TOYOTA SIENNA 2007 Service Repair Manual

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

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
R 0 111 6 3 E 1 0
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.
C068124
SA02352
F001259