Diferencial Frontal Tacoma

1998 Toyota Truck Tacoma Extra Cab 4WD V6-3.4L (5VZ-FE) Copyright © 2013, ALLDATA 10.
52SS Page 1
Differential Assembly: Service and Repair

Front
DISASSEMBLY
1998 Toyota Truck Tacoma Extra Cab 4WD V6-3.4L (5VZ-FE) Copyright © 2013, ALLDATA 10.52SS Page 2
1. Check runout of companion flange.

Using a dial indicator, measure the vertical and horizontal runout of the companion flange.
Maximum:
Vertical runout: 0.10 mm (0.0039 inch)
Horizontal runout: 0.10 mm (0.0039 inch)
If the runout is greater than the maximum, replace the companion flange.
2. Check ring gear backlash.

Using Special Service Tool (SST) 09564-32011 or equivalent, and a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
3. Measure drive pinion preload.

Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)
4. Check total preload.
Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
5. w/ Automatic Disconnecting Differential (A.D.D.):
Remove A.D.D. actuator.
a. Remove the 4 bolts.
b. Using a hammer handle, remove the actuator.

6. w/ A.D.D.:
Remove differential tube.
a. Remove the 4 torx bolts. Torx socket E14.
b. Using a plastic hammer, tap on the differential tube to remove it.

c. Remove the sleeve.
d. Remove the O-ring from the differential tube.
7. w/o A.D.D.:
Remove differential tube.
a. Remove the 4 bolts.
b. Using a plastic hammer, tap on the differential tube to remove it.
8. w/ A.D.D.:
Remove clutch case.
a. Remove the 2 torx bolts. Torx socket E14.
b. Using a plastic hammer, tap on the clutch case to remove it.
9. Remove side oil seal.

Using Special Service Tool (SST) 09308-00010 or equivalent, remove the side oil seal.
10. w/ A.D.D.:
Remove intermediate shaft No. 1.
Using SST 09350-20015, 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04010, 09957-04010,
09958-04010), remove the intermediate shaft No. 1.
11. Remove companion flange.

a. Using a chisel and a hammer, unstake the nut.
b. Using SST 09330-00021 to hold the flange, remove the nut.
c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange.
12. Remove oil seal and oil slinger.

a. Using SST 09308-10010, remove the oil seal.
b. Remove the oil slinger.
13. Remove rear bearing and bearing spacer.

a. Using SST 09556-22010, remove the rear bearing from the drive pinion.
b. Remove the bearing spacer.
14. Remove side bearing retainer.

Remove the 10 bolts and tap out the retainer with a plastic hammer.
15. Remove differential case assembly.
16. Remove drive pinion from differential carrier.
17. Remove drive pinion front bearing.

Using SST 09950-00020 and a press, remove the bearing and washer from the drive pinion.
HINT: If the drive pinion or ring gear are damaged replace them as a set.
18. Remove drive pinion bearing outer races.

a. Using a brass bar and a hammer, remove the front bearing outer race.
b. Using SST 09502-12010, 09612-65014 (09612-01020, 09612-01050), remove the rear bearing outer race.
19. Remove side bearing outer races.
HINT:
- Measure the plate washer and note the thickness.
- Tag the bearing outer races to show the location for reassembly.
a. Using SST 09950-60010 (09951-00540), 09550-70010 (09951-01500) and a press, remove the plate washer and outer race from the
bearing retainer.
b. Using SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) and a press, remove the plate washer and outer race from the
differential carrier.
20. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver, unstake the lock plates.

c. Remove the 10 bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
21. Remove side bearings.

Using SST 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04060, 09957-04010, 09958-04010),
09950-60010 (09951-00480), remove the side bearings from the differential case.
HINT: Fix the claws of SST to the notch in the differential case.
22. Disassemble differential case assembly.

a. Using a pin punch and a hammer, remove the straight pin.
b. Remove these parts from the differential case:
- Pinion shaft.
- 2 pinion gears.
- 2 pinion gear thrust washers.
- 2 side gears.
- 2 side gear thrust washers.
23. w/ A.D.D.:
Remove bearing.
Using a brass bar and a hammer, remove the 2 bearings.
REPLACEMENT
1. Replace companion flange dust deflector, if necessary.

a. Using SST 09950 - 00020 and a press, remove the dust deflector.
b. Using SST 09636 - 20010 and a press, install a new dust deflector.
2. Replace intermediate shaft No.2, if necessary.

a. w/ A.D.D.:
Remove clutch hub.
1) Using a snap ring expander, remove the snap ring.
2) Remove the clutch hub from the intermediate shaft No. 2.
b. Remove oil seal.

Using SST 09308-00010, remove the oil seal from the tube.
c Remove intermediate shaft No. 2 from tube.

1) Using needle nose pliers, remove the snap ring.
2) Remove the shaft from the tube.
d. Remove intermediate shaft No. 2 bearing.

1) Using a snap ring expander, remove the snap ring.
2) Using SST 09950-00020, a brass bar and a press, remove the bearing.
e. Install new intermediate shaft No. 2 bearing.

1) Using SST 09309-37010 and a press, install a new bearing.
2) Using a snap ring expander, install the snap ring.
f. Install intermediate shaft No. 2 to tube.
1) Install the shaft into the tube.
2) Using needle nose pliers, install the snap ring.
g. Install new oil seal.

1) Using SST 09223-15020 and a hammer install a new oil seal.
Oil seal drive in depth: 5.5 mm (0.217 inch)
2) Coat the oil seal lip with MP grease.
h. w/ A.D.D.:
Install clutch hub.
1) Install the clutch hub to the shaft.
2) Using snap ring pliers, install the snap ring.
3. Replace A.D.D. actuator, if necessary.

a. Remove A.D.D. switch.
b. Remove sleeve fork pin.
1) Using a hexagon wrench, remove the screw plug.
2) Using a pin punch and a hammer, remove the pin through the hole of clutch case cover.
c. Separate A.D.D. actuator from clutch case cover and remove sleeve fork.
1) Using a hexagon wrench, remove the screw plug.
2) Remove the spring seat, spring and steel ball.
3) Remove the 2 bolts and actuator from the clutch case cover.
4) Separate the actuator from the clutch case cover and remove the sleeve fork.
5) Remove the O-ring from the actuator.
d. Install sleeve fork and actuator into clutch case cover.

1) Install a new O-ring to the actuator.
2) Coat the O-ring with MP grease.
3) Place the sleeve fork and install the actuator to the clutch case cover.
4) Torque the 2 bolts.
Torque to 21 Nm (15 ft. lbs.)
5) Install the steel ball, spring and spring seat.
6) Coat the threads of screw plug with Formed In Place Gasket (FIPG).
FIPG: THREE BOND 1281, or equivalent.
7) Using a hexagon wrench, install the screw plug.
e. Install sleeve fork pin.
1) Using a pin punch and a hammer, install the pin through the hole of clutch case cover.
2) Coat the threads of screw plug with FIPG.
FIPG: THREE BOND 1281, or equivalent.
3) Using a hexagon wrench, install the screw plug.
f. Install A.D.D. switch.
Install a new gasket and indicator switch.
REASSEMBLY
1. w/A.D.D.:
Install new bearings.
Using SST 09950-60010 (09951-00380) and a press, install new bearings.
Bearing press in depth: 0.3 ± 0.3 mm (0.012 ± 0.012 inch)
2. Assemble differential case.

a. Install the proper thrust washers on the side gears.
Washer thickness:
0.96 - 1.04 mm (0.0378 - 0.0409 inch)
1.06 - 1.14 mm (0.0417 - 0.0449 inch)
1.16 - 1.24 mm (0.0457 - 0.0488 inch)
1.26 - 1.34 mm (0.0496 - 0.0528 inch)
HINT: Select thrust washers which will ensure that the backlash is within the specifications.
b. Install the side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.
HINT: Align the holes of the differential case and pinion shaft.
c. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case.
Backlash: 0 - 0.20 mm (0 - 0.0079 inch)
If the backlash is not within the specification, install side gear thrust washers with different thicknesses.
3. Install straight pin and stake differential case.

a. Using a pin punch and a hammer, install the straight pin through the differential case and hole of the pinion shaft
b. Stake the differential case.
4. Install ring gear on differential case.
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to about 100° C (212° F) in boiling water.

c. Carefully remove the ring gear from the water.
d. after the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT: Align the matchmarks on the ring gear and differential case.
e. Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential case are not misaligned.
f. After the ring gear has cooled sufficiently, torque the ring gear set bolts.
g. Using a hammer and a drift. punch, stake the lock plates.

HINT: Stake one claw flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the half
portion of the tightening side.
5. Install side bearings.

Using SST 09226-10010 and a press, install the bearing into the differential case.
6. Install side bearing outer races.
HINT: When replacing the side bearings, fit the thinnest washers to each bearing and when reusing the bearings, fit the washers with the same
thickness as removed.
a. Install a new plate washer to the bearing retainer.
b. Using SST 09950-60020 (09951-007903, 09950-70010 (09951-07150) and a press, install the bearing outer race.
c. Install a new plate washer to the differential carrier.
d. Using SST 09950-60020 (09951-00790), 09950-70010 (09951-07150) and a press, install the bearing outer race.
7. Install drive pinion front and rear bearing outer races.

Using SST 09570-22011, install the outer races.
8. Install drive pinion front bearing.
a. Install the washer on the drive pinion.
HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace
the washer with one of a different thickness if necessary.
b. Using SST 09506-30012 and a press, install the front bearing onto the drive pinion.
9. Temporarily adjust drive pinion preload.
a. Install the drive pinion and oil slinger.
HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern.
b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), install the rear bearing, oil slinger and
companion flange.
c. Coat the threads of the nut with hypoid gear oil.
d. Using SST 09330-00021 to hold the flange, tighten the nut.
HINT: Adjust the drive pinion preload by tightening the companion flange nut.
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.

New bearing preload (at starting): 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.)
Reused bearing preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)
10. Install differential case in differential carrier.
11. Adjust ring gear backlash.
a. Install the side bearing retainer with the 10 bolts.

b. Using SST 09564-32011 and a dial indicator, measure the ring gear backlash. If it is not within the specification, adjust by either in
creasing or decreasing the washers on both sides by an equal amount.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
HINT: There should be no clearance between the plate washer and case. Ensure that there is ring gear backlash.
Washer thickness:
2.00 - 2.02 mm (0.0787 - 0.0795 inch)
2.03 - 2.05 mm (0.0799 - 0.0807 inch)
2.06 - 2.08 mm (0.0811 - 0.0819 inch)
2.09 - 2.11 mm (0.0823 - 0.0831 inch)
2.12 - 2.14 mm (0.0835 - 0.0843 inch)
2.15 - 2.17 mm (0.0846 - 0.0854 inch)
2.18 - 2.20 mm (0.0858 - 0.0866 inch)
2.21 - 2.23 mm (0.0870 - 0.0878 inch)
2.24 - 2.26 mm (0.0882 - 0.0890 inch)
2.27 - 2.29 mm (0.0894 - 0.0902 inch)
2.30 - 2.32 mm (0.0906 - 0.0913 inch)
2.33 - 2.35 mm (0.0917 - 0.0925 inch)
2.36 - 2.38 mm (0.0929 - 0.0937 inch)
2.39 - 2.41 mm (0.0941 - 0.0949 inch)
2.42 - 2.44 mm (0.0953 - 0.0961 inch)
2.45 - 2.47 mm (0.0965 - 0.0972 inch)
2.48 - 2.50 mm (0.0976 - 0.0984 inch)
2.51 - 2.53 mm (0.0988 - 0.0996 inch)
2.54 - 2.56 mm (0.1000 - 0.1008 inch)
2.57 - 2.59 mm (0.1012 - 0.1020 inch)
2.60 - 2.62 mm (0.1024 - 0.1031 inch)
2.63 - 2.65 mm (0.1035 - 0.1043 inch)
2.66 - 2.68 mm (0.1047 - 0.1055 inch)
2.69 - 2.71 mm (0.1059 - 0.1067 inch)
2.72 - 2.74 mm (0.1071 - 0.1079 inch)
2.75 - 2.77 mm (0.1083 - 0.1091 inch)
2.78 - 2.80 mm (0.1094 - 0.1102 inch)
12. Measure total preload.
Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.)
13. Inspect tooth contact between ring gear and drive pinion.
a. Remove the side bearing retainer and differential case.
b. Coat 3 or 4 teeth at three different positions on the ring gear with red lead.
c. Install the differential case and side bearing retainer.
d. Hold the companion flange firmly and rotate the ring gear in both directions.
e. Remove the side bearing retainer and differential case.
f. Inspect the tooth contact pattern. If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Washer thickness
1.69 - 1.71 mm (0.0665 - 0.0673 inch)
1.72 - 1.74 mm (0.0677 - 0.0685 inch)
1.75 - 1.77 mm (0.0689 - 0.0697 inch)
1.78 - 1.80 mm (0.0701 - 0.0709 inch)
1.81 - 1.83 mm (0.0713 - 0.0720 inch)
1.84 - 1.86 mm (0.0724 - 0.0732 inch)
1.87 - 1.89 mm (0.0736 - 0.0744 inch)
1.90 - 1.92 mm (0.0748 - 0.0756 inch)
1.93 - 1.95 mm (0.0760 - 0.0768 inch)
1.96 - 1.98 mm (0.0772 - 0.0780 inch)
1.99 - 2.01 mm (0.0783 - 0.0791 inch)
2.02 - 2.04 mm (0.0795 - 0.0803 inch)
2.05 - 2.07 mm (0.0807 - 0.0815 inch)
2.08 - 2.10 mm (0.0819 - 0.0827 inch)
2.11 - 2.13 mm (0.0831 - 0.0839 inch)
2.14 - 2.16 mm (0.0843 - 0.0850 inch)
2.17 - 2.19 mm (0.0854 - 0.0862 inch)
2.20 - 2.22 mm (0.0866 - 0.0874 inch)
2.23 - 2.25 mm (0.0878 - 0.0886 inch)
2.26 - 2.28 mm (0.0890 - 0.0898 inch)
2.29 - 2.31 mm (0.0902 - 0.0909 inch)
2.32 - 2.34 mm (0.0913 - 0.0921 inch)
14. Remove companion flange and oil slinger.
15. Remove rear bearing.
16. Install new bearing spacer, rear bearing and oil slinger.
a. Install a new bearing spacer and place the rear bearing and oil slinger.
b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) and the companion flange, install the
rear bearing then remove the companion flange.

17. Install oil seal.
a. Coat a new oil seal lip with MP grease.
b. Using SST 09554-22010 and a hammer, install the oil seal.

Oil seal drive in depth: 4.5 mm (0.177 inch)
18. Install companion flange.
a. Place the companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil.
c. Using SST 09330-00021 to hold the flange, torque the nut.

19. Adjust drive pinion preload.

Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
New bearing preload (at starting): 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.)
Reused bearing preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)
- If the preload is greater than the specification, replace the bearing spacer.
- If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) a little at a time until the specified preload is reached.
Torque: 223 Nm (165 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back
off the nut to reduce the preload.
20. Install differential case.
21. Install side bearing retainer.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG: THREE BOND 1281, or equivalent, to the side bearing retainer, as shown.
HINT: Install the side bearing retainer within 10 minutes after applying FIPG.
d. Install the side bearing retainer with the 10 bolts.

22. Check total preload.
23. Recheck ring gear backlash.
24. Recheck tooth contact between ring gear and drive pinion.
25. Check runout of companion flange.
26. Stake drive pinion nut.
27. Install side oil seal.

Using SST 09608-32010 and a hammer, install a new oil seal until its surface is flush with the differential carrier end.
Side oil seal drive in depth: 0 mm (0 inch)
b. Coat the oil seal lip with MP geese.

28. w/ A.D.D.:
Install intermediate shaft.
a. Install a new snap ring to the shaft
b. Using a plastic-faced hammer, install the shaft to the differential case.
c. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction.
d. Check that the intermediate shaft will not come out by trying to pull it completely out by hand.
29. w/ A.D.D.:
Install clutch case to differential tube.
a. Install a new O-ring to the tube.
b. Coat the O-ring with MP grease.
c. Install the clutch case to the tube.
d. Torque the 2 torx bolts using Torx socket E14.
30. w/ A.D.D.:
Install clutch sleeve.
31. Install differential tube to differential.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
c. Apply FIPG THREE BOND 1281, or equivalent, to the differential, as shown.
HINT: Install the differential tube within 10 minutes after applying FIPG.
d. Install the differential tube to the differential.
e. Clean the threads of the 4 bolts (w/o A.D.D.) or 2 torx bolts (w/ A.D.D.) and retainer bolt holes with toluene or trichloroethylene.
f. Apply adhesive THREE BOND 1324, or equivalent, to 2 or 3 threads of the bolts end.
g. Torque the 4 bolts (w/o A.D.D.) or 4 torx bolts (w/ A. D.D.) using Torx socket E14.
Torque:
w/o A.D.D.: 105 Nm (77 ft. lbs.)
w/ A.D.D.: 78 Nm (58 ft. lbs.)
32. w/ A.D.D.:
Install A.D.D. actuator.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case.
c. Apply FIPG: THREE BOND 1281, or equivalent, to the clutch case, as shown.
HINT: Install the actuator within 10 minutes after applying FIPG.
d. Torque the 4 bolts.


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1998 Toyota Truck Tacoma Extra Cab 4WD V6-3.4L (5VZ-FE) Copyright © 2013, ALLDATA 10.

Differential Assembly: Service and Repair

1. Check runout of companion flange.

2. Check ring gear backlash.

3. Measure drive pinion preload.

b. Using a hammer handle, remove the actuator.

b. Using a plastic hammer, tap on the differential tube to remove it.

9. Remove side oil seal.

11. Remove companion flange.

12. Remove oil seal and oil slinger.

13. Remove rear bearing and bearing spacer.

14. Remove side bearing retainer.

17. Remove drive pinion front bearing.

18. Remove drive pinion bearing outer races.

b. Using a screwdriver, unstake the lock plates.

21. Remove side bearings.

22. Disassemble differential case assembly.

1. Replace companion flange dust deflector, if necessary.

2. Replace intermediate shaft No.2, if necessary.

b. Remove oil seal.

c Remove intermediate shaft No. 2 from tube.

d. Remove intermediate shaft No. 2 bearing.

e. Install new intermediate shaft No. 2 bearing.

g. Install new oil seal.

3. Replace A.D.D. actuator, if necessary.

d. Install sleeve fork and actuator into clutch case cover.

2. Assemble differential case.

3. Install straight pin and stake differential case.

b. Heat the ring gear to about 100° C (212° F) in boiling water.

g. Using a hammer and a drift. punch, stake the lock plates.

5. Install side bearings.

a. Install a new plate washer to the bearing retainer.

7. Install drive pinion front and rear bearing outer races.

d. Using SST 09330-00021 to hold the flange, tighten the nut.

e. Using a torque wrench, measure the preload.

a. Install the side bearing retainer with the 10 bolts.

rear bearing then remove the companion flange.

b. Using SST 09554-22010 and a hammer, install the oil seal.

c. Using SST 09330-00021 to hold the flange, torque the nut.

19. Adjust drive pinion preload.

d. Install the side bearing retainer with the 10 bolts.

27. Install side oil seal.

b. Coat the oil seal lip with MP geese.

c. Apply FIPG THREE BOND 1281, or equivalent, to the differential, as shown.

d. Install the differential tube to the differential.

HINT: Install the actuator within 10 minutes after applying FIPG.

d. Torque the 4 bolts.

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