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Differential Case ASSY (MTM): Overhaul

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR 
    1. Remove the speedometer drive (MTM) gear from the front differential case.
    Fig 1: Removing Speedometer Drive Gear
    G00922216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FRONT DIFFERENTIAL RING GEAR 
    1. Place matchmarks on the front differential ring gear and front differential case.
      Fig 2: Placing Matchmarks On Front Differential Ring Gear And Front Differential Case
      G00922217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts. Using a hammer, remove the front differential ring gear.
    Fig 3: Removing Front Differential Ring Gear
    G00922218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Fixing the front differential pinion from the front differential case side. Using a dial indicator, measure the backlash of the front differential side gear.
      1. Standard backlash:0.05 - 0.20 mm (0.0020 - 0.0079 in.) 
    Fig 4: Measuring Backlash Of Front Differential Side Gear
    G00922219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the backlash is not within the specification, install the connect side gear thrust washers.

  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a chisel and a hammer, loosen the staked part of the front differential case.
      Fig 5: Loosening Staked Part Of Front Differential Case
      G00922220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (phi 3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
    Fig 6: Removing Front Differential Pinion Shaft Straight Pin From Front Differential Case
    G00922221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO. 1 
    1. Remove the front differential pinion shaft No. 1 from the front differential case.
    Fig 7: Removing Front Differential Pinion Shaft No. 1
    G00922222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR 
    1. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gear thrust washers and 2 front differential side gears from the front differential case.
    Fig 8: Removing Front Differential Side Gear
    G00922223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    Turning the front differential pinion, remove the 2 pinions and side gear.

  7. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER 
    1. Using a micrometer, measure the thickness of the front differential pinion thrust washer.
      1. Minimum thickness: 0.92 mm (0.0362 in.) 
    Fig 9: Measuring Thickness Of Front Differential Pinion Thrust Washer
    G00922224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the clearance is below the minimum, replace the front differential pinion thrust washer.

  8. INSPECT FRONT DIFFERENTIAL PINION SHAFT NO. 1 
    1. Using a micrometer, measure the outer diameter of the front differential pinion shaft No. 1.
      1. Minimum outer diameter: 16.982 mm (0.6686 in.) 
    Fig 10: Measuring Outer Diameter Of Front Differential Pinion Shaft No. 1
    G00922225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the outer diameter is less than the minimum, replace the front differential pinion shaft No. 1.

  9. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the sliding and rotating surface of the 2 front differential side gears with MP grease.
    2. Install the 2 front differential side gear thrust washers to the 2 front differential side gear.
      Fig 11: Installing Front Differential Side Gear
      G00922226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install the front differential side gear thrust washer that has the same thickness as the removed one.

    3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side gear thrust washers to the front differential case.
    NOTE:

    Turning the front differential pinion, install the 2 front differential pinions with front differential case.

  10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1 
    1. Coat the rotating surface of the front differential pinion shaft No. 1 with gear oil.
    2. Install the front differential pinion shaft No. 1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
    Fig 12: Installing Front Differential Pinion Shaft No. 1
    G00922227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Fixing the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.
      1. Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.) 
    Fig 13: Measuring Front Differential Side Gear Backlash
    G00922228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the backlash is out of specification, replace the side gear thrust washer.

    Thrust washer thickness: 

    Fig 14: Thrust Washer Thickness Specifications
    G00922229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Because the thrust washer does not have any identification mark, measure the front thickness with a micrometer to select a proper thrust washer.
    • Select washers that has the same thickness as both the right and left.
  12. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch (phi 3 mm) and a hammer, install the front differential pinion shaft straight pin to the front differential case.
      Fig 15: Installing Front Differential Pinion Shaft Straight Pin
      G00922230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the front case hole.
    Fig 16: Staking Front Case Hole
    G00922231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Using a heater, heat the front differential ring gear to 90 - 110°C (194.0 - 230.0°F)
    2. Clean the contact surface of the front differential case.
      Fig 17: Heating Front Differential Ring Gear
      G00922232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the both matchmarks, quickly install the 8 bolts with the front differential ring gear to the front differential case.
      1. Torque: 77.4 N.m (789 kgf.cm, 57 ft.lbf) 
    Fig 18: Aligning Both Matchmarks
    G00922233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL SPEEDOMETER DRIVE (MTM) GEAR 
    1. Install the speedometer drive (MTM) gear to the front differential case.
    Fig 19: Installing Speedometer Drive Gear
    G00922234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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