Rear Extension Housing: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL BALL BEARING 
   1. Using SST and a press, press in the ball bearing.
      Fig 1: Identifying Ball Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   2. Select a snap ring that will allow the minimum axial play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS SPECIFICATION
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      A	1.70 (0.0669)	B	1.80 (0.0709)

      Fig 2: Identifying Snap Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a screwdriver, install a new snap ring.
2. INSTALL OIL SEAL 
   1. Apply MP grease to the lip of a new oil seal.
   2. Using SST and a hammer, tap in the oil seal.
   Fig 3: Identifying Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

3. INSTALL DUST DEFLECTOR 
   1. Using SST and a hammer, tap in a new rear extension housing dust deflector.
      Fig 4: Identifying Rear Extension Housing Dust Deflector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   2. Using SST and a press, press in a new rear output shaft dust deflector.

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

   Fig 5: Identifying Rear Output Shaft Dust Deflector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL REAR OUTPUT SHAFT 
   1. Using SST and a press, press in the output shaft.
      Fig 6: Identifying Rear Output Shaft

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   2. Install the 2 seal rings to the output shaft.
   3. Select a snap ring that will allow the minimum axial play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS SPECIFICATION
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      1	1.95 (0.0768)	3	2.15 (0.0847)
      2	2.05 (0.0807)	4	2.25 (0.0886)

      Fig 7: Identifying Snap Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Using a snap ring expander, install a new snap ring.
5. INSTALL SPEEDOMETER DRIVE GEAR 
   1. Install the 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 the 3 bolts.
   Fig 8: Identifying Oil Pump Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG 
   1. Apply gear oil to the ball.
   2. Install the valve seat, ball and spring.
   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 the screw plug.
   Fig 9: Identifying Valve Seat, Ball, Spring And Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

8. INSTALL OIL PUMP DRIVEN ROTOR 
   1. Apply gear oil to the driven rotor.
   2. Install the drive rotor to the rear extension housing.
9. INSTALL OIL PUMP DRIVE ROTOR 
   1. Apply gear oil to the drive rotor.
   2. Install the drive rotor.

   HINT:

   Align the alignment marks to the driven rotor.

   Fig 10: Identifying Oil Pump Drive Rotor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL OIL PUMP COVER 
    1. Install the oil pump cover.
    2. Using a T30 "torx" socket, install 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: Identifying Oil Pump Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL OIL PUMP DRIVE SHAFT