front differential growl/howl/rumble noise at 15-30...

T-SB-0121-08 Rev1 June 30, 2008

Front Differential Growl/Howl/Rumble Noise at 15-30 MPH

ServiceCategory Drivetrain

Section Axle/Differential Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2007 – 2008 Tundra Body Type(s): Double Cab, Crew Max, RegularCabDrive Type(s): 4WDEngine(s): 2UZ, 3URTransmission(s): 5AT, 6ATVDS(s): BT541, BT581, BV541, BV581, CT541,CV541, DT541, DT581, DV541, DV581, KT521,KV521, MT521, MV521

TSB REVISION NOTICE

• December 14, 2009 Rev1:

Key changes to the TSB are:

• The Differential Carrier Assembly is being repaired instead of being replaced.

• The Differential Case Sub-assembly Kit and Oil Seal have replaced the Front DifferentialCarrier Assembly in Parts Information.

• Warranty Information has been updated.

• SSTs have been updated in Required Tools & Equipment.

• Repair Procedure has been updated and expanded from step 5 to the end.

Any previous printed versions of this service bulletin should be discarded.

Introduction

2007 – 2008 model year four-wheel drive Tundra trucks may exhibit a condition where a cyclic noisecan be heard from the front of the vehicle between 15 and 30 mph (24 – 48 km/h) ONLY whendriving in 2WD. This noise can be described as a howl, growl, grind, or drone noise. Productionchanges have been implemented to help prevent this noise. Follow the repair procedure below toaddress this condition.

© 2009 Toyota Motor Sales, USA of 21

T-SB-0121-08 Rev1 June 30, 2008 of 21


Warranty Information

OP CODE DESCRIPTION TIME OFP T1 T2

TC8008Installation of Differential Case, Washers,Gaskets, & Seals into Existing Housing

and Inspection of Front Axles6.0 41110-34### 91 19

APPLICABLE WARRANTY• This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60

months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date.

• Warranty application is limited to occurrence of the specified condition described in thisbulletin.

Parts Information

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY

N/A 04009-27134 Case Sub-assembly Kit, Differential 1

90311-47012 Same Seal, Oil 1

43425-0C010 Same Ring, Shaft Snap (for Front DriveInner Shaft Outer) 2

95381-04050 Same Cotter Pins (for Front Axle Shaft Lock Nut) 2

90252-04003 Same Cotter pins (for Tie Rod End Lock Nut) 2

95381-03225 Same Cotter Pins (for Lower Ball Joint) 2

REQUIRED MATERIAL QUANTITY

Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 2.05 – 2.15 liters(2.17 – 2.27 qts)

Required Tools & Equipment

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY

ChassisEAR™ (or Equivalent) ADE JSPSM06606(JS Products) 1

NOTE• A mechanic’s stethoscope or similar tool may be used in place of ChassisEAR™.

• ChassisEAR™ may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787.

© 2009 Toyota Motor Sales, USA

T-SB-0121-08 Rev1 June 30, 2008 of 21


Required Tools & Equipment (Continued)

SPECIAL SERVICE TOOLS (SST’S) PART NUMBER QTY

3/4-inch Drive Torque Wrench* 00002-35000 1

Drive Shaft Remover Attachment* 09520-01010-02 1

Differential Side Gear Shaft Tool(Shocker Set)

09520-24010(09521-32040) 1

39 mm Socket* 00002-00039 1

Transmission Housing Remover* 09520-10021 1

Universal Puller Set “B”*(Hanger 200)(Slide Arm)(Center Bolt 200)(Arm 25)(Claw No. 6)(Attachment)(Holder)

09950-40011(09951-04020)(09952-04010)(09953-04030)(09954-04010)(09955-04061)(09957-04010)(09958-04011)

1

Oil Seal Puller 09308-00010 1

Steering Knuckle Oil Seal Replacer* 09608-32010 1

Replacer Set 2*(Replacer 68)(Replacer 89)

09950-60020-01(09951-00680-01)(09951-00890-01)

1

Handle Set*(Handle Assembly 150 – 6.25 inch)

09950-70010-01(09951-07150-01) 1

Replacer Set 1*(Replacer 55)(Replacer 42)

09950-60010-01(09951-00550-01)(09951-00420-01)

1

All Trac Tool Set*(Transfer Bearing Replacer)(Transmission Rear Bearing Replacer)

00002-00909-01(09316-20011-01)(09309-36010-01)

1

* Essential SST.

NOTEAdditional SSTs may be ordered by calling 1-800-933-8335.

REQUIRED MATERIAL QUANTITY

Toyota Genuine Seal Packing 1281, Three Bond 1281, or Equivalent As Needed

Toyota Genuine Seal Packing 1360K, Three Bond 1360K, or Equivalent As Needed


http://toyota.spx.com/detail.aspx?id=993&cid=1146

http://toyota.spx.com/detail.aspx?id=696











T-SB-0121-08 Rev1 June 30, 2008 of 21


Repair Procedure Overview

1. Confirm that the noise between 15 and 30 mph (24 – 48 km/h) goes away in 4WD.

2. Install ChassisEAR™ (or equivalent) and isolate the noise to the front differential assembly.

3. Remove the front differential assembly and inspect axles for abnormal wear.

4. Install new differential case, washers, gaskets, and seals into existing differential housing.

5. Reinstall the front differential assembly and confirm the noise is no longer present.

Repair Procedure

1. Test drive the vehicle to confirm the customer complaint.

Is the condition present below 30 mph?

• YES — Go to step 2.

• NO — This TSB does NOT apply.

2. Does the noise go away or is it significantly reduced when driving in 4WD?

• YES — Go to step 4.

• NO — Go to step 3.

3. Install ChassisEAR™ (or equivalent) on the vehicle and attempt to isolate the source of thenoise in 2WD.

Is the noise loudest near the front differential assembly?

• YES — This TSB applies. Go to step 4.

• NO — This TSB does NOT apply. Continue diagnosis to isolate the source of this noise.

4. Remove the front differential carrier assembly.

Refer to the Technical Information System (TIS), 2007 or 2008 model year Tundra Repair Manual:

2007 or 2008 Tundra, Drivetrain – Axle/Differential – “Differential: Front Differential CarrierAssembly (for 4WD): Removal”


/t3Portal/siviewer/t3ID/RM0000017BM00BX

/t3Portal/siviewer/t3ID/RM0000017BM00MX

T-SB-0121-08 Rev1 June 30, 2008 of 21


Repair Procedure (Continued)

5. Examine both front axle assemblies for unusual wear.

Do the axles display any unusual wear where they are inserted into the front differential carrierassembly?

• YES — Replace the affected axle(s).

• NO — Do NOT replace axles.Figure 1.


T-SB-0121-08 Rev1 June 30, 2008 of 21


Repair Procedure: Differential DisassemblyFigure 2. Front Differential Assembly Components

1

12

2

3

3

4 5

1 Differential Housing

2 Washer

3 Bearing

4 Differential Case

5 Ring Gear

1. Remove the front differential tube assembly.

A. Remove the 4 bolts.

B. Using a plastic-faced hammer, remove thedifferential tube.

Figure 3. .


T-SB-0121-08 Rev1 June 30, 2008 of 21


Repair Procedure: Differential Disassembly (Continued)

2. Remove the differential side gear intermediateshaft sub-assembly.

A. Insert a slide hammer claw under the sidegear flange.

B. Apply pressure against the flange to removeend play and firmly seat the claw.

C. Using the SSTs, remove the side gearintermediate shaft.SST: 09520-10021; 09520-01010

NOTEThe side gear intermediate shaft sub-assemblyis secured into the differential with a C-ringsimilar to an axle shaft.

Figure 4. .

3. Remove the axle shaft oil seal.

Using the SST, tap out the oil seal as shown inFigure 5.SST: 09308-00010

NOTEIf SST 09308-00010 is not available, separatethe differential housing and tap the seal outfrom the inside.

Figure 5. .

1

1 SST


T-SB-0121-08 Rev1 June 30, 2008 of 21



4. Separate the differential housing.

A. Remove the bolts B (3) and differential supportbracket.

B. Remove the bolts A (11).

C. Using a plastic-faced hammer, separate thedifferential housing.

Figure 6. .

A

A

AAA

A

A

AA

A

A B B

B

A Bolt A (11)

B Bolt B (3)

5. Remove the differential ring gear.

A. Remove the 12 bolts.

B. Using a plastic-faced hammer, tap on the ringgear to separate it from the differential case.

NOTICEDo NOT strike the ring gear with any metalobject.

Figure 7. .


T-SB-0121-08 Rev1 June 30, 2008 of 21



6. Using the SST, remove the front differential casebearings from both sides.SST: 09950-60010 (09951-00550); 09950-40011(09951-04020, 09952-04010, 09953-04030,09954-04010, 09955-04061, 09957-04010,09958-04011)

HINTInsert the claws of the SST into the notch inthe differential case assembly.

Figure 8..

1

1 SST


T-SB-0121-08 Rev1 June 30, 2008 of 21


Repair Procedure: Differential Reassembly

1. Install the front differential side gear needle rollerbearings.

Using the SST and a press, press in 2 NEWbearings into the NEW differential case.SST: 09950-60010 (09951-00420)Standard Bearing Depth:1.2 to 1.8 mm (0.0472 to 0.0709 in.)

Figure 9. .

1

1 SST

2. Install the differential ring gear.

A. Clean the contact surfaces of the differential case and ring gear.

B. Heat the ring gear to about 212◦F (100◦C) inboiling water.

CAUTIONDo NOT use flame directly on gear.

HINT

• Heating the ring gear allows easierinstallation onto the differential case.

• Placing the differential case into afreezer the night before will also aidinstallation.

Figure 10.

1

1 Boiling Water (approx. 212◦F [100◦C])

C. After the moisture on the ring gear has completely evaporated, quickly set the ring gearonto the differential case.

D. Temporarily install the 12 bolts so that the bolt holes in the ring gear and differential caseare aligned.

E. After the ring gear cools down sufficiently, apply adhesive to the bolts and install them.Adhesive: Toyota Genuine Adhesive 1360K, Three Bond 1360K, or equivalentTorque: 137 N*m (1397 kgf*cm, 101 ft*lbf)


T-SB-0121-08 Rev1 June 30, 2008 of 21


Repair Procedure: Differential Reassembly (Continued)

3. Install the front differential case bearings.

Using the SST and a press, press on the twobearings.SST: 09316-20011-01; 09309-36010-01

NOTERe-use the bearings removed from the olddifferential case.

Figure 11. .

4. Assemble the differential housing with the newdifferential case.

A. Carefully set the NEW differential case intothe housing.

B. Torque bolts A and B.Bolt A:Torque: 65 N*m (633 kgf*cm, 48 ft*lbf)Bolt B:Torque: 155 N*m (1581 kgf*cm, 114 ft*lbf)

NOTICERotate the pinion gear while tightening thebolts to be sure the original washers are NOTtoo large. Washers that are too large couldcause the ring gear to bind and damage thehousing. Reduce washer thickness if bindingoccurs.

Figure 12. .

A

A

AAA

A

A

AA

A

A B B

B

A Bolt A (11)

B Bolt B (3)


T-SB-0121-08 Rev1 June 30, 2008 of 21



5. Inspect backlash between the differential ring gear and pinion gear.

A. Mount the dial indicator to the differential case.

B. Measure backlash from the pinion gear flangeas shown in Figure 13.Specification: 0.36 to 0.52 mm (0.014 to 0.020 in.)

NOTE• The dial indicator must be at a 90

degree angle to the stud.

• Be sure the ring gear does NOT moveduring backlash inspection.

Figure 13.

6. Using the SST, measure the total pre-load.SST: 00002-02955Standard Total Pre-load (at starting):3.47 to 4.58 N*m (36 to 45 kgf*cm, 31 to 39 in*lbf)

NOTETotal pre-load measurement is the amount offorce required to start the rotation of the piniongear (highest reading before pinion gear startsto rotate). Do NOT use traditional rotating forcemeasurement.

• If backlash or total pre-load is NOT withinspecification, proceed to the next step.

• If NO adjustment is required, proceed tostep 13.

Figure 14. .


T-SB-0121-08 Rev1 June 30, 2008 of 21



7. Determine washer thickness adjustment.

Using the chart below along with pre-load and backlash measurements, determine the requiredwasher adjustment.

TOTAL PRE-LOAD3.47 to 4.58 N*m / 36 to 45 kgf*cm / 31 to 39 in*lbf

Not Enough Too Much OK

NotEnough

Increase washerthickness on ringgear tooth side

ONLY.

Reduce washerthickness on ring

gear bolt sideONLY.

Reduce washer thicknesson ring gear bolt side ANDincrease washer thickness

on ring gear tooth side.(Reduce and increase

washer thicknesses by thesame amount.)

TooMuch

Increase washerthickness on ring

gear bolt side ONLY.

Reduce washerthickness on ringgear tooth side

ONLY.

Increase washer thicknesson ring gear bolt side ANDreduce washer thicknesson ring gear tooth side.(Reduce and increase

washer thicknesses by thesame amount.)

BACKLASH0.36 to 0.52

mm (0.014 to0.020 in.)

OK

Increase washerthickness on ring

gear bolt side ANDring gear tooth side.

(Increase bothwashers by thesame amount.)

Reduce washerthickness on ring

gear bolt side ANDring gear tooth side.

(Reduce bothwashers by thesame amount.)

Document backlash andtotal pre-load values.Proceed to step 13.

Figure 15.

1

2

1 Ring Gear Bolt Side

2 Ring Gear Tooth Side


T-SB-0121-08 Rev1 June 30, 2008 of 21



8. Remove the bearing race(s) from the bearing retainer and/or differential carrier.

A. Using the SST and a press, press out thebearing race and washer from the bearingretainer.SST: 09950-60020 (09951-00680); 09950-70010(09951-07150)

Figure 16.

1

2

1 SST

2 Washer

B. Using the SST and a press, press out the raceand washer from the differential carrier.SST: 09950-60020 (09951-00680); 09950-70010(09951-07150)

NOTEIf the washer needs to be changed on ONEside only, removal of the bearing race onthe opposite side is NOT required.

Figure 17.

1

2

1 SST

2 Washer


T-SB-0121-08 Rev1 June 30, 2008 of 21



9. Install the bearing race(s) and NEW washer(s).

A. Insert the NEW washer(s) into the bearingretainer and/or differential carrier.

Figure 18.

B. Using the SST and a press, press the bearingrace into the differential bearing retainer.SST: 09950-60020 (09951-00890); 09950-70010(09951-07150)

Figure 19.

1

2

1 SST

2 Washer


T-SB-0121-08 Rev1 June 30, 2008 of 21



C. Using the SST and a press, press the bearingrace into the differential carrier assembly.SST: 09950-60020 (09951-00890); 09950-70010(09951-07150)

Figure 20.

1

2

1 SST

2 Washer

10. Assemble the differential housing.

A. Carefully set the differential case into thehousing.

B. Torque bolts A and B.Bolt A:Torque: 65 N*m (633 kgf*cm, 48 ft*lbf)Bolt B:Torque: 155 N*m (1581 kgf*cm, 114 ft*lbf)

Figure 21. .

A

A

AAA

A

A

AA

A

A B B

B

A Bolt A (11)

B Bolt B (3)


T-SB-0121-08 Rev1 June 30, 2008 of 21



11. Inspect backlash between the differential ring gear and pinion gear.

A. Mount the dial indicator to the differential case.

B. Measure backlash from the pinion gear flangeas shown in Figure 22.Specification: 0.36 to 0.52 mm (0.014 to 0.020 in.)

NOTE• The dial indicator must be at a 90

degree angle to the stud.

• Be sure the ring gear does NOT moveduring backlash inspection.

Figure 22.

12. Measure the total pre-load.

A. Using the SST, measure the total pre-load.SST: 00002-02955Standard Total Pre-load (at starting):3.47 to 4.58 N*m (36 to 45 kgf*cm, 31 to 39 in*lbf)

Figure 23.

B. Repeat steps 7 – 12 until backlash and pre-load are within specification.

NOTEMultiple washer changes and inspections may be required. Changing the washers can be atrial and error process until the backlash and pre-load are correct.


T-SB-0121-08 Rev1 June 30, 2008 of 21



13. Separate the differential housing and apply seal packing.

A. Be sure contact surfaces are clean.

B. Apply seal packing to the differential housingcontact surfaces as shown.Adhesive:Toyota Genuine Adhesive 1281,Three Bond 1281, or equivalent

HINTInstall the other half of the differentialhousing within 10 minutes of applying sealpacking.

Figure 24.

1

2

1 Seal Packing

2 Diameter: 2.0 to 3.0 mm (0.0788 to 0.118 in.)

C. Reinstall the differential bearing retainerhousing with 11 bolts A and 3 bolts B.Bolt A:Torque: 65 N*m (633 kgf*cm, 48 ft*lbf)Bolt B:Torque: 155 N*m (1581 kgf*cm, 114 ft*lbf)

Figure 25.

A

A

AAA

A

A

AA

A

A B B

B

A Bolt A (11)

B Bolt B (3)


T-SB-0121-08 Rev1 June 30, 2008 of 21



14. Install the differential side gear intermediate shaftsub-assembly.

A. Install a NEW C-ring onto the side gearintermediate shaft.

B. Using a plastic-faced hammer, install the sidegear intermediate shaft.

C. Check that there is 2 to 3 mm (0.0788 to 0.118in.) end play in the axial direction.

D. Check that the side gear intermediate shaftdoes NOT come out when trying to pull on itby hand.

Figure 26. .

15. Install the axle shaft seal.

A. Using the SST and plastic-faced hammer, tapin a new oil seal until its surface is flush withthe differential housing.SST: 09608-32010

B. Coat the lip of the oil seal with grease.Standard Oil Seal Depth:–0.45 to 0.45 mm (–0.0177 to 0.0177 in.)

Figure 27. .

1

1 SST


T-SB-0121-08 Rev1 June 30, 2008 of 21



16. Install the front differential tube assembly.

A. Remove any old sealant and FIPG.

B. Clean contact surface and apply seal packing.Adhesive:Toyota Genuine Adhesive 1281,Three Bond 1281, or equivalent

HINTInstall the differential tube within 10 minutesof applying seal packing.

Figure 28.

1

1 Seal Packing

C. Align the ADD collar spines and install 4 NEWbolts.Torque: 65 N*m (663 kgf*cm, 48 ft*lbf)

Figure 29.

17. Install the front differential carrier assembly.

Refer to TIS, 2007 or 2008 model year Tundra Repair Manual:

2007 or 2008 Tundra, Drivetrain – Axle/Differential – “Differential: Front Differential CarrierAssembly (for 4WD): Installation”


/t3Portal/siviewer/t3ID/RM0000017BL00BX

/t3Portal/siviewer/t3ID/RM0000017BL00MX

T-SB-0121-08 Rev1 June 30, 2008 of 21



18. Add differential oil.

A. Add differential oil so that the oil level isbetween 0 to 5 mm (0 to 0.197 in.) from thebottom of the differential filler plug hole.

NOTICEDo NOT add oil immediately afterassembling the differential carrier.Wait at LEAST 1 hour for the adhesive todry.

Oil Type and Viscosity:Toyota Genuine Differential Gear Oil LT 75W-85GL-5 or equivalent

Figure 30.

1

1 0 to 5 mm (0 to 0.197 in.)

B. Using a 10 mm hexagon wrench, install a new gasket and the filler plug.Torque: 39 N*m (398 kgf*cm, 29 ft*lbf)

19. Test drive the vehicle and confirm the noise is eliminated.

20. Re-check oil level and confirm NO leaks are present.


front differential growl/howl/rumble noise at 15-30...

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