Toyota 1KZ-TE engine factory workshop and repair manual download

Step-by-step differential service for a Toyota 1KZ-TE (truck/SUV platform). Covers routine drain/refill, front/rear differences, and basic cover removal/inspection. Tools, safety, how tools are used, replacement parts and common pitfalls are included. Follow OEM manual for exact torque and capacity values for your specific vehicle year/model.

Safety & prep
- Work on a flat, level surface. Chock opposite wheels.
- Engage parking brake. If 4WD, put transfer case in neutral or 2H per vehicle procedure to reduce drivetrain load.
- Use quality jack stands under axle/differential or proper vehicle lift. Never rely on a hydraulic jack alone.
- Wear safety glasses and gloves. Have a fire extinguisher nearby.
- Allow differential to cool if hot.

Tools & supplies
- Floor jack and jack stands or vehicle lift.
- Wheel chocks.
- Drain pan (large, low profile) and rags.
- Socket set (metric), ratchet, breaker bar. Common plug sizes often 14–17 mm; confirm on vehicle.
- Torque wrench (capable of 5–200 Nm / 4–150 ft-lb).
- Gear oil pump (hand or electric) for filling through fill hole. How used: pump fits hose into fill hole; operate to push oil until level reached or oil runs out of fill hole.
- Funnel, hose, or flexible spout.
- Wire brush and gasket scraper (if removing cover).
- Clean metal/brass brush for drain/fill plug magnet.
- RTV silicone or new gasket (if cover style uses RTV or gasket).
- New crush washer for drain plug (if applicable) or replacement drain plug.
- Replacement differential fluid: OEM-specified gear oil (typical choices: API GL‑5 gear oil, e.g., 75W-90 or 80W-90; some climates use 75W-140/85W-140). For limited slip differentials, use appropriate limited-slip additive per Toyota spec. How used: pour/additive to required volume and mix by driving a short distance per instructions.
- Threadlocker (blue Loctite) for pinion nut or ring gear bolts if required in major service.
- Clean solvent and lint-free rags.
- Drain plug gasket/crush washer.
- Replacement axle seals, pinion seal, bearings if doing rebuild.
- Dial indicator and magnetic base (only if checking backlash/preload during rebuild).
- Bearing puller, press, seal driver (for full overhaul).

Routine drain-and-refill (rear or front differential) — quick service
1. Warm the differential: run engine briefly to raise oil temperature. Warm oil drains faster and carries contaminants.

2. Raise & secure vehicle: jack and support on stands. Chock wheels.

3. Locate fill and drain plugs: always remove the fill plug first to ensure you can refill. Fill plug usually midway-up on housing. If fill plug is stuck, you will not drain.

4. Remove fill plug: use appropriate socket/hex. Clean area before opening. Inspect threads and plug magnet for metal. Keep fill plug accessible.

5. Position drain pan under drain hole or under lowest point (or under cover seam if no plug).

6. Remove drain plug (or loosen cover lower bolts if cover-style solid axle): allow oil to drain fully. If there is no drain plug and fluid must be drained by removing cover, loosen cover bolts from bottom up and tap to crack seal — catch fluid in pan.

7. Inspect oil & drain plug: check for metal particles on magnet — small fine particles are normal; large chunks or strong metal filings indicate major wear. Smell for burnt oil.

8. Clean drain plug and magnet: remove filings with rag/solvent. Replace crush washer if present.

9. Reinstall drain plug: torque to OEM spec (typical 20–50 Nm depending on thread size; verify manual). If using new crush washer, seat it correctly. If cover was removed, clean flange and mating surface thoroughly.

10. Fill differential: insert pump hose into fill hole and pump oil until oil reaches bottom of the fill hole. The correct level is flush with the fill hole. If using a funnel and squeeze bulb, fill slowly to avoid aeration.

11. Reinstall fill plug: clean threads and apply small amount of threadlocker if specified; torque to OEM spec. Wipe area clean.

12. Lower vehicle and test drive: drive gently and re-check for leaks after a short drive. Re-check fill plug torque and level if necessary.

Full cover removal (solid axle/service inspection)
1. After draining and removing bolts, remove cover. Pry carefully to avoid gouging face. Catch remainder of oil.

2. Clean cover and housing mating surfaces. Scrape old gasket/RTV clean.

3. Inspect ring gear, bearings, carrier, spider gears: look for chipped teeth, scoring, discoloration. If only light wear, you may reuse; heavy wear requires parts replacement.

4. Replace gasket or use recommended RTV bead (continuous 2–3 mm bead on cover or housing as directed by Toyota).

5. If replacing pinion seal or bearings: this becomes a rebuild — requires special tools (press, bearing puller, installer) and micrometer/dial indicator to set pinion preload and ring gear backlash.

Rebuild/high-level steps (only for experienced techs with tools)
- Remove differential carrier, press off bearings, replace bearings and seal.
- Set pinion preload using crush spacer or shims per spec and torque pinion nut to spec, measure rotation torque.
- Install carrier with new bearings, set backlash via shims, measure with dial indicator. Typical backlash spec ~0.10–0.20 mm (check manual).
- Check gear pattern using gear marking compound and adjust until correct.
- Torque all bolts to spec and apply threadlocker where required.
- Fill with correct gear oil and limited-slip additive if applicable.

Replacement parts commonly required
- Drain plug crush washer.
- Differential cover gasket or RTV.
- Differential fluid (volume varies by diff; typical rear solid axle ~1.5–2.0 L, front differential slightly less — confirm in manual).
- If damage found: ring & pinion set, bearings, seals, carrier shims, bolts.

How specific tools are used
- Gear oil pump: insert hose into fill hole, pump until oil flows out fill hole level. Prevent air pockets and overfilling.
- Torque wrench: tighten drain/fill/cover bolts to specified Nm in a star pattern for covers. Avoid over-torque which can strip aluminum housings.
- Dial indicator: mounted to housing, tip on ring gear tooth; rotate carrier to measure backlash. Adjust with shims. Used only in rebuilds.
- Bearing press/puller: remove/install bearings and races when replacing pinion or carrier bearings.

Common pitfalls & how to avoid them
- Removing drain plug before fill plug: can leave you unable to refill. Always remove fill plug first.
- Overfilling or underfilling: if overfilled the differential can vent oil and cause leaks; underfilled causes overheating and wear. Fill to the bottom of the fill hole.
- Cross-threading fill/drain plugs: start by hand, then ratchet. Use correct socket.
- Reusing damaged gasket surface or not cleaning: causes leaks. Clean both surfaces thoroughly.
- Incorrect fluid or forgetting LSD additive: using wrong additive can cause clutch chatter and damage. If unit is limited-slip, add the OEM-specified LSD additive.
- Ignoring magnet findings: heavy metal chunks mean internal failure — do not just refill; inspect.
- Over-torquing cover bolts or fill plug: can strip threads, crack housing. Use proper torque wrench.
- Attempting full rebuild without proper tools/knowledge: setting pinion preload and backlash is critical — if unsure, have a specialist perform the rebuild.

Notes on fluid choice & capacities
- Use OEM-recommended viscosity and spec. Commonly GL‑5 gear oil 75W-90 or 80W-90; some climates need heavier 85W-140. If vehicle has limited-slip diff, use Toyota LSD additive or oil formulated for limited-slip diffs per the service manual.
- Typical capacities (approximate): rear solid axle ~1.6–2.0 L, front differential ~1.2–1.8 L. Confirm exact capacity from the model’s repair manual.

Disposal
- Collect used gear oil and dispose of at an approved recycling center. Do not pour down drains.

Final checklist before returning vehicle
- Torque fill and drain plugs to spec.
- Check for leaks around plugs, cover, axle seals.
- Road test, listen for unusual noises, re-inspect after short drive.
- Top up if necessary.

If you need exact torque numbers, fill capacities, or the LSD additive part number for your exact year/model (Hilux/Surf/Hiace/etc.), consult the Toyota repair manual for that vehicle.
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