Differential Case: Reassembly

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. After applying ATF to the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers, install them to the front differential case.
  HINT:
  
  Fig 1: Identifying Front Differential Side Gears And Front Differential Pinions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.
INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
1. Install the No. 1 pinion shaft so as to align the lock pin holes in the pinion shaft and differential case.
  
  Fig 2: Installing Front Differential Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

Measure the differential side gear backlash while holding 1 pinion gear toward the case.
Standard backlash:

0.05 to 0.20 mm (0.0020 to 0.0079 in.)

If the backlash is outside the specifications, install the correct thrust washer to the side gear.

Fig 3: Measuring Differential Side Gear Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Referring to the table below, select thrust washers which will ensure that the backlash is within the specifications for both sides.

Thrust washer thickness

THRUST WASHER THICKNESS SPECIFICATION

Thickness mm (in.)	Thickness mm (in.)
0.95 (0.0374)	1.10 (0.0433)
1.00 (0.0394)	1.15 (0.0453)
1.05 (0.0413)	1.20 (0.0472)

If the backlash is not within the specifications, install a thrust washer of a different thickness.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and a hammer, install the pinion shaft straight pin.
  
  Fig 4: Installing Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the differential case.
  
  Fig 5: Staking Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
2. Clean the contact surface of the front differential case.
3. Install 4 new ring gear lock plates with the 8 bolts.
  Torque: 88 N*m (898 kgf*cm, 65 ft.*lbf)
  
  Fig 7: Identifying Ring Gear Lock Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, stake the ring gear lock plate.
  SST 09930-00010
  
  Fig 8: Staking Ring Gear Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case LH tapered roller bearing inner race to the differential case.
  SST 09726-40010, 09950-60020 (09951-00790)
  
  Fig 9: Installing Front Differential Case LH Tapered Roller Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the shim and bearing outer race to the transaxle case.
  SST 09950-60020 (09951-00720), 09950-60010 (09951-00650), 09950-70010 (09951-07100, 09951-07200)
  
  Fig 10: Installing Shim And Bearing Outer Race To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the bearing inner race to the differential case.
  SST 09950-60010 (09951-00460), 09950-70010 (09951-07100)
  
  Fig 11: Installing Bearing Inner Race To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the tapered roller bearing to the transaxle housing.
  SST 09950-70010 (09951-07150), 09950-60020 (09951-00680)
  
  Fig 12: Installing Tapered Roller Bearing To Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002