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Differential Case: Reassembly

  1. INSTALL DIFFERENTIAL SIDE GEAR 
    1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
      Fig 1: Identifying Front Differential Pinions, Front Differential Side Gears And Side Gear Thrust Washers
      G04977076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.
    Fig 2: Installing Front No 1 Differential Pinion Shaft
    G04977075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (See  INSPECTION   ) 
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch (3 mm) and hammer, install the pinion shaft straight pin.
      NOTE: Align the holes, and install the pinion shaft straight pin.
      Fig 3: Installing Pinion Shaft Straight Pin
      G04977082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and hammer, stake the differential case.
      NOTE: Stake the differential case after adjusting the backlash.
      Fig 4: Staking Differential Case
      G04977083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.

      SST 09710-04081, 09950-60010 (09951-00480), 09950-70010 (09951-07100) 

      NOTE: Do not damage the bearing cage during bearing inner race installation.
      Fig 5: Installing Front Differential Case Rear Tapered Roller Bearing
      G04977084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle case.

      SST 09950-70010 (09951-07150), 09950-60020 (09951-00790) 

      NOTE: Ensure that there is no clearance between the bearing and transaxle case.
      Fig 6: Installing Front Differential Case Rear Tapered Roller Bearing Outer Race
      G04977085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing to the differential case.

      SST 09710-04081, 09950-60010 (09951-00480), 09950-70010 (09951-07100) 

      NOTE: Do not damage the bearing cage during bearing inner race installation.
    2. Install the shim to the transaxle housing.
      Fig 7: Installing Front Differential Case Front Tapered Roller Bearing
      G04977086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.
      NOTE: Ensure that there is no clearance between the bearing and transaxle housing.
      Fig 8: Installing Front Differential Case Front Tapered Roller Bearing Outer Race
      G04977087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Install the differential assembly to the transaxle case.
    2. Clean the contact surfaces of the transaxle case and transaxle housing.
      Fig 9: Identifying Differential Case Sub-Assembly
      G04976860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case with the 20 bolts.

      Torque: 

      Bolt A 

      31 N*m (316 kgf*cm, 23 ft.*lbf) 

      Bolt B 

      23 N*m (234 kgf*cm, 17 ft.*lbf) 

      Fig 10: Identifying Transaxle Housing Bolts
      G04976982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.

      SST 09564-33010 

    5. Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.

      SST 09564-33010 

      Turning torque: 

      1.05 to 1.93 N*m (10.70 to 19.67 kgf*cm, 9.29 to 17.08 in.*lbf) 

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      Shim thickness: mm (in.) 

      SHIM THICKNESS SPECIFICATION

      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.225 (0.0876) 2.450 (0.0965) 2.675 (0.1054)
      2.025 (0.0797) 2.250 (0.0886) 2.475 (0.0974) 2.700 (0.1063)
      2.050 (0.0807) 2.275 (0.0896) 2.500 (0.0984) 2.725 (0.1073)
      2.075 (0.0817) 2.300 (0.0906) 2.525 (0.0994) 2.750 (0.1083)
      2.100 (0.0827) 2.325 (0.0915) 2.550 (0.1004) 2.775 (0.1093)
      2.125 (0.0837) 2.350 (0.0925) 2.575 (0.1014) 2.800 (0.1102)
      2.150 (0.0847) 2.375 (0.0935) 2.600 (0.1024) 2.825 (0.1112)
      2.175 (0.0856) 2.400 (0.0945) 2.625 (0.1034) 2.850 (0.1122)
      2.200 (0.0866) 2.425 (0.0955) 2.650 (0.1043) 2.875 (0.1132)
      Fig 11: Measuring Turning Torque Of Differential Side Bearing
      G04976983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 20 bolts and the transaxle housing from the transaxle case.
      Fig 12: Identifying Transaxle Housing Bolts
      G04976840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential assembly from the transaxle case.
      Fig 13: Identifying Differential Case Sub-Assembly
      G04976860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
      NOTE: Do not heat the ring gear to more than 110°C (230.0°F).
    2. Clean the contact surface of the front differential case.
      Fig 14: Heating Front Differential Ring Gear
      G04977093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks, and install the front differential ring gear case quickly.
      NOTE: Do not install the bolts while the ring gear is hot.
      Fig 15: Identifying Matchmarks On Front Differential Ring Gear And Differential Case
      G04977067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 12 bolts.

      Torque: 120 N*m (1,223 kgf*cm, 88 ft.*lbf) 

      NOTE: Tighten the bolts a little at a time in diagonal order.
      Fig 16: Locating Front Differential Ring Gear Bolts
      G04977068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new oil seal with MP grease.
    2. Using SST and a hammer, install the oil seal.

      SST 09316-10010, 09950-70010 (09951-07100) 

      Oil seal drive in depth: 

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 

      Fig 17: Installing Transaxle Case Oil Seal
      G04977096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new oil seal with MP grease.
    2. Using SST and a hammer, install the oil seal.

      SST 09308-14010 

      Oil seal drive in depth: 

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 

      Fig 18: Installing Front Transaxle Case Oil Seal
      G04977097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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