Replacing the seal without removing the gearbox from the vehicle
1. Disconnect the driveshaft from the differential.
a) Apply marks to the flanges for subsequent alignment.
b) Unscrew the four bolts and nuts and disconnect the propeller shaft.
2. Remove the counter flange.
a) Use a hammer and chisel to chisel out the nuts.
b) Using the special tool to hold the flange, unscrew the nut.
Rear axle gearbox.
1 - For vehicles with axle: Type A - 31 Nm; Type B - 47 Nm; Type C – 50 Nm,
2 - Gasket,
3 - Bushing,
4 - Bearing,
5 - Oil deflector,
6 - Seal,
7 - Counter flange,
8 - For bridges with Type A and Type B - 74 Nm; Type C - 88Nm,
9 - Cardan shaft.
c) Use a special key to remove the counter flange.
3. Remove the oil seal and oil deflector.
a) Using a special tool, remove the oil seal and oil deflector.
4. Remove the bearing and bushing.
a) Using a special tool, remove the bearing from the drive gear.
b) Remove the bushing.
5. Install the new bushing and bearing.
6. Install the oil seal and oil deflector.
a) Install the oil deflector.
b) Using a tool head of suitable diameter, install the seal.
- Seal installation depth: 1.0 mm
c) Apply grease to the lip of the oil seal.
7. Install the counter flange.
a) Install the counter flange using a special tool.
Reducer (Type A).
1 - Bearing cover,
2 - Gasket,
3 - Adjusting nut,
4, 8, 11 - Bearing,
5 - Differential cup,
6 - Driven gear,
7 - Drive gear,
9 - Bushing,
10 - Gearbox housing,
12 - Oil deflector,
13 - Seal,
14 - Dust cover,
15 - Counter flange,
16 - Nut,
17 - Locking plate,
18 - Satellite,
19, 20 - Thrust washer,
21 - Half-shaft gear,
22 - Axle of satellites,
23 - Cotter pin.
Reducer (Type B).
1 - Bearing cover,
2 - Lock nut,
3, 4 - Gasket,
5 - Rear differential cover,
6 - Adjusting nut,
7, 12, 15 - Bearing,
8 - Differential cup,
9 - Driven gear,
10 - Drive gear,
11, 21, 22 - Thrust washer,
13 - Spacer,
14 - Gearbox housing,
16 - Oil deflector,
17 - Seal,
18 - Dust cover,
19 - Counter flange,
20 - Axle of satellites,
23 - Half-shaft gear,
24 - Cotter pin,
25 - Satellite.
b) Apply transmission oil to the threads of the new nut.
The text is quoted from the source website: www.ToyotaMAN.ru
c) Hold the flange and tighten the nut.
Tightening torque:
- Type A - 270 Nm
- Type B - 343 Nm
- Type C - 304 Nm
Note: Tighten the nut to the torque specified above and adjust the pinion preload to the torque specified below.
Preload (initial):
- Type A - 0.9-1.3 Nm
- Type B - 0.7-1.0 Nm
- Type C - 0.8-1.3 Nm
8. Pin the drive gear nut.
9. Connect the cardan shaft to the mating flange.
a) Align the marks on the flanges and tighten the four bolts and nuts.
Tightening torque:
- Type A and Type B - 74 Nm
- Type C - 88 Nm
10. Check the transmission oil level and top up if necessary.
- Oil type - APL GL-5
Viscosity:
- Above -18°C — SAE 90
- Below -18°C — SAE 80W or 80W - 90
Filling capacity:
- Type A - 1.8 l
- Type B - 2.5 l
- Type C - 3.8 l
Removal the gearbox
1. Drain the transmission oil.
2. Remove the axle shaft
- Dyna 100 - Page 155
- Dyna 150 - Single Tires p. 157
- Dyna 150 - Dual Tyres p. 158
Note: (Dyna 150 Single Tires) To avoid damage to the drive gear and washer, after removing the axle shafts, install the satellite axle and cotter pin.
3. Disconnect the cardan shaft from the mating flange.
4. Remove the gearbox assembly.
Installing the gearbox
1. Install a new sealing gasket, gearbox assembly and tighten the nuts.
Tightening torque:
- Type A - 31 Nm
- Type B - 47 Nm
- Type C - 50 Nm
2. Connect the propeller shaft.
3. Install the axle shaft.
4. Check the transmission oil level and top up if necessary.
Reducer (Type C).
1 - Bearing cover,
2 - Gasket,
3 - Locking plate,
4 - Adjusting nut,
5, 11, 13 - Bearing,
6 - Differential cup,
7 - Driven gear,
8 - Differential cup cover,
9 - Drive gear,
10 - Adjusting washer,
12 - Spacer,
14 - Oil deflector,
15 - Seal,
16 - Dust cover,
17 - Counter flange,
18, 19 - Thrust washer,
20 - Half-shaft gear,
21 - Satellite.