2007 TOYOTA SIENNA differential

DF–18DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT
DUST COVER
(a) Using a screwdriver and a hammer, remove the side
gear shaft dust cover.
12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT
SEAL OIL
(a) Using SST, remove the 2 oil seals from the housing.
SST 09308-00010
13. REMOVE REAR DRIVE PINION NUT
(a) Using SST and a hammer, unstake the staked part
of the nut.
SST 09930-00010
(b) Using SST to hold the flange, remove the nut.
SST 09330-00021
14. REMOVE REAR DRIVE PINION COMPANION
FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03030, 09956-03020)
C068113
C097804E01
G024173E02
SA02349E08
R011391E04

DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–19
DF
15. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00360), 09950-70010
(09951-07150), 09950-00020
16. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal from the differential
carrier.
SST 09308-10010
17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL
SLINGER
18. REMOVE REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front tapered roller bearing
from the drive pinion.
SST 09556-22010
19. REMOVE REAR DIFFERENTIAL DRIVE PINION
BEARING SPACER
20. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Align matchmarks on the bearing cap and
differential carrier.
(b) Remove the 4bolts and 2 bearing caps.
(c) Using SST and a hammer, remove the 2 plate
washers.
SST 09504-22011
HINT:
Measure the thickness of the plate washers and
note it down.
F040564E10
SA02348E06
Z000641E06
F003753E01
C067710E02

DF–20DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
(d) Remove the differential case assembly and the 2
bearing outer races from the differential carrier.
HINT:
Tag the 2 bearing outer races races to show the
location for reassembly.
21. REMOVE DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion.
22. REMOVE REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, remove the rear bearing
from the drive pinion.
SST 09950-00020
HINT:
If either the drive pinion or ring gear is damaged,
replace both as a set.
(b) Remove the plate washer.
23. REMOVE REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING
(a) Using a brass bar and a hammer, remove the front
bearing (outer race) from the carrier.
24. REMOVE REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) Using a brass bar and a hammer, remove the rear
bearing (outer race) from the carrier.
25. REMOVE DIFFERENTIAL RING GEAR
(a) Align matchmarks on the ring gear and differential
case.
(b) Using a screwdriver and a hammer, unstake the 4
lock plates.
(c) Remove the 8 ring gear set bolts and 4 lock plates.
(d) Using a plastic hammer, tap on the ring gear to
separate it from the differential case.
C068107
R010668E05
C051361
C051362
F003755E01

DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–21
DF
26. INSPECT DIFFERENTIAL CASE ASSEMBLY
(a) Install the differential case to the differential carrier.
(b) Install the right and left bearing caps with the 4 bolts.
Torque: 79 N*m (800 kgf*cm, 58 ft.*lbf)
(c) Using a dial gauge, measure the differential case
runout.
Maximum case runout:
0.07 mm (0.0028 in.)
(d) Remove the differential case.
27. REMOVE REAR DIFFERENTIAL CASE BEARING LH
(a) Using SST, remove the case bearing (LH) from the
differential case.
SST 09950-40011 (09951-00240, 09951-04020,
09952-04010, 09953-04030, 09954-04010,
09955-04061, 09957-04010, 09958-04011),
09950-60010 (09951-00360)
28. REMOVE REAR DIFFERENTIAL CASE BEARING RH
(a) Using SST, remove the case bearing (RH) from the
differential case.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04061,
09957-04010, 09958-04011), 09950-60010
(09951-00360)
29. REMOVE REAR DIFFERENTIAL PINION SHAFT
(a) Using a pin punch (5 mm) and a hammer, remove
the straight pin.
(b) Remove the differential pinion shaft. (A)
(c) Remove the 2 differential pinion gears. (B)
(d) Remove the 2 differential pinion thrust washers. (C)
(e) Remove the 2 side gears. (D)
(f) Remove the 2 side gear thrust washers. (E)
C068112
F040345E05
F040346E02
C063262
ZK01879E04

DF–22DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
INSPECTION
1. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Using a dial gauge , check the runout of the ring
gear.
Maximum runout:
0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace
the ring gear with a new one.
2. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial gauge, check the backlash of the ring
gear.
Backlash:
0.13 to 0.18 mm (0.0051 to 0.0071 in.)
If the backlash is not within the specification, adjust
the side bearing preload or repair as necessary.
3. INSPECT RUNOUT OF REAR DRIVE PINION
COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial gauge, measure the runout of the
companion flange vertically and horizontally.
Maximum runout:
0.10 mm (0.0039 in.)
REASSEMBLY
1. INSTALL REAR DIFFERENTIAL PINION SHAFT
(a) Install the 2 thrust washers to the 2 side gears.
(b) Install the 2 side gears, 2 differential pinion gears, 2
differential pinion thrust washers and differential
pinion shaft to the differential case.
HINT:
Align the holes of the differential case and
differential pinion shaft.
2. ADJUST DIFFERENTIAL PINION GEAR BACKLASH
(a) Install the side gear shaft.
G021128
G021129
F001237E01
FA01121

DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–23
DF
(b) Measure the side gear backlash while holding 1
pinion gear toward the differential case.
Backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specification, install
the 2 side gear thrust washers of different
thicknesses.
HINT:
• Measure the backlash of the side gear with the
side gear shaft installed.
• Refer to the following table to select 2 thrust
washers which ensures that the backlash is
within the specification.
Thrust washer thickness
(c) Remove the side gear shaft.
(d) Using a pin punch (5 mm) and a hammer, install the
straight pin through the differential case and hole of
the pinion shaft.
(e) Using a chisel and a hammer, stake the outside of
the differential case pin hole.
3. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case
and ring gear.
(b) Heat the ring gear to approx. 100
C (212F) 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 install the ring gear to the
differential case.
C082953
Thickness mm (in.) Thickness mm (in.)
0.93 to 0.97 (0.0366 to 0.0382) 1.18 to 1.22 (0.0465 to 0.0480)
0.98 to 1.02 (0.0386 to 0.0402) 1.23 to 1.27 (0.0484 to 0.0500)
1.03 to 1.07 (0.0406 to 0.0421) 1.28 to 1.32 (0.0504 to 0.0520)
1.08 to 1.12 (0.0425 to 0.0441) 1.33 to 1.37 (0.0524 to 0.0539)
1.13 to 1.17 (0.0445 to 0.0461) 1.38 to 1.42 (0.0543 to 0.0559)
FA01124
SA01143E03

DF–24DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
(e) Align the matchmarks on the ring gear and
differential case.
(f) Temporarily install 4 new lock plates and 8 bolts.
(g) After the ring gear cools down enough, torque the 8
bolts uniformly.
Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf)
HINT:
Tighten the bolts, in diagonal order, a little at a time
until they are all tightened.
(h) Using a chisel and a hammer, stake the 4 lock
plates.
(1) Stake one claw so that it is flush against the flat
surface of the bolt.
(2) As for the head so as to act as a stopper if the
bolt should start to loosen.
4. INSTALL REAR DIFFERENTIAL CASE BEARING RH
(a) Using SST and a press, install the case bearing
(RH) to the differential case.
SST 09636-20010
5. INSTALL REAR DIFFERENTIAL CASE BEARING LH
(a) Using SST and a press, install the case bearing
(LH) to the differential case.
SST 09636-20010
6. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Install the differential case to the carrier, and install
the 2 plate washers so that there is no play in the
bearing.
(b) Install the 2 bearing caps with the 4 bolts
Torque: 79 N*m (800 kgf*cm, 58 ft.*lbf)
(c) Using a dial gage, measure the runout of the ring
gear.
Maximum runout:
0.07 mm (0.0028 in.)
F003758E04
Z002483
F040347E01
F040463E01
C068116

DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–25
DF
(d) Remove the 2 bearing caps, 2 plate washers and
differential carrier.
7. INSTALL REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front bearing
(outer race) to the carrier.
SST 09950-60010 (09951-00620), 09950-70010
(09951-07150)
8. INSTALL REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the rear bearing
(outer race) to the carrier.
SST 09950-60020 (09951-00710), 09950-70010
(09951-07150)
(b) Install the removed plate washer to the drive pinion.
(c) Using SST and a press, install the bearing to the
drive pinion.
SST 09506-30012
9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer and oil seal after adjusting the
gear contact pattern.
F040461E01
F040462E01
SA03102E04
F001250