Center Differential: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL LOW GEAR 
   1. Clean the contact surface of the differential case.
   2. Heat the low gear in boiling water.
   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.
   Fig 1: Heating Low Gear In Boiling Water

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL THRUST WASHER AND FRONT SIDE GEAR 
   Fig 2: Installing Thrust Washer And Front Side Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS 
   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 To Differential Front Case

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a dial indicator, measure the front case backlash.

      HINT:

      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.

      THRUST WASHER THICKNESS 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)

      Fig 4: Measuring Front Case Backlash

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT 
5. INSTALL REAR SIDE GEAR AND THRUST WASHER 
6. INSTALL DIFFERENTIAL REAR CASE 
   1. Install the differential rear case and 12 set bolts.

      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) 

   Fig 5: Installing Differential Rear Case Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL REAR TAPER ROLLER BEARING 

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

   SST 09316-12010

   Fig 6: Installing Rear Taper Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL CLUTCH HUB 

   Using SST and a press, install the clutch hub.

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

   Fig 7: Installing Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL HIGH SPEED OUTPUT GEAR BUSHING 
   1. Apply MP grease to the straight pin.
   2. Install the straight pin, as shown.
      Fig 8: Installing Straight Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using SST and a press, install the high speed output gear bushing.

      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.
   Fig 9: Aligning Bushing With Pin In Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL HIGH AND LOW CLUTCH SLEEVE 

    HINT:

    Make sure to install the high and low clutch sleeve in the correct direction.

    Fig 10: Installing High And Low Clutch Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR 
    1. Apply gear oil to the needle roller bearing.
    2. Install the needle roller bearing and high speed output gear.
12. INSTALL FRONT TAPER ROLLER BEARING 

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

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

    Fig 11: Installing Front Taper Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL FRONT DRIVE GEAR PIECE 

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

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

    Fig 12: Installing Front Drive Gear Piece

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. INSTALL SNAP RING 
    1. Select a snap ring that will allow the minimum axial play.
       SNAP RING THICKNESS SPECIFICATION
       
       

       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)	-	-

       Fig 13: Selecting Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install a new snap ring.
15. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See  DISASSEMBLY   )