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Differential Case: Inspection

  1. INSPECT FRONT DIFFERENTIAL 
    1. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.

      Standard backlash: 

      0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

      NOTE: Do not mount the surface of the front differential case which contacts with the bushing in a vise.
      Fig 1: Measuring Backlash Of Pinion Gear
      G05246449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Thrust washer thickness: mm (in.) 

      THRUST WASHER THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      A 0.95 (0.0373) F 1.20 (0.0472)
      B 1.00 (0.0393) G 1.25 (0.0492)
      C 1.05 (0.0413) H 1.30 (0.0512)
      D 1.10 (0.0433) J 1.35 (0.0532)
      E 1.15 (0.0453) K 1.40 (0.0552)
    2. Engage the front differential side to the above mentioned front differential case.
    3. Install the differential case LH to the front differential case and measure its center.
    4. After that, remove the differential case LH.
      Fig 2: Identifying Differential Case LH And No. 2 Differential Case
      G05269264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a straightedge and feeler gauge, measure the clearance between the front differential case and the front differential side gear.

      HINT:

      • t= Thrust washer thickness
      • L= Clearance
      • t= L-0.162 to 0.265 mm (0.0064 to 0.0104 in.)
        Fig 3: Measuring Clearance Between Front Differential Case And Front Differential Side Gear
        G05246451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the clearance is not within the specified range, refer to the table below and select a thrust washer so that the clearance is within the specified range.

      Thrust washer thickness: mm (in.) 

      THRUST WASHER THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      A 0.95 (0.0373) F 1.20 (0.0472)
      B 1.00 (0.0393) G 1.25 (0.0492)
      C 1.05 (0.0413) H 1.30 (0.0512)
      D 1.10 (0.0433) J 1.35 (0.0532)
      E 1.15 (0.0453) K 1.40 (0.0552)

      If the clearance is not within the specified range, parts may have been assembled incorrectly, so check and reassemble it.

  2. INSPECT CENTER DIFFERENTIAL 
    1. Pressing and holding the differential spider toward the differential case RH, measure the pinion's backlash with a dial indicator as illustrated.

      Standard backlash: 

      0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Fig 4: Measuring Pinion's Backlash
      G05246452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust washer thickness: mm (in.) 

      THRUST WASHER THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
    2. Temporarily install the No. 2 differential side gear thrust washer LH, center differential side gear conical spring washer, and No. 2 differential case to the differential case LH.

      HINT:

      Ensure that the conical washers are installed correctly.

      Fig 5: Identifying Differential Side Gear Thrust Washer And Differential Case LH
      G05246453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the differential intermediate case to the differential case and secure the assembled parts with the 4 bolts.
      Fig 6: Identifying Differential Intermediate Case
      G05246454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the differential spider, 5 center differential pinions, and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and secure the case.
      Fig 7: Identifying Differential Spider And Center Differential Pinions
      G05246455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Pressing and holding the differential spider toward the differential intermediate case, measure the pinion's backlash with a dial indicator.

      Standard backlash: 

      0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Fig 8: Measuring Pinion's Backlash
      G05246456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust washer thickness: mm (in.) 

      THRUST WASHER THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
    6. Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case.
      Fig 9: Identifying Differential Case LH And Differential Intermediate Case
      G05246457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the No. 2 differential case from the differential case LH.
      Fig 10: Identifying No. 2 Differential Case And Differential Case LH
      G05416885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. ADJUST TAPERED ROLLER BEARING PRELOAD 
    1. Install the intermediate case to the differential case LH and secure them with the 4 bolts.
    2. Install the differential assembly to the transaxle case.
      Fig 11: Identifying Tapered Roller Bearing Preload
      G05246459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the matching surfaces of the transaxle case and transaxle housing.
    4. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.

      Torque: Bolt A 

      25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Bolt B, E 

      33 N*m (337 kgf*cm, 24 ft.*lbf) 

      Bolt C 

      29 N*m (295 kgf*cm, 21 ft.*lbf) 

      Bolt D 

      28 N*m (286 kgf*cm, 21 ft.*lbf) 

      Fig 12: Identifying Transaxle Housing Bolts
      G05841794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt length: 

      Bolt A, D, E: 50 mm (1.969 in.) 

      Bolt B, C: 42 mm (1.654 in.) 

      HINT:

      Bolt A is a non-reusable bolt. However, bolt A can be used after cleaning it.

    5. Using SST, turn the differential assembly right and left 2 or 3 times to allow the bearing to settle.

      SST 09564-32011 

    6. Using SST and a torque wrench, measure the turning torque of the differential case assembly.

      SST 09564-32011 

      Torque: New bearing (*) 

      0.2 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf) 

      Used bearing (*) 

      0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) 

      HINT:

      • (*): Turning torque at 60 rpm
      • If the turning torque is not within the specified range, refer to the table below and select a thrust washer so that the turning torque is within the specified range.

      Flange thickness: mm (in.) 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      0 2.000 (0.0787) 9 2.450 (0.0965)
      j 2.025 (0.0797) T 2.475 (0.0974)
      1 2.050 (0.0807) A 2.500 (0.0984)
      K 2.075 (0.0817) U 2.525 (0.0994)
      2 2.100 (0.0827) B 2.550 (0.1004)
      L 2.125 (0.0837) V 2.575 (0.1014)
      3 2.150 (0.0846) C 2.600 (0.1024)
      M 2.175 (0.0857) W 2.625 (0.1034)
      4 2.200 (0.0866) D 2.650 (0.1043)
      N 2.225 (0.0876) X 2.675 (0.1053)
      5 2.250 (0.0886) E 2.700 (0.1063)
      P 2.275 (0.0896) Y 2.725 (0.1073)
      6 2.300 (0.0906) F 2.750 (0.1083)
      Q 2.325 (0.0915) AA 2.775 (0.1093)
      7 2.350 (0.0925) G 2.800 (0.1102)
      R 2.375 (0.0935) AB 2.825 (0.1112)
      8 2.400 (0.0945) H 2.850 (0.1122)
      S 2.425 (0.0954) - -
      Fig 13: Measuring Turning Torque Of Differential Case Assembly
      G05269275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 16 bolts and the transaxle housing.
      Fig 14: Locating Transaxle Housing Bolts
      G05246462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the differential assembly.
      Fig 15: Identifying Differential Assembly
      G05841797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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