Toyota Tundra Service Manual: Disassembly

DISASSEMBLY

PROCEDURE

1. 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

Standard 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.

2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

(a) 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 with a new one.

3. INSPECT DIFFERENTIAL RING GEAR BACKLASH

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

Standard backlash:

0.10 to 0.20 mm (0.00394 to 0.00787 in.)

HINT:

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

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

4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

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

Standard backlash:

0.15 mm (0.00591 in.) or less

If the backlash is not within the specification, replace the side gear thrust washer with one of a different thickness.

5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard drive pinion preload (at starting):

1.62 to 2.25 N*m (17 to 22 kgf*cm, 15 to 19 in.*lbf)

If necessary, disassemble and inspect the differential.

6. INSPECT TOTAL PRELOAD

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

Standard total preload (at starting):

Standard drive pinion preload plus 0.19 to 0.38 N*m (2 to 3 kgf*cm, 2 to 3 in.*lbf)

If necessary, disassemble and inspect the differential.

7. REMOVE REAR DRIVE PINION NUT

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

SST: 09930-00010

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

SST: 09330-00021

09330-00030

8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, remove the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09956-03030

SST: 09955-03050

Text in Illustration

*a

Turn

*b

Hold

9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST, remove the oil seal.

SST: 09308-10010

10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

11. REMOVE REAR DRIVE PINION FRONT BEARING

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

SST: 09950-40011

09951-04010

09953-04020

09952-04010

SST: 09955-04130

SST: 09958-04020

(b) Remove the 2 preload adjusting shims.

12. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY

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

Text in Illustration

*a

Matchmark

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

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

SST: 09504-22012

HINT:

Measure the plate washer thickness and note it down.

(d) Remove the differential case with the bearing outer races from the carrier.

HINT:

Tag the bearing outer races to show the location for reassembling.

13. REMOVE REAR DIFFERENTIAL DRIVE PINION

(a) Remove the differential drive pinion and bearing spacer from the differential carrier.

14. REMOVE REAR DRIVE PINION REAR BEARING

(a) Using SST and a press, press out the bearing (inner race).

SST: 09950-00020

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

15. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

16. REMOVE REAR DRIVE PINION FRONT BEARING

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

SST: 09308-00010

If the bearing is damaged during removal, replace it.

17. REMOVE DIFFERENTIAL OIL STORAGE RING

(a) Using a brass bar and hammer, tap out the storage ring.

18. REMOVE REAR DRIVE PINION REAR BEARING

(a) Using a brass bar and hammer, tap out the bearing (outer race).

If the bearing is damaged during removal, replace it.

19. REMOVE DIFFERENTIAL RING GEAR

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

Text in Illustration

*a

Matchmark

(b) Remove the 12 ring gear set bolts.

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

20. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Using SST, remove the 2 bearings.

SST: 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09957-04010

09958-04011

SST: 09950-60010

09951-00500

SST: 09955-04120

HINT:

Fix the claws of SST to the notches in the differential case.

21. DISASSEMBLE DIFFERENTIAL CASE

(a) Using a pin punch and hammer, tap out the straight pin.

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

    Components

    Installation

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