Fig Measuring Clearance Between Shift Fork Sleeve With Electronic Locking Differential Courtesy of Toyota Motor Sales Usa Inc

Reassembly & Adjustments

1. Using a press, install NEW dust deflector on companion flange (if removed).

2. Install spider, side gears, pinion gears and thrust washers in right differential case. Using dial indicator, check side gear backlash in 4 locations, while holding side gear and spider. See Fig. 8 . Check side gear backlash in left and right differential cases.

3. Side gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS . If side gear backlash is not within specification, install different thickness thrust washer onto both side gears and recheck side gear backlash. Thrust washers are available in various thicknesses.

4. Once correct side gear backlash is obtained, coat components with gear oil. Assemble right and left differential cases with reference marks aligned. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

5. Using a press, install NEW side bearings onto differential case (if removed). Place ring gear in water and heat to 212°F (100°C).

6. Remove ring gear from water and allow moisture to evaporate. Install ring gear on differential case with reference marks aligned.

7. Loosely install all ring gear bolts and NEW lock plates. Allow ring gear to cool.

CAUTION: DO NOT tighten ring gear bolts to specification until ring gear has cooled.

8. Once ring gear has cooled, tighten ring gear bolts in a crisscross pattern to specification. See TORQUE SPECIFICATIONS . Bend tabs on lock plates against ring gear bolts.

9. Install differential case with side bearings and races into differential carrier. Install side bearing caps and adjusting nuts. Tighten adjusting nuts until no play exists in side bearing. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS .

10. Using dial indicator, check ring gear runout while rotating differential case. Replace ring gear and pinion gear if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.

11. Using a hammer and Replacer Pipe (09316-60011), install NEW oil storage ring in differential carrier. Using a press, install NEW outer races for front and rear pinion bearings in differential carrier (if removed). If installing NEW rear bearing on drive pinion, install washer on drive pinion. Press rear bearing onto drive pinion.

12. Install drive pinion, front bearing and oil slinger in differential carrier. DO NOT install spacer and oil seal at this time.

13. Install companion flange on drive pinion. Coat threads of drive pinion nut with oil. Install drive pinion nut onto drive pinion. Hold companion flange and slightly tighten drive pinion nut in small increments.

CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer is not installed on drive pinion. Drive pinion nut must be tightened until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .

14. Rotate drive pinion clockwise and counterclockwise several times. Using an INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload for reassembly reference. Tighten drive pinion nut until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .

15. Apply grease to shift fork rack and connecting part of indicator switch. Insert shift fork into differential carrier. Install outer races onto side bearings. Ensure bearing races are installed on original side bearings. Install adjusting nuts and left side sleeve. Ensure sleeve moves smoothly. Install differential case into differential carrier with aligning shift fork in groove of sleeve. Ensure backlash exists between ring gear and drive pinion.

16. Install side bearing caps in original location with reference marks aligned. Install bearing cap bolts about 3 revolutions and press side bearing caps downward.

17. If bearing caps do not seat tightly on differential carrier, adjusting nuts are not properly threaded into

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier differential carrier. Remove adjusting nuts and reinstall (if necessary).

18. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Loosen bearing cap bolts until side bearing cap bolts can be rotated by hand.

19. Fully tighten side bearing cap bolts by hand. Tighten adjusting nut on backside (opposite ring gear teeth) until ring gear has a backlash of about .008" (0.20 mm).

20. While rotating ring gear, fully tighten adjusting nut on front side (teeth side of ring gear) to fully seat bearings. Loosen adjusting nut on front side (teeth side of ring gear).

21. Position dial indicator on differential carrier with stem resting against top of adjusting nut on backside (opposite ring gear teeth). Tighten adjusting nut on front side (teeth side of ring gear) until dial indicator starts to move.

22. Tighten adjusting nut on front side (teeth side of ring gear) an additional 1 to 1 1/2 notches.

23. Using dial indicator, check ring gear backlash. Ring gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

24. If ring gear backlash is not within specification, rotate both adjusting nuts same amount. For example, if adjusting nut on front side (teeth side of ring gear) is loosened one notch, adjusting nut on backside (opposite ring gear teeth) must be tightened one notch. Ensure adjusting nuts are moved same amount to maintain proper bearing preload.

25. Once correct gear backlash is obtained, tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Recheck ring gear backlash.

26. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

27. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, change thickness of plate washer on drive pinion.

28. Remove drive pinion nut. Using puller, remove companion flange from drive pinion. Remove front bearing and oil slinger from differential carrier.

29. Install NEW spacer onto drive pinion. Install front bearing and oil slinger onto drive pinion. Use installer tool and companion flange to fully install bearing. Remove companion flange.

30. Install NEW oil seal to correct depth on differential carrier. See DRIVE PINION OIL SEAL DEPTH INSTALLATION SPECIFICATIONS table.

31. Apply grease to lip of oil seal. Install companion flange onto drive pinion. Apply grease to threads of NEW drive pinion nut. Install washer and drive pinion nut onto drive pinion.

32. Tighten drive pinion nut to minimum specification. See TORQUE SPECIFICATIONS . Using INCH-lb. torque wrench installed onto drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

33. If drive pinion rotating torque exceeds specification, replace spacer and repeat procedure. If drive pinion rotating torque is less than specified, tighten drive pinion nut in small increments until correct rotating torque is obtained. DO NOT exceed maximum drive pinion nut torque. If maximum torque is exceeded, replace spacer and repeat procedure. DO NOT back off drive pinion nut.

34. Recheck ring gear backlash and gear tooth contact pattern. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Fig. 6 . If vertical or lateral runout

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier exceeds .0039" (0.100 mm), check bearing on drive pinion.

35. Once all specifications are correct, stake drive pinion nut against drive pinion. Install adjusting nut lock on each bearing cap. Install and tighten bolts to specification.

36. Apply grease to fork shaft. Install fork shaft. Align fork shaft screw plug holes with holes on shift fork. Place a bead of RTV sealant to shaft retainer. See Fig. 11 . Apply adhesive to bolt threads, and install shaft retainer bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

37. Using a punch and hammer, install slotted spring pin into shift lock. Push shift fork into lock position. See Fig. 12 . Install ball, compression spring and spring seat. Apply adhesive to screw plug, and install and tighten plugs. See TORQUE SPECIFICATIONS .

38. Measure distance between sleeve and tip of differential case when differential is in free position and in locked position. See Fig. 13 . Distance should be 1.276-1.335" (32.41-33.91 mm) with differential in free position, and .687-.743" (17.45-18.87 mm) with differential in locked position. Install indicator switch and NEW gasket. See TORQUE SPECIFICATIONS .

39. Verify outermost rack tooth of shift fork is above center line of actuator installation hole. See Fig. 14 . Apply 1.5 volts to actuator connector terminals No. 2 (Light Green/Red wire) and No. 3 (Light Green wire). Actuator pinion should rotate about 108 degrees counterclockwise from top of center line of actuator. See Fig. 15 . Reverse polarity. Actuator should rotate back to near original position.

40. Insert actuator so that long hole on actuator side fits with knock pin on carrier side. See Fig. 16 . DO NOT damage "O" ring of actuator. Align actuator with long hole. Rotate actuator counterclockwise when knock pin reaches right side. Install actuator to differential carrier with bolt so that outermost rack tooth of shift fork will fit reference marks of pinion of actuator.

41. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fill differential. Ensure electronic locking differential operates properly.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

4runner Lock Differential
Fig. 11: Identifying RTV Sealant Location On Shaft Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Toyota Sequoia Rack And Pinion 2001
Fig. 12: Installing Shift Fork Into Differential Case

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Axle Differential Repair Sleeve
Fig. 13: Measuring Distance Between Sleeve & Tip Of Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Electronic Locking Rear Differential
Fig. 14: Identifying Rack Tooth Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Toyota Sequoia Rear Differential

G97C08691

Fig. 15: Checking Actuator Pinion Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Imagen Motor Toyota Corolla 2003

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