Print-Toyota Service Information 11/3/17, 8(48 pm

Print Exit

AXLE AND DIFFERENTIAL DIFFERENTIAL OIL REPLACEMENT

PROCEDURE

1.DRAIN DIFFERENTIAL OIL

a. for front differential:

i. Stop the vehicle on a level surface.

ii.

*1 10 mm Straight Hexagon Wrench

*2 10 mm Union Nut Wrench
*3 Socket Adaptor

Using SST and a 10 mm straight hexagon wrench, 10 mm union nut wrench and socket adaptor,
remove the differential filler plug and gasket.
SST
09961-00950

iii. Remove the drain plug and gasket, and drain the oil.

iv. Install a new gasket and the drain plug.

Torque:
64.7 N*m (660 kgf*cm, 48 ft.*lbf)

b. for rear differential:

i. Stop the vehicle on a level surface.

ii. Remove the rear axle housing filler plug and gasket.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-j…manual/repair/contents/RM100000000TFDE.html?PUB_TYPE=RM&MODE=1 Page 1 of 5
Print-Toyota Service Information 11/3/17, 8(48 pm

iii. Remove the rear axle housing drain plug and gasket, and drain the oil.

iv. Install a new gasket and the rear axle housing drain plug.
Torque:
49 N*m (500 kgf*cm, 36 ft.*lbf)

2.ADD DIFFERENTIAL OIL

HINT:
Check the shape of the companion flange and if there are serration bolts and a connector to determine whether
the vehicle has a BD20 or BD22 differential.
· BD20:
Companion flange is round and there are no serration bolts and no connector.
· BD22:
Companion flange has an irregular shape and there are serration bolts.
· BD22:
Connectors are installed when the vehicle is equipped with a differential lock.

*a for BD20 (w/o Differential Lock) *b for BD22 (w/ Differential Lock)
*c for BD22 (w/o Differential Lock) *d for DANA Made (w/ Differential Lock)
*e for DANA Made (w/o Differential Lock) - -

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000TFDE.html?PUB_TYPE=RM&MODE=1 Page 2 of 5
Print-Toyota Service Information 11/3/17, 8(48 pm

a.

*a 0 to 5 mm

Add differential oil so that the oil level is within 0 to 5 mm (0 to 0.196 in.) from the bottom lip of the
differential filler plug hole.
NOTICE:
· After changing the oil, drive the vehicle, and then check the oil level again.
· Too much or too little oil will lead to differential problems.

If necessary, fill the differential carrier with hypoid gear oil.

Recommended Viscosity:
Item Viscosity
Front Differential (w/
A.D.D.)
SAE 75W-85
Front Differential (w/o
A.D.D.)
Rear Differential SAE 75W-85

Differential Oil Type:

Item Oil type
Front Differential (w/
A.D.D.) Toyota Genuine
Differential gear oil LT
Front Differential (w/o
75W-85 GL-5 or
A.D.D.)
equivalent
Rear Differential

Standard Front Differential Oil Capacity:

Item Capacity
1.55 to 1.65 liters
w/ A.D.D. (1.64 to 1.74 US qts.,
1.37 to 1.45 Imp. qts.)
1.40 to 1.50 liters
w/o A.D.D. (1.48 to 1.58 US qts.,
1.24 to 1.32 Imp. qts.)

Standard Rear Differential Oil Capacity:

Item Capacity
BD20 2.70 to 2.80 liters (2.86
(w/o Differential to 2.95 US qts., 2.38 to
Lock) 2.46 Imp. qts.)
BD22 3.55 to 3.65 liters (3.76
(w/ Differential to 3.85 US qts., 3.13 to
Lock) 3.21 Imp. qts.)

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000TFDE.html?PUB_TYPE=RM&MODE=1 Page 3 of 5
Print-Toyota Service Information 11/3/17, 8(48 pm

BD22 3.60 to 3.70 liters (3.81

(w/o Differential to 3.91 US qts., 3.17 to
Lock) 3.25 Imp. qts.)

for DANA Made 3.55 to 3.65 liters (3.76

(w/ Differential to 3.85 US qts., 3.13 to
Lock) 3.21 Imp. qts.)
for DANA Made 3.70 to 3.80 liters (3.92
(w/o Differential to 4.01 US qts., 3.26 to
Lock) 3.34 Imp. qts.)

b. Check for oil leakage when the oil level is low.

c.

*1 10 mm Straight Hexagon Wrench

*2 10 mm Union Nut Wrench
*3 Socket Adaptor

for front differential:

i. Using SST and a 10 mm straight hexagon wrench, 10 mm union nut wrench and socket adaptor, install
a new gasket and the differential filler plug.
SST
09961-00950

Torque:
39.2 N*m (400 kgf*cm, 29 ft.*lbf)

NOTICE:
· Make sure all the tools are connected in a straight line.
· Use the formula to calculate special torque values for situations where a union nut wrench is
combined with a torque wrench.

Formula:

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000TFDE.html?PUB_TYPE=RM&MODE=1 Page 4 of 5
Print-Toyota Service Information 11/3/17, 8(48 pm

T' = T x L3 / (L1 + L2 + L3)

- T' = Spec. value of torque wrench
- T = Value of specified tightening torque
- L1 = Length of union nut wrench
- L2 = Length of SST
- L3 = Length of torque wrench

d. for rear differential:

i. Install a new gasket and the rear axle housing filler plug.
Torque:
49 N*m (500 kgf*cm, 36 ft.*lbf)

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000TFDE.html?PUB_TYPE=RM&MODE=1 Page 5 of 5