Front Differential Growl/Howl/Rumble Noise at MPH

Transcription

1 T-SB Rev1 June 30, 2008 Service Category Drivetrain Section Axle/Differential Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION Tundra Body Type(s): Double Cab, Crew Max, Regular Cab Drive Type(s): 4WD Engine(s): 2UZ, 3UR Transmission(s): 5AT, 6AT VDS(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 Differential Carrier 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 model year four-wheel drive Tundra trucks may exhibit a condition where a cyclic noise can be heard from the front of the vehicle between 15 and 30 mph (24 48 km/h) ONLY when driving in 2WD. This noise can be described as a howl, growl, grind, or drone noise. Production changes have been implemented to help prevent this noise. Follow the repair procedure below to address this condition. Page 1 of 21

2 T-SB Rev1 June 30, 2008 Page 2 of 21 Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 TC8008 Installation of Differential Case, Washers, Gaskets, & Seals into Existing Housing and Inspection of Front Axles ### 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 this bulletin. Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY N/A Case Sub-assembly Kit, Differential Same Seal, Oil C010 Same Ring, Shaft Snap (for Front Drive Inner Shaft Outer) Same Cotter Pins (for Front Axle Shaft Lock Nut) Same Cotter pins (for Tie Rod End Lock Nut) Same Cotter Pins (for Lower Ball Joint) 2 2 REQUIRED MATERIAL Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 QUANTITY liters ( 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

3 T-SB Rev1 June 30, 2008 Page 3 of 21 Required Tools & Equipment (Continued) SPECIAL SERVICE TOOLS (SST S) PART NUMBER QTY 3/4-inch Drive Torque Wrench* Drive Shaft Remover Attachment* Differential Side Gear Shaft Tool (Shocker Set) ( ) 39 mm Socket* Transmission Housing Remover* Universal Puller Set B * (Hanger 200) (Slide Arm) (Center Bolt 200) (Arm 25) (Claw No. 6) (Attachment) (Holder) ( ) ( ) ( ) ( ) ( ) ( ) ( ) Oil Seal Puller Steering Knuckle Oil Seal Replacer* Replacer Set 2* (Replacer 68) (Replacer 89) Handle Set* (Handle Assembly inch) Replacer Set 1* (Replacer 55) (Replacer 42) All Trac Tool Set* (Transfer Bearing Replacer) (Transmission Rear Bearing Replacer) * Essential SST ( ) ( ) ( ) ( ) ( ) ( ) ( ) NOTE Additional SSTs may be ordered by calling REQUIRED MATERIAL Toyota Genuine Seal Packing 1281, Three Bond 1281, or Equivalent Toyota Genuine Seal Packing 1360K, Three Bond 1360K, or Equivalent QUANTITY As Needed As Needed

4 T-SB Rev1 June 30, 2008 Page 4 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 Install ChassisEAR (or equivalent) on the vehicle and attempt to isolate the source of the noise 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 Carrier Assembly (for 4WD): Removal

5 T-SB Rev1 June 30, 2008 Page 5 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 carrier assembly? YES Replace the affected axle(s). NO Do NOT replace axles. Figure 1.

6 T-SB Rev1 June 30, 2008 Page 6 of 21 Repair Procedure: Differential Disassembly Figure 2. Front Differential Assembly Components 1 Differential Housing 2 Washer 3 Bearing 1. Remove the front differential tube assembly. 4 Differential Case 5 Ring Gear Figure 3.. A. Remove the 4 bolts. B. Using a plastic-faced hammer, remove the differential tube.

7 T-SB Rev1 June 30, 2008 Page 7 of 21 Repair Procedure: Differential Disassembly (Continued) 2. Remove the differential side gear intermediate shaft sub-assembly. Figure 4.. A. Insert a slide hammer claw under the side gear flange. B. Apply pressure against the flange to remove end play and firmly seat the claw. C. Using the SSTs, remove the side gear intermediate shaft. SST: ; NOTE The side gear intermediate shaft sub-assembly is secured into the differential with a C-ring similar to an axle shaft. 3. Remove the axle shaft oil seal. Figure 5.. Using the SST, tap out the oil seal as shown in Figure 5. SST: NOTE If SST is not available, separate the differential housing and tap the seal out from the inside. 1 SST

8 T-SB Rev1 June 30, 2008 Page 8 of 21 Repair Procedure: Differential Disassembly (Continued) 4. Separate the differential housing. Figure 6.. A. Remove the bolts B (3) and differential support bracket. B. Remove the bolts A (11). C. Using a plastic-faced hammer, separate the differential housing. A Bolt A (11) B Bolt B (3) 5. Remove the differential ring gear. Figure 7.. A. Remove the 12 bolts. B. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case. NOTICE Do NOT strike the ring gear with any metal object.

9 T-SB Rev1 June 30, 2008 Page 9 of 21 Repair Procedure: Differential Disassembly (Continued) 6. Using the SST, remove the front differential case bearings from both sides. SST: ( ); ( , , , , , , ) Figure 8.. HINT Insert the claws of the SST into the notch in the differential case assembly. 1 SST

10 T-SB Rev1 June 30, 2008 Page 10 of 21 Repair Procedure: Differential Reassembly 1. Install the front differential side gear needle roller bearings. Figure 9.. Using the SST and a press, press in 2 NEW bearings into the NEW differential case. SST: ( ) Standard Bearing Depth: 1.2 to 1.8 mm ( to in.) 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) in boiling water. Figure 10. CAUTION Do NOT use flame directly on gear. HINT Heating the ring gear allows easier installation onto the differential case. Placing the differential case into a freezer the night before will also aid installation. 1 Boiling Water (approx. 212 F [100 C]) C. After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the differential case. D. Temporarily install the 12 bolts so that the bolt holes in the ring gear and differential case are 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 equivalent Torque: 137 N*m (1397 kgf*cm, 101 ft*lbf)

11 T-SB Rev1 June 30, 2008 Page 11 of Install the front differential case bearings. Figure 11.. Using the SST and a press, press on the two bearings. SST: ; NOTE Re-use the bearings removed from the old differential case. 4. Assemble the differential housing with the new differential case. Figure 12.. A. Carefully set the NEW differential case into the 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) NOTICE Rotate the pinion gear while tightening the bolts to be sure the original washers are NOT too large. Washers that are too large could cause the ring gear to bind and damage the housing. Reduce washer thickness if binding occurs. A Bolt A (11) B Bolt B (3)

12 T-SB Rev1 June 30, 2008 Page 12 of 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 flange as shown in Figure 13. Specification: 0.36 to 0.52 mm (0.014 to in.) Figure 13. NOTE The dial indicator must be at a 90 degree angle to the stud. Be sure the ring gear does NOT move during backlash inspection. 6. Using the SST, measure the total pre-load. SST: Standard Total Pre-load (at starting): 3.47 to 4.58 N*m (36 to 45 kgf*cm, 31 to 39 in*lbf) Figure 14.. NOTE Total pre-load measurement is the amount of force required to start the rotation of the pinion gear (highest reading before pinion gear starts to rotate). Do NOT use traditional rotating force measurement. If backlash or total pre-load is NOT within specification, proceed to the next step. If NO adjustment is required, proceed to step 13.

13 T-SB Rev1 June 30, 2008 Page 13 of Determine washer thickness adjustment. Using the chart below along with pre-load and backlash measurements, determine the required washer adjustment. TOTAL PRE-LOAD 3.47 to 4.58 N*m / 36 to 45 kgf*cm / 31 to 39 in*lbf BACKLASH 0.36 to 0.52 mm (0.014 to in.) Not Enough Too Much OK Not Enough Too Much OK Increase washer thickness on ring gear tooth side ONLY. Increase washer thickness on ring gear bolt side ONLY. Increase washer thickness on ring gear bolt side AND ring gear tooth side. (Increase both washers by the same amount.) Figure 15. Reduce washer thickness on ring gear bolt side ONLY. Reduce washer thickness on ring gear tooth side ONLY. Reduce washer thickness on ring gear bolt side AND ring gear tooth side. (Reduce both washers by the same amount.) Reduce washer thickness on ring gear bolt side AND increase washer thickness on ring gear tooth side. (Reduce and increase washer thicknesses by the same amount.) Increase washer thickness on ring gear bolt side AND reduce washer thickness on ring gear tooth side. (Reduce and increase washer thicknesses by the same amount.) Document backlash and total pre-load values. Proceed to step Ring Gear Bolt Side 2 Ring Gear Tooth Side

14 T-SB Rev1 June 30, 2008 Page 14 of Remove the bearing race(s) from the bearing retainer and/or differential carrier. A. Using the SST and a press, press out the bearing race and washer from the bearing retainer. SST: ( ); ( ) Figure SST 2 Washer B. Using the SST and a press, press out the race and washer from the differential carrier. SST: ( ); ( ) Figure 17. NOTE If the washer needs to be changed on ONE side only, removal of the bearing race on the opposite side is NOT required. 1 SST 2 Washer

15 T-SB Rev1 June 30, 2008 Page 15 of Install the bearing race(s) and NEW washer(s). A. Insert the NEW washer(s) into the bearing retainer and/or differential carrier. Figure 18. B. Using the SST and a press, press the bearing race into the differential bearing retainer. SST: ( ); ( ) Figure SST 2 Washer

16 T-SB Rev1 June 30, 2008 Page 16 of 21 C. Using the SST and a press, press the bearing race into the differential carrier assembly. SST: ( ); ( ) Figure SST 2 Washer 10. Assemble the differential housing. Figure 21.. A. Carefully set the differential case into the 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) A Bolt A (11) B Bolt B (3)

17 T-SB Rev1 June 30, 2008 Page 17 of 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 flange as shown in Figure 22. Specification: 0.36 to 0.52 mm (0.014 to in.) Figure 22. NOTE The dial indicator must be at a 90 degree angle to the stud. Be sure the ring gear does NOT move during backlash inspection. 12. Measure the total pre-load. A. Using the SST, measure the total pre-load. SST: Standard 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. NOTE Multiple washer changes and inspections may be required. Changing the washers can be a trial and error process until the backlash and pre-load are correct.

18 T-SB Rev1 June 30, 2008 Page 18 of Separate the differential housing and apply seal packing. A. Be sure contact surfaces are clean. B. Apply seal packing to the differential housing contact surfaces as shown. Adhesive: Toyota Genuine Adhesive 1281, Three Bond 1281, or equivalent Figure 24. HINT Install the other half of the differential housing within 10 minutes of applying seal packing. 1 Seal Packing 2 Diameter: 2.0 to 3.0 mm ( to in.) C. Reinstall the differential bearing retainer housing 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 Bolt A (11) B Bolt B (3)

19 T-SB Rev1 June 30, 2008 Page 19 of Install the differential side gear intermediate shaft sub-assembly. Figure 26.. A. Install a NEW C-ring onto the side gear intermediate shaft. B. Using a plastic-faced hammer, install the side gear intermediate shaft. C. Check that there is 2 to 3 mm ( to in.) end play in the axial direction. D. Check that the side gear intermediate shaft does NOT come out when trying to pull on it by hand. 15. Install the axle shaft seal. Figure 27.. A. Using the SST and plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential housing. SST: B. Coat the lip of the oil seal with grease. Standard Oil Seal Depth: 0.45 to 0.45 mm ( to in.) 1 SST

20 T-SB Rev1 June 30, 2008 Page 20 of 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 Figure 28. HINT Install the differential tube within 10 minutes of applying seal packing. 1 Seal Packing C. Align the ADD collar spines and install 4 NEW bolts. Torque: 65 N*m (663 kgf*cm, 48 ft*lbf) Figure 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 Carrier Assembly (for 4WD): Installation

21 T-SB Rev1 June 30, 2008 Page 21 of Add differential oil. A. Add differential oil so that the oil level is between 0 to 5 mm (0 to in.) from the bottom of the differential filler plug hole. Figure 30. NOTICE Do NOT add oil immediately after assembling the differential carrier. Wait at LEAST 1 hour for the adhesive to dry. Oil Type and Viscosity: Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 or equivalent 1 0 to 5 mm (0 to 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.