 0.0466 in.)

    1.440 to 1.460 mm (0.0567 to 0.0574 in.)

    1.190 to 1.210 mm (0.0469 to 0.0476 in.)

    1.465 to 1.485 mm (0.0577 to 0.0584 in.)

    1.215 to 1.235 mm (0.0478 to 0.0486 in.)

    1.490 to 1.510 mm (0.0587 to 0.0594 in.)

    1.240 to 1.260 mm (0.0489 to 0.0496 in.)

    1.515 to 1.535 mm (0.0597 to 0.0604 in.)

    1.265 to 1.285 mm (0.0498 to 0.0505 in.)

    1.540 to 1.560 mm (0.0607 to 0.0614 in.)

    1.290 to 1.310 mm (0.0508 to 0.0516 in.)

    -

14. REMOVE REAR DRIVE PINION NUT

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

SST: 09330-00021

09330-00030

15. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

17. REMOVE REAR DRIVE PINION FRONT BEARING

(a) Using SST, remove the bearing (inner race).

SST: 09556-22010

18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new spacer onto the drive pinion.

19. INSTALL REAR DRIVE PINION FRONT BEARING

(a) Install the drive pinion, front bearing (inner race) and oil slinger.

(b) Using SST and the companion flange, install the bearing (inner race) and then remove the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09956-03050

SST: 09955-03050

Text in Illustration

*a

Turn

*b

Hold

20. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end.

SST: 09316-12010

SST: 09649-17010

Standard oil seal depth:

0.05 to 0.95 mm (0.00197 to 0.0374 in.)

Text in Illustration

*a

Vinyl Tape

HINT:

Connect 2 SST with vinyl tape.

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

21. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, install the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09956-03030

SST: 09955-03050

Text in Illustration

*a

Turn

*b

Hold

22. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

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

(b) Using SST to hold the companion flange.

SST: 09330-00021

09330-00030

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

Torque:

441 N·m {4497 kgf·cm, 325 ft·lbf}

or less

(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

1.04 to 1.69 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)

Reused

0.85 to 1.37 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)

  • If the preload is greater than the maximum, replace the bearing spacer.
  • If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

Torque:

441 N·m {4497 kgf·cm, 325 ft·lbf}

or less

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

HINT:

Do not loosen the pinion nut to reduce the preload.

23. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Standard total preload (at starting):

Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

24. INSPECT DIFFERENTIAL RING GEAR BACKLASH

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

Standard backlash:

0.10 to 0.20 mm (0.00394 to 0.00787 in.)

  • If the backlash is not as specified, adjust the side bearing preload or repair as necessary.

    HINT:

    Perform the measurements at 3 or more positions around the circumference of the ring gear.

25. 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.

Text in Illustration

*a

72 mm (2.83 in.)

Maximum runout:

Runout

Specified Condition

Vertical runout

0.10 mm (0.00394 in.)

Lateral runout

0.10 mm (0.00394 in.)

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

26. STAKE REAR DRIVE PINION NUT

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

27. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

(a) Install 2 new adjusting locks onto the bearing caps with the 2 bolts.

Torque:

13 N·m {130 kgf·cm, 9 ft·lbf}

(b) Bend the nut locks.

    Installation

    Removal

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