Page 1617 of 2062
Downloaded from www.Manualslib.com manuals search engine R00055
SST
R11163SST
SA2351
SST
SA2446
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−147
1996 TOYOTA T100 (RM449U)
HINT:
First fit a washer with the same thickness as the washer which
was removed, then after checking the tooth contact pattern, re-
place the washer with one of a different thickness if necessary.
6. INSTALL DRIVE PINION REAR BEARING
Using SST and a press, install the rear bearing onto the drive
pinion.
SST 09506−35010
7. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer, washers and oil seal after adjusting the
gear contact pattern.
(b) Using SST, install the companion flange.
SST 09950−30010
(c) Coat the threads of the nut with hypoid gear oil.
(d) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
Using SST to hold the flange, torque the nut.
SST 09330−00021
NOTICE:
As there is no spacer, tighten the nut a little at a time, being
careful not to overtighten it.
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
Page 1618 of 2062
Downloaded from www.Manualslib.com manuals search engine R04453
R04535
R04558
R04453
R04455
SA−148
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
8. INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the bearing outer races on their respective bear-
ings. Make sure the left and right races are not inter-
changed.
(b) Install the differential case in the carrier.
9. ADJUST RING GEAR BACKLASH
(a) Only install the plate washer on the ring gear back side.
HINT:
Makes that the ring gear has a backlash.
(b) Tap on the ring gear with a plastic hammer so that the
washer fit to the bearing.
(c) Using a dial indicator, measure the side gear backlash
with holding one pinion gear toward the differential case.
Backlash (reference):
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(d) Select a plate washer for back side ring gear, using the
backlash as reference (See page SA−145).
(e) Select a ring gear teeth side plate washer of a thickness
which eliminates any clearance between the outer race
and case.
Page 1619 of 2062
Downloaded from www.Manualslib.com manuals search engine R04338
R04456
RA0090
R04456
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−149
1996 TOYOTA T100 (RM449U)
(f) Remove the plate washers and differential case.
(g) Install the plate washer into the ring gear back side of the
carrier.
(h) Place the other plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Tap on the ring gear with a plastic hammer so that the
washer fit to the bearing.
(j) Using a dial indicator, measure the ring gear backlash.
Backlash:
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(k) If the backlash not within specification, adjust by either in-
creasing or decreasing the thickness of washers on both
sides by an equal amount.
HINT:
There should be no clearance between the plate washer
and case.
Make sure that there is ring gear backlash.
10. ADJUST SIDE BEARING PRELOAD
(a) After adjustment with the backlash as reference, remove
the ring gear teeth side plate washer and measure the
thickness.
(b) Install a new washer of 0.06 − 0.09 mm (0.00024 − 0.0035
in.) thicker than the washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way by fin-
ger.
(c) Using a plastic hammer, tap in the plate washer.
(d) Recheck the ring gear backlash.
Backlash:
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(e) If the backlash is not within specification, adjust by either
increasing or decreasing the thickness washers on both
sides by equal amount.
HINT:
The backlash will change by about 0.20 mm (0.0008 in.) with
every 0.03 mm (0.0012 in.) change in the side washer.
Page 1620 of 2062
Downloaded from www.Manualslib.com manuals search engine R04323
SA−150
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
Washer thickness
Thickness
Mark mm (in.)Thickness
Mark mm (in.)Thickness
Mark mm (in.)
58 2.58 (0.1015) 90 2.90 (0.1142) 22 3.22 (0.1268)
60 2.60 (0.1024) 92 2.92 (0.1150) 24 3.24 (0.1276)
62 2.62 (0.1031) 94 2.94 (0.1157) 26 3.26 (0.1283)
64 2.64 (0.1039) 96 2.96 (0.1165) 28 3.28 (0.1291)
66 2.66 (0.1047) 98 2.98 (0.1173) 30 3.30 (0.1299)
68 2.68 (0.1055) 00 3.00 (0.1181) 32 3.32 (0.1307)
70 2.70 (0.1063) 02 3.02 (0.1189) 34 3.34 (0.1315)
72 2.72 (0.1071) 04 3.04 (0.1197) 36 3.36 (0.1323)
74 2.74 (0.1079) 06 3.06 (0.1205) 38 3.38 (0.1331)
76 2.76 (0.1087) 08 3.08 (0.1213) 40 3.40 (0.1339)
78 2.78 (0.1094) 10 3.10 (0.1220) 42 3.42 (0.1346)
80 2.80 (0.1102) 12 3.12 (0.1228) 44 3.44 (0.1354)
82 2.82 (0.1110) 14 3.14 (0.1236) 46 3.46 (0.1362)
84 2.84 (0.1118) 16 3.16 (0.1244) 48 3.48 (0.1370)
86 2.86 (0.1126) 18 3.18 (0.1252)−
88 2.88 (0.1134) 20 3.20 (0.1260)−
11. INSTALL BEARING CAPS
Align the matchmarks on the 2 caps and carrier and torque the
4 bolts.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
12. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the ring
gear with red lead primer.
(b) Turn the companion flange in both directions to inspect
the ring gear for proper tooth contact.
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Downloaded from www.Manualslib.com manuals search engine R02495
Proper ContactToe Contact Flank Contact Heel Contact Face Contact
Select an adjusting shim that will bring the drive
pinion closer to the ring gear.
Select an adjusting shim that will shift the drive
pinion away from the gear.
R04554
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−151
1996 TOYOTA T100 (RM449U)
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
Washer thickness
Thickness
Mark mm (in.)Thickness
Mark mm (in.)Thickness
Mark mm (in.)
87 1.87 (0.0736) 01 2.01 (0.0791) 15 2.15 (0.0846)
88 1.88 (0.0740) 02 2.02 (0.0795) 16 2.16 (0.0850)
89 1.89 (0.0744) 03 2.03 (0.0799) 17 2.17 (0.0854)
90 1.90 (0.0748) 04 2.04 (0.0803) 18 2.18 (0.0858)
91 1.91 (0.0752) 05 2.05 (0.0807) 19 2.19 (0.0862)
92 1.92 (0.0756) 06 2.06 (0.0811) 20 2.20 (0.0866)
93 1.93 (0.0760) 07 2.07 (0.0815) 21 2.21 (0.0870)
94 1.94 (0.0764) 08 2.08 (0.0819) 22 2.22 (0.0874)
95 1.95 (0.0768) 09 2.09 (0.0823) 23 2.23 (0.0878)
96 1.96 (0.0772) 10 2.10 (0.0827) 24 2.24 (0.0882)
97 1.97 (0.0776) 11 2.11 (0.0831) 25 2.25 (0.0886)
98 1.98 (0.0780) 12 2.12 (0.0835) 26 2.26 (0.0890)
99 1.99 (0.0783) 13 2.13 (0.0839) 27 2.27 (0.0894)
00 2.00 (0.0787) 14 2.14 (0.0843) 28 2.28 (0.0898)
Page 1622 of 2062
Downloaded from www.Manualslib.com manuals search engine R11163SST
R04341
SST
SA2351
SST
SA2352
SA−152
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
14. REMOVE COMPANION FLANGE (See page SA−140)
15. REMOVE FRONT BEARING (See page SA−140)
16. INSTALL NEW BEARING SPACER, WASHERS AND
FRONT BEARING
(a) Install a new bearing spacer and 2 washers, and place the
front bearing.
(b) Using SST and the companion flange, install the front
bearing then remove the companion flange.
SST 09950−30010
17. INSTALL NEW OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST and a press, tap in the oil seal until its surface
with the differential carrier end.
SST 09316−12010, 09649−17010,
HINT:
Connect SST with vinyl tape.
18. INSTALL COMPANION FLANGE
(a) Install the companion flange on the shaft.
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 147 N·m (1,500 kgf·cm, 109 ft·lbf)
19. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
If preload is greater than the specification, replace the bearing
spacer.
If preload is less than specification, retorque the nut a little at
a time with a torque of 13 N·m (130 kgf·cm, 9 ft·lbf) until the spe-
cified preload is reached.
Page 1623 of 2062
Downloaded from www.Manualslib.com manuals search engine SA2351
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−153
1996 TOYOTA T100 (RM449U)
Torque: 451 N·m (4,600 kgf·cm, 333 ft·lbf) or less
If the maximum torque is exceeded with retightening the nut, re-
place the bearing spacer and repeat the preload adjusting pro-
cedure. Do not loosen the pinion nut to reduce the preload.
20. INSTALL DIFFERENTIAL CASE IN CARRIER (See
page SA−145)
21. RECHECK TOTAL PRELOAD (See page SA−145)
22. RECHECK RING GEAR BACKLASH (See page
SA−145)
23. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−145)
24. CHECK RUNOUT OF COMPANION FLANGE (See
page SA−140)
25. STAKE DRIVE PINION NUT
Page 1624 of 2062
Downloaded from www.Manualslib.com manuals search engine SA0I7−02
RA10720 − 5 mm (0 − 0.20 in.) OilFiller Hole SA−154
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL NEW GASKET TO AXLE HOUSING
2. INSTALL DIFFERENTIAL CARRIER ASSEMBLY
Install the differential carrier assembly in the axle housing.
Torque: 73 N·m (740 kgf·cm, 54 ft·lbf)
3. INSTALL PROPELLER SHAFT
2WD: See page PR−9
4WD: See page PR−16
4. INSTALL REAR AXLE SHAFTS
(See page SA−135)
5. FILL DIFFERENTIAL WITH DIFFERENTIAL OIL
Torque:
Drain plug: 49 N·m (500 kgf·cm, 39 ft·lbf)
Filler plug: 39 N·m (400 kgf·cm, 29 ft·lbf)
Oil type: Hypoid gear oil API GL−5
Recommended oil viscosity:
Above −18°C (0°F) SAE 90
Below −18°C (0°F) SAE 80W or 80W − 90
Capacity: 2.35 liters (2.22 US qts, 2.67 lmp.qts)
