Assembly
Fig. 19 Side gear thrust washer identification. Pickup & 4Runner:
1. Select suitable thrust washers from chart, Fig. 19. that will bring backlash to .0020-.0079 inch, then install thrust washers into differential case.
2. Drive in straight pin, using a hammer and suitable drift, through case and hole in pinion shaft, then stake pin to differential case.
3. Install side bearings using tool No. 09608-30012.
4. Clean mating surfaces of differential case, then heat ring gear in a suitable oil bath to approximately 212 degrees F.
5. Install ring gear into differential case, aligning mating marks on gear and case.
6. Apply a suitable lubricant to ring gear, then install lock plates and attaching bolts. Torque bolts uniformly to 71 ft. lbs.
7. Stake lock plates using a hammer and suitable drift.
8. Check ring gear runout. Maximum runout should be .0028 inch on 1/2 ton Pickup and Van models, or .0039 inch on 4WD Pickup and 4Runner models.
9. Temporarily adjust drive pinion preload as follows:
a. Install drive pinion and front bearing.
b. Install companion flange using tool No. 09557-22022.
c. Retain companion flange using tool No. 09330-0021, then adjust drive pinion preload to 5.2-8.7 inch lbs. on 1/2 ton Pickup, 7.8-11.3 on 4WD Pickup and 4Runner or 6.9-9.5 inch lbs. on Van models.
10. Place bearing outer races on their respective bearings, then insert case into carrier.
11. Install adjusting nuts on their respective carrier, ensuring backlash exists between ring gear and drive pinion.
12. Align mating marks on bearing caps and carrier, then rotate cap bolts 2-3 turns and manually depress cap.
13. Tighten cap bolts until adjusting nut on ring gear side until backlash is approximately .008 inch.
14. Tighten adjusting nut from drive pinion side as shown, Fig. 7, then check for backlash. If tightening nut causes backlash, loosen nut until backlash is eliminated.
15. Install a suitable dial indicator on top of adjusting nut, then adjust side bearing for zero preload, or until indicator begins to move. Tighten nut 1-1/2 notches from zero preload position.
16. Adjust ring gear backlash to .0051-.0071 inch, by rotating both left and right adjusting nuts equal amounts, then torque bearing cap bolts to 58 ft. lbs.
17. Measure total preload. Preload should be 3.5-5.2 inch lbs., with a preload of .0051-.0071 inch.
Fig. 9 Ring gear and pinion tooth contact inspection:
Fig. 21 Drive pinion shim identification. Pickup, 4Runner & Van:
18. Inspect gear tooth contact as shown, Fig. 9. If contacting pattern is not correct, select a suitable shim from chart, Fig. 21, that will ensure proper contact. Shims for Van models are the same as those available for 1/2 ton Pickup.
19. Install new bearing spacer and front bearing.
20. Install oil slinger, then drive in new oil seal to a depth of .059 inch on 1/2 ton Pickup or .039 inch on 4WD Pickup, 4Runner and Van.
21. Install companion flange, using tool No. 09557-22022, then apply a suitable lubricant to new nut. Retain companion flange, using tool No. 09330-00021, then install nut and torque to 80-173 ft. lbs. on 1/2 ton Pickup, 145-253 ft. lbs. on 1 ton and 4WD Pickup and 4Runner or 127 ft. lbs. on Van models.
22. Check drive pinion preload. Drive pinion preload should be 5.2-8.7 inch lbs. on 1/2 ton Pickup, 7.8-11.3 inch lbs on 1 ton and 4WD Pickup and 4Runner or 6.9-9.5 inch lbs. on Van models.
23. If preload is greater than specified, replace bearing spacer. If preload is less than specified torque nut 9 ft. lbs. at a time until specified preload is obtained. If maximum torque is exceeded during tightening procedure, replace bearing spacer and repeat preload adjustment.
24. Check companion flange deviation. Deviation in any direction should not exceed .0039 inch.
25. Stake drive pinion nut.
26. Install bearing cap nut lock, then torque attaching bolt to 9 ft. lbs.