Center Differential: Reassembly

1. Clean the contact surface of the differential case.
2. Heat the low gear in boiling water.
Fig 1: Heating Low Gear In Boiling Water
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Carefully remove the low gear from the water.
4. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.

1. Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case.
   Fig 3: Installing Pinion Shaft Pinion Gears And Thrust Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the front case backlash.
   Fig 4: Measuring Rear Case Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Push the pinion shaft.

   Maximum backlash: 0.05 mm (0.0020 in.) 

   If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.

   BACKLASH SPECIFICATION
   
   

   Thickness mm (in.)	Thickness mm (in.)
   1.70 (0.0669)	2.45 (0.0965)
   1.85 (0.0728)	2.60 (0.1024)
   2.00 (0.0787)	2.75 (0.1083)
   2.15 (0.0846)	2.90 (0.1142)
   2.30 (0.0906)	3.05 (0.1201)

3. In the same way, measure the rear case backlash.

1. Install the differential rear case and 12 set bolts.
   Fig 5: Installing Differential Rear Case Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 88 N.m (900 kgf.cm, 65 ft.lbf) 

2. Turn the pinion gear.
3. Loosen the 12 rear case set bolts.
4. Torque the 12 rear case set bolts.

   Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf) 

Using SST and a press, install the rear taper roller bearing.

Fig 6: Installing Rear Taper Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09316-12010

Using SST and a press, install the clutch hub.

Fig 7: Installing Clutch Hub

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09316-12010, 09316-60011 (09316-00011)

1. Apply MP grease to the straight pin.
2. Install the straight pin, as shown in Fig 8.
   Fig 8: Installing Straight Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the high speed output gear bushing.
   Fig 9: Installing High Speed Output Gear Bushing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09316-12010, 09316-60011 (09316-00011)

   NOTE: Before pressing on the differential front case, align the groove on the bushing with the pin on the shaft.

1. Apply gear oil to the needle roller bearing.
2. Install the needle roller bearing and high speed output gear.

Using SST and a press, install the front taper roller bearing.

Fig 11: Installing Front Taper Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09316-12010, 09316-60011 (09316-00011)

Using SST and a press, install the front drive gear piece.

Fig 12: Installing Front Drive Gear Piece

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09316-12010, 09316-60011 (09316-00011)

1. Select a snap ring that will allow the minimum axial play.
   Fig 13: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   SNAP RING THICKNESS
   
   

   Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
   A	2.00 (0.0787)	G	2.60 (0.1024)
   B	2.10 (0.0827)	H	2.70 (0.1063)
   C	2.20 (0.0866)	J	2.80 (0.1102)
   D	2.30 (0.0906)	K	1.80 (0.0709)
   E	2.40 (0.0945)	L	1.90 (0.0748)
   F	2.50 (0.0984)	-	-

2. Using a snap ring expander, install a new snap ring.