Toyota 90311-38066
Seal, Oil (For Front Differential Carrier)

The procedure for front differential seal replacement requires removal of front wheels at 131 Nm (1,340 kgf-cm and 97 ft. lbs. torque). Start by eliminating the front drive shaft before applying hypoid gear oil to the new oil seal's edge while removing the old seal with Special Service Tool: 09308-00010. Reinstall new oil seals using Special Service Tool: 09550-00032, 09950-70010 (09951-07100) fitted to a hammer and treat them with MP grease for their lip surface. The installation of the new oil seal requires Special Service Tools: 09550-00032, 09950-70010 (09951-07100) and a hammer along with applying MP grease to the oil seal lip. Install the front drive shaft before putting hypoid gear oil into the differential space with a torque setting of 49 Nm (500 kgf-cm, 36 ft. lbs.). Hypoid gear oil API GL-5 should be used in service with SAE 90 viscosity for -18 degrees Celsius (0 degrees Fahrenheit) and above and SAE 80W-90 or 80W viscosity for temperatures under -18 degrees Celsius (0 degrees Fahrenheit). The differential storage amount reaches 1.70 liters at a capacity between 1.80 US qts. and 1.50 Imp.qts.

The first step to replace the Front Differential Rear Oil Seal requires unbolting the engine under cover followed by draining differential oil. First unfasten the front propeller shaft and take off the companion flange by dislodging the staked part of the nut using a chisel and hammer followed by employing Special Service Tool: 09330-00021 as a retainer for the flange while removing the nut. The required tool for removing the companion flange is Special Service Tool: 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020). Managing the oil seal and oil slinger removal requires Special Service Tool: 09308-10010 for the oil seal with subsequent removal of the oil slinger. Special Service Tool: 0955-22010 allows you to dismantle the drive pinion rear bearing and extract the bearing spacer. Begin by installing a new bearing spacer and then proceed to install the rear bearing and oil slinger with Special Service Tool: 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) assisted by the companion flange before once again removing the companion flange. To install the oil seal position the new lip under a coating of MP grease and utilize Special Service Tool: 09554-22010 with a hammer to insert it by maintaining the correct drive in depth at 4.5 plus or minus 0.3 mm (0.177 plus or minus 0.012 inch). To complete this step install the companion flange on the drive pinion before you apply hypoid gear oil to threads of a new nut for torque application with Special Service Tool: 09330-00021 until you reach 108 Nm (1,100 kgf-cm, 80 ft. lbs.). The drive pinion preload should be adjusted followed by staking the drive pinion nut before reinstalling the front propeller shaft. To refill the differential it requires hypoid gear oil belonging to API GL-5 family with SAE 75W-90 viscosity and 1.15 liter (1.22 US qts, 1.01 Imp. qts) capacity. Torque the oil to 39 Nm (400 kgf-cm, 29 ft. lbs.). In the final step you need to restore the engine under cover back into position.

The process to disconnect and replace rear differential seals and gaskets begins with marking the propeller shaft and companion flange for alignment then unfastening the 4 nuts, bolts and washers before properly supporting the shaft when it comes loose. First use Special Service Tool: 09330-00021 to hold the flange while unstaking the nut with a chisel and hammer until removal. Then use Special Service Tool: 09950-30011 together with 09951-03010, 09953-03010, 09954-03010, 09955-03030, and 09956-03040 tools to extract the flange. Afterward drain all hypoid gear oil. Special Service Tool: 09308-10010 enables the removal of the oil seal followed by the oil slinger and the front bearing removal procedure is completed with Special Service Tool: 09556-22010. Use Special Service Tool: 09308-00010 to remove the bearing outer race while carefully protecting the taper surface and after that remove the bearing spacer. Use Special Service Tools: 09318-60011 (09316-00011, 09316-00021) together with a hammer to install the bearing spacer before installing the bearing outer race. The repair procedure involves applying hypoid gear oil on the periphery of the new oil seal before installation with Special Service Tool: 09214-76011 and a hammer to achieve a depth of 0.5 mm (0.020 inch). After oil seal installation, coat its lip with MP grease. To install the drive pinion flange secure its threads with gear oil then tighten it to 245 Nm (2,500 kgf-cm, 181 ft. lbs.) while stabilizing the part with Special Service Tool: 09330-00021. Reconnect the rear propeller shaft using the drive pinion preload adjustment followed by drive pinion nut staking then bolt the 4 components along with their washers and nuts with 106 Nm (1,080 kgf-cm, 78 ft. lbs.) torque while matching marks. The last step requires filling the differential with hypoid gear oil but only API GL-5 without LSD or hypoid gear oil LSD API GL-5 with LSD. The oil viscosity should match SAE 90 above -18 degrees Celsius (0 degrees Fahrenheit) or SAE 80W-90 or 80W below -18 degrees Celsius (0 degrees Fahrenheit). The differential capacity is 3.20 liters (3.38 US qts, 2.82 Imp.qts) with differential lock or 3.30 liters (3.49 US qts, 2.90 Imp.qts) for others.

Fill the differential with hypoid gear oil, torquing to 49 Nm (500 kgf-cm, 36 ft. lbs.), using the appropriate hypoid gear oil based on the type of differential and the recommended oil viscosity.

Remove the companion flange nut by loosening the staked part with a chisel and hammer, then install 3 stud bolts to extend the heads 40 mm (1.57 inch) out.

The required oil type is hypoid gear oil API GL-5.