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Rear Extension Housing: Reassembly

NOTE: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
  1. INSTALL BALL BEARING 
    1. Using SST and a press, install the ball bearing.

      SST 09316-60011 (09316-00011, 09316-00031)

      Fig 1: Installing Ball Bearing
      G03322379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring that will allow the minimum axial play.
      Fig 2: Installing Snap Ring
      G03322380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS

      Mark Thickness mm (in.)
      A 1.70 (0.0669)
      B 1.80 (0.0709)
    3. Using a screwdriver, install a new snap ring.
  2. INSTALL DUST DEFLECTOR 
      Fig 3: Installing Dust Deflector
      G03322381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, install a new rear extension housing dust deflector.

      SST 09316-60011 (09316-00011, 09316-00041)

    2. Using SST and a press, install a new rear output shaft dust deflector.
      Fig 4: Installing Rear Output Shaft Dust Deflector
      G03322382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09316-20011, 09316-60011 (09316-00011)

  3. INSTALL OIL SEAL 
    1. Apply MP grease to the lip of a new oil seal.
      Fig 5: Installing Oil Seal
      G03322383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, drive in the oil seal.

      SST 09316-60011 (09316-00011, 09316-00031)

  4. INSTALL REAR OUTPUT SHAFT 
    1. Using SST and a press, install the rear output shaft.

      SST 09316-20011, 09316-60011 (09316-00011, 09316-00031)

    2. Install the 2 seal rings to the rear output shaft.
      Fig 6: Installing Rear Output Shaft
      G03322384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select a snap ring that will allow the minimum axial play.
      Fig 7: Installing Snap Ring
      G03322385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS

      Mark Thickness mm (in.)
      1 1.95 (0.0768)
      2 2.05 (0.0807)
      3 2.15 (0.0847)
      4 2.25 (0.0886)
    4. Using a snap ring expander, install a new snap ring.
  5. INSTALL SPEED SENSOR DRIVE GEAR 
    1. Install the speed sensor drive gear.
    2. Using a snap ring expander, install the snap ring.
  6. INSTALL OIL PUMP PLATE 
    1. Install the oil pump plate.
    2. Install and torque the 3 bolts.

      Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

      Fig 8: Installing Oil Pump Plate
      G03322386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG 
    1. Apply gear oil to the ball.
    2. Install the valve seat, ball and spring.
      Fig 9: Installing Valve Seat Ball Spring And Screw Plug
      G03322387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply liquid sealer to the screw plug threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    4. Using a hexagon wrench, install and torque the screw plug.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

  8. INSTALL DRIVEN ROTOR 
    1. Apply gear oil to the driven rotor.
    2. Install the driven rotor.
  9. INSTALL DRIVE ROTOR 
    1. Apply gear oil to the drive rotor.
    2. Install the drive rotor.
      NOTE: Align the alignment marks.
      Fig 10: Aligning Alignment Marks
      G03322388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL OIL PUMP COVER 
    1. Install the oil pump cover.
    2. Using a torx socket wrench (T30), install and torque the 3 screws.

      Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

      NOTE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.
      Fig 11: Installing Oil Pump Cover
      G03322389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL OIL PUMP DRIVE SHAFT 
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