Toyota Tundra. Manual — part 1038

Fig. 211: Pressing In Bearing Using SST
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using a snap ring expander, install a new snap ring.

Fig. 212: Removal/Installation Of Snap Ring Using Snap Ring Expander
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

a. Install the side gear shaft into the differential tube.

b. Using snap ring pliers, install a new snap ring.

Fig. 213: Removal/Installation Of Snap Ring Using Snap Ring Expander
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

a. Using SST and a plastic-faced hammer, tap in a new oil seal.

SST 09608-32010

Standard oil seal depth: 4.8 to 5.8 mm (0.189 to 0.228 in.)

2009 Toyota Tundra

2009 DRIVELINE/AXLES Differential - Tundra

Fig. 214: Identifying Differential side Gear Shaft Oil Seal
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Coat the lip of the oil seal with MP grease.

5. INSTALL DIFFERENTIAL CLUTCH HUB

a. Install the clutch hub onto the side gear inter shaft.

Fig. 215: Identifying Differential Clutch Hub
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using snap ring pliers, install a new snap ring.

Fig. 216: Installing Snap Ring Using Snap Ring Pliers
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Be sure to install the differential clutch hub in the correct direction.

2009 Toyota Tundra

2009 DRIVELINE/AXLES Differential - Tundra

6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING

a. Using SST and a press, press in 2 new bearings.

SST 09950-60010(09951-00420)

Standard bearing depth: 1.2 to 1.8 mm (0.0472 to 0.0709 in.)

Fig. 217: Identifying Front Differential Side Gear Needle Roller Bearing
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

7. INSTALL FRONT DIFFERENTIAL CASE

a. Install the 2 side gear thrust washers onto the 2 side gears.

Fig. 218: Installing Thrust Washer
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HINT:

Using the table below, select the thrust washer which will ensure that the backlash is within the
specifications.

Washer thickness

WASHER THICKNESS SPECIFICATIONS

Thickness

Thickness

1.43 to 1.47 mm (0.0563 to 0.0579 in.) 1.68 to 1.72 mm (0.0661 to 0.0677 in.)

2009 Toyota Tundra

2009 DRIVELINE/AXLES Differential - Tundra

b. Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and

pinion shaft into the differential case assembly.

HINT:



Align the holes of the differential case assembly and pinion shaft.



Apply hypoid gear oil to each sliding surface and rotating part.

c. Measure the side gear backlash.

1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward

the differential case assembly.

Standard backlash: 0 to 0.15 mm (0 to 0.00591 in.)

If the backlash is not within the specification, install a side gear thrust washer with a different
thickness.

Fig. 219: Measuring Side Gear Backlash
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the

pinion shaft.

1.48 to 1.52 mm (0.0583 to 0.0598 in.) 1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.) 1.78 to 1.82 mm (0.0701 to 0.0717 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.) 1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)

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2009 Toyota Tundra

2009 DRIVELINE/AXLES Differential - Tundra