OEM 2006 Toyota Sienna Differential

2006 Toyota Sienna Parts Questions & Experts Answers

• Q: How to disassemble the rear differential carrier on 2006 Toyota Sienna?

  A: The first step to disassemble the rear differential carrier requires removing its eight cover bolts followed by using a brass bar and hammer to peel the cover away from the differential carrier assembly. The carrier cover requires removal of its breather plug together with bolt and oil deflector. Start by fixing the rear differential carrier assembly followed by differential ring gear runout evaluation using a dial gauge to check if the measurement exceeds 0.07 mm (0.0028 inch). A replacement ring gear is necessary if that happens. The ring gear backlash should measure between 0.13 to 0.18 mm (0.0051 to 0.0071 inch), and side bearing preload adjustment becomes necessary if needed. The technician should inspect the ring gear tooth contact with the drive pinion followed by a backlash measurement of the side gear when holding one pinion gear toward the differential case; the acceptable backlash range is 0.05 to 0.20 mm (0.0020 to 0.0079 inch). Install differentially thick side gear thrust washers if the measurement is out of spec. Check the rear drive pinion companion flange sub-assembly runout at both vertical and horizontal positions until the measurement reaches within 0.10 mm (0.0039 inch). Drop a torque wrench measurement on the drive pinion preload to verify values within the range of 0.6 to 0.9 Nm (6 to 9 kg-cm, 5.2 to 7.9 inch lbs.) with a total preload scope of 0.3 to 0.5 Nm (3 to 5 kg-cm, 2.6 to 4.3 inch lbs.). Open up the rear differential side gear shaft sub-assembly by extracting its 2 snap rings with needle nose pliers followed by removing the shaft pieces. Use a screwdriver with a hammer to extract the side gear shaft dust cover after which Special Service Tool: 09308-00010 will remove the two oil seals from the housing. Special Service Tool: 09930-00010 and a hammer can unstake the rear drive pinion nut. The flange can be held by Special Service Tool: 09330-00021 to remove the nut from the assembly. Dismantle the rear drive pinion companion flange sub-assembly using Special Service Tool: 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) and later separate the rear differential dust deflector using Special Service Tool: 09950-60010 (09951-00360), 09950-70010 (09951-07150), 09950-00020 and a press. Use Special Service Tool: 09308-10010 to remove the rear differential carrier oil seal after which the technician should replace the rear differential drive pinion oil slinger and subsequently remove the front tapered roller bearing using Special Service Tool: 09556-22010. The procedure requires users to align matchmarks on the bearing cap and differential carrier before removing the 4 bolts and 2 bearing caps while utilizing Special Service Tool: 09504-22011 and a screwdriver to remove the 2 plate washers that users must note for their thickness. First separate the differential drive pinion from the rear drive pinion rear tapered roller bearing using Special Service Tool: 09950-00020 and place it in a press followed by both components. A brass bar along with a hammer will remove the front tapered roller bearing from the carrier before performing the same procedure on the rear bearing. To separate the differential ring gear, start by properly aligning matchmarks then unstake the 4 lock plates to finally extract the 8 ring gear set bolts combined with the 4 lock plates. The differential case inspection requires installation onto the carrier that must be secured by torquing right and left caps with 79 Nm (800 kg-cm, 58 ft. lbs.) followed by differential case runout measurement below 0.07 mm (0.0028 inch). For each differential case bearing removal proceed with Special Service Tools: 09950-40011 (with components 09951-00240, 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011) and 09950-60010 applied to the LH and then to the RH side respectively. To extract the rear differential pinion shaft use a 5 mm pin punch and hammer to remove its straight pin before taking out the differential pinion shaft with its two gears and two differential pinion thrust washers and two side gears including their thrust washers.