2007 TOYOTA SIENNA differential

DF–26DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
(b) Install the oil slinger, as shown in the illustration.
(c) Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03030, 09956-03020)
(d) Coat the threads of the nut with hypoid gear oil LSD.
(e) Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf)
NOTICE:
• Torque the nut a little at a time, being careful
not to overtighten it.
• Apply hypoid gear oil LSD to the nut.
(f) Using a torque wrench, measure the preload.
Torque: New bearing
1.1 to 1.7 N*m (1.1 to 1.7 kgf*cm, 9.6 to
14.8 in.*lbf)
Reused bearing
0.6 to 0.9 N*m (6 to 9 kgf*cm, 5.2 to 7.8
in.*lbf)
10. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Place the 2 bearing outer races on their respective
bearings. Make sure the right and left races are not
interchanged.
11. ADJUST DIFFERENTIAL RING GEAR BACKLASH
(a) Install the right and left bearing caps with the 4 bolts.
Torque: 79 N*m (800 kgf*cm, 58 ft.*lbf)
HINT:
• When using a new side bearing select a thrust
shim which is thinner than the removed one.
• If the side bearing is reused, select a thrust shim
of the same thickness as the removed one.
C083862
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SA02351E08
SA02352

DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–27
DF
(b) Make sure the differential case bearing and thrust
shim by tapping on the ring gear with a plastic
hammer.
(c) Set the dial gauge perpendicular to the end of the
ring gear face.
(d) While holding the rear drive pinion companion
flange, rotate the ring gear and measure the
backlash.
Backlash:
0.13 to 0.18 mm (0.0051 to 0.0071 in.)
NOTICE:
Measure it at 3 points or more on the ring gear
periphery.
If the measured value is out of the specified value,
select a proper thrust shim so that the backlash of
the differential ring gear is within the value, and
install it to the ring gear back side.
Washer thickness
12. ADJUST TOTAL PRELOAD
(a) After adjusting the backlash of the differential ring
gear, remove the teeth side thrust shim.
(b) Using a micrometer, measure the thickness of the
removed thrust shim.
(c) Select a new thrust shim 0.06 to 0.09 mm (0.0024 to
0.0035 in.) which is thicker than the removed one.
HINT:
Select a thrust shim whish can pressed in 2/3 rds of
the way by finger.
(d) Using SST and a plastic hammer, drive in the thrust
shim.
SST 09504-22011
(e) Align matchmarks on the bearing cap and
differential carrier, and install the 2 bearing caps.
NOTICE:
Make sure the right and left bearing caps are not
interchanged.
(f) Tighten both bearing caps with the 4 bolts.
Torque: 79 N*m (800 kgf*cm, 58 ft.*lbf)
F001239
Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
2.21 to 2.23 (0.0870 to 0.0878) 2.57 to 2.59 (0.1012 to 0.1020) 2.93 to 2.95 (0.1154 to 0.1161)
2.24 to 2.26 (0.0882 to 0.0890) 2.60 to 2.62 (0.1024 to 0.1030) 2.96 to 2.98 (0.1165 to 0.1173)
2.27 to 2.29 (0.0894 to 0.0902) 2.63 to 2.65 (0.1035 to 0.1043) 2.99 to 3.01 (0.1177 to 0.1185)
2.30 to 2.32 (0.0906 to 0.0913) 2.66 to 2.68 (0.1047 to 0.1055) 3.02 to 3.04 (0.1189 to 0.1197)
2.33 to 2.35 (0.0917 to 0.0925) 2.69 to 2.71 (0.1059 to 0.1067) 3.05 to 3.07(0.1201 to 0.1209)
2.36 to 2.38 (0.0929 to 0.0937) 2.72 to 2.74 (0.1071 to 0.1079) 3.08 to 3.10 (0.1213 to 0.1220)
2.39 to 2.41 (0.0941 to 0.0949) 2.75 to 2.77 (0.1083 to 0.1091) 3.11 to 3.13 (0.1224 to 0.1232)
2.42 to 2.44 (0.0953 to 0.0961) 2.78 to 2.80 (0.1094 to 0.1102) 3.14 to 3.16 (0.1236 to 0.1244)
2.45 to 2.47 (0.0965 to 0.0972) 2.81 to 2.83 (0.1106 to 0.1114) 3.17 to 3.19 (0.1248 to 0.1256)
2.48 to 2.50 (0.0976 to 0.0984) 2.84 to 2.86 (0.1118 to 0.1126) 3.20 to 3.22 (0.1260 to 0.1268)
2.51 to 2.53 (0.0988 to 0.0996) 2.87 to 2.89 (0.1130 to 0.1138) -
2.54 to 2.56 (0.1000 to 0.1008) 2.90 to 2.92 (0.1142 to 0.1150) -
F040494E02

DF–28DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
(g) Set the dial gauge to the end of the differential ring
gear face.
(h) While holding the rear drive pinion companion
flange, rotate the differential ring gear and measure
the backlash.
Backlash:
0.13 to 0.18 mm (0.0051 to 0.0071 in.)
(i) If the measured value is out of the specified value,
adjust it by increasing or decreasing the thickness of
both right and left thrust shims equally.
(j) Using a torque wrench, measure the preload.
Torque: Total preload
0.3 to 0.5 N*m (3 to 5 kgf*cm, 2.6 to 4.3
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 red lead primer.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
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DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–29
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(c) Inspection the tooth contact pattern.
If the teeth are not contacting properly, use following
table to select proper washer for correction.
Washer thickness
14. REMOVE REAR DRIVE PINION NUT (See page DF-18)
15. REMOVE REAR DRIVE PINION COMPANION
FLANGE SUB-ASSEMBLY (See page DF-18)
16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL
SLINGER
(a) Remove the rear differential drive pinion oil slinger.
17. REMOVE REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING (See page DF-19)
SA01586E01
SA01653E05
Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
2.26 to 2.28 (0.0890 to 0.0898) 2.41 to 2.43 (0.0949 to 0.0957) 2.56 to 2.58 (0.1008 to 0.1016)
2.29 to 2.31 (0.0902 to 0.0909) 2.44 to 2.46 (0.0961 to 0.0969) 2.59 to 2.61 (0.1020 to 0.1028)
2.32 to 2.34 (0.0913 to 0.0921) 2.47 to 2.49 (0.0972 to 0.0980) 2.62 to 2.64 (0.1031 to 0.1039)
2.35 to 2.37 (0.0925 to 0.0933) 2.50 to 2.52 (0.0984 to 0.0992) 2.65 to 2.67 (0.1043 to 0.1051)
2.38 to 2.40 (0.0937 to 0.0945) 2.53 to 2.55 (0.0996 to 0.1004) 2.68 to 2.70 (0.1055 to 0.1063)

DF–30DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
18. INSTALL REAR DIFFERENTIAL DRIVE PINION
BEARING SPACER
(a) Install a new bearing spacer.
19. INSTALL REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING
(a) Install the rear drive pinion front tapered roller
bearing to the drive pinion.
20. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL
SLINGER
(a) Install the oil slinger, as shown in the illustration.
21. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09554-22010
Oil seal drive in depth:
2.0+- 0.3 mm (0.079 +- 0.012 in.)
(b) Apply MP grease to the oil seal lip.
22. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, install a new dust deflector.
SST 09223-00010
NOTICE:
Be careful not to damage the dust deflector.
F001250
C083862
F001261E01
F040464E03

DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–31
DF
23. INSTALL REAR DRIVE PINION COMPANION FLANGE
SUB-ASSEMBLY
(a) Using SST, install the companion flange to the drive
pinion.
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03030, 09956-03020)
(b) Coat the threads of a new nut with hypoid gear oil
LSD.
(c) Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf)
24. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the
drive pinon.
Torque: New bearing
1.1 to 1.7 N*m (11 to 17 kgf*cm, 9.6 to
14.8 in.*lbf)
Reused bearing
0.6 to 0.9 N*m (6 to 9 kgf*cm, 5.2 to 7.8
in.*lbf)
• If the preload is greater than the specification,
replace the bearing spacer.
• If the preload is less than the specification,
replace the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf)
of torque at a time until the specified preload is
reached.
Torque: 235 N*m (2,400 kgf*cm, 174 ft.*lbf)
• If the torque exceeds the maximum while
retightening the nut, replace the bearing spacer
and repeat the preload adjusting procedure.
NOTICE:
Do not loosen the pinion nut to reduce the
preload.
HINT:
This preload is within the backlash between the
drive pinion and ring gear.
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DF–32DIFFERENTIAL – REAR DIFFERENTIAL CARRIER
DF
25. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload.
Torque: Total preload
0.3 to 0.5 N*m (3 to 5 kgf*cm, 2.6 to 4.3
in.*lbf)
26. 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.
27. INSPECT REAR DRIVE PINION COMPANION
FLANGE SUB-ASSEMBLY
(a) Using a dial gauge, measure the runout of the
companion flange vertically.
Maximum runout:
0.10 mm (0.0039 in.)
28. INSTALL REAR DRIVE PINION NUT
(a) Using a chisel and hammer, stake the drive pinion
nut.
29. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT
SEAL OIL
(a) Using SST and a hammer, install 2 new oil seals.
SST 09550-00032, 09950-70010 (09951-07200)
Oil seal drive in depth:
0 +- 0.5 mm (0 +- 0.019 in.)
(b) Apply MP grease to the oil seal lip.
30. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT
DUST COVER
(a) Using a steel plate and a press, install a new dust
cover.
NOTICE:
Be careful not to damage the dust cover.
SA02352
G021129
F001237E01
F001262E02
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DIFFERENTIAL – REAR DIFFERENTIAL CARRIERDF–33
DF
31. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT
SUB-ASSEMBLY
(a) Install the 2 side gear shaft to the differential case.
(b) Using needle nose pliers, install 2 new snap rings to
the 2 side gear shafts.
(c) Using vernier calipers, measure the distance
between the right and left side gear shafts, as
shown in the illustration.
Standard distance:
242 mm (9.528 in.)
32. INSTALL REAR DIFFERENTIAL CARRIER COVER
(a) Install the oil deflector and bolt to the carrier cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
(b) Install the breather plug to the carrier cover.
Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf)
(c) Clean contacting surfaces of any residual FIPG
material using gasoline or alcohol.
(d) Apply FIPG to the carrier.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or equivalent
HINT:
• FIPG should be applied 2 to 3 mm (0.08 to 0.12
in.) in diameter with no break.
• Allow for an overlap of 10 mm (0.37 in.) or more
between the start and end of FIPG application.
• Install the carrier cover within 3 minutes after
applying FIPG.
• Do not add oil or drive the vehicle immediately
after installing the cover, and leave it as is for at
least an hour or more. Also, for 12 hours or more,
avoid rapid acceleration/deceleration.
C067701
F040466E01
C067695
F003983E01