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.
      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.
2. INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER 
   1. Install the front side gear and thrust washer.
      Fig 2: Identifying Front Side Gear And Thrust Washer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the pinion shaft, 2 pinion gears and thrust washers to the front differential case.
      Fig 3: Installing Pinion Shaft, Pinion Gears And Thrust Washers To Front Differential Case

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Push the pinion shaft.

      Maximum backlash: 0.05 mm (0.0020 in.) 

      If the backlash is greater than the maximum, replace the thrust washer with one of the correct size and reinstall the thrust washer.

      Standard snap ring thickness 

      STANDARD SNAP RING 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)

   4. Use the procedures described for the front case backlash to measure the rear case backlash.
   5. Install the straight pin to the pinion shaft.
   Fig 5: Identifying Straight Pin And Pinion Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL THRUST WASHER AND REAR SIDE GEAR 
   Fig 6: Identifying Thrust Washer And Rear Side Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL REAR DIFFERENTIAL CASE 
   1. Install the differential case with the 12 set bolts.

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

   2. Turn the pinion gear.
   3. Loosen the 12 case set bolts.
   4. Torque the 12 case set bolts.
   Fig 7: Tightening Rear Differential Case Set Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

5. INSTALL REAR TAPER ROLLER BEARING 
   1. Using SST and a press, press in the taper roller bearing.
   Fig 8: Identifying Rear Taper Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09316-12010 

6. INSTALL CLUTCH HUB 
   1. Using SST and a press, press in the clutch hub.
   Fig 9: Identifying Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

7. INSTALL HIGH SPEED OUTPUT GEAR BUSH 
   1. Apply MP grease to the straight pin.
   2. Install the straight pin, as shown in the illustration.
      Fig 10: Identifying Straight Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using SST and a press, press in the high speed output gear bushing.
   Fig 11: Identifying High Speed Output Gear Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE: Before pressing on the front differential case, align the groove on the bushing with the pin on the shaft.
8. INSTALL HIGH AND LOW CLUTCH SLEEVE 

   HINT:

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

   Fig 12: Identifying High And Low Clutch Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. 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.
10. INSTALL FRONT TAPER ROLLER BEARING 
    1. Using SST and a press, press in the taper roller bearing.
    Fig 13: Identifying Front Taper Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

11. INSTALL FRONT DRIVE GEAR PIECE 
    1. Using SST and a press, press in the drive gear piece.
    Fig 14: Identifying Front Drive Gear Piece

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

12. INSTALL SNAP RING 
    1. Select a snap ring that will allow the minimum axial play.

       Standard snap ring thickness 

       STANDARD 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 15: Identifying Snap Ring

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