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Differential Case: Reassembly

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
    Fig 1: Identifying Differential Pinions, Pinion Thrust Washers And Front Differential Side Gears
    G05139065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT 
    1. Coat the No. 1 front differential pinion shaft with ATF, and install it to the differential case.
    Fig 2: Installing No. 1 Front Differential Pinion Shaft
    G05582784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch and a hammer, tap in the pinion shaft straight pin.
      Fig 3: Tapping Pinion Shaft Straight Pin
      G05582785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the differential case.
      NOTE: Stake it after adjusting the backlash.
      Fig 4: Staking Differential Case
      G05582786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, press in the front differential case rear tapered roller bearing to the differential case.

      SST 09550-60010, 09950-60020 (09951 -00680), 09950-70010 (09951-07100) 

      Fig 5: Pressing Front Differential Case Rear Tapered Roller Bearing
      G06043663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap in the front differential case rear tapered roller bearing outer race to the transaxle case.

      SST 09550-60010, 09950-60020 (09951-00680), 09950-70010 (09951-07100, 09951-00890) 

      Fig 6: Tapping Front Differential Case Rear Tapered Roller Bearing Outer Race
      G06043664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, press in the front differential case front tapered roller bearing to the differential case.

      SST 09550-60010, 09950-60020 (09951-00680), 09950-70010 (09951-07100, 09951-00890) 

      Fig 7: Pressing Front Differential Case Front Tapered Roller Bearing
      G06043665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap in the front differential case front tapered roller bearing outer race to the transaxle housing.

      SST 09550-60010, 09950-60020 (09951-00680), 09950-70010 (09951-07100, 09951-00890) 

      NOTE: Make sure that there is no clearance between the bearing and transaxle housing.
      Fig 8: Tapping Front Differential Case Front Tapered Roller Bearing Outer Race
      G05246480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Install the differential assembly to the transaxle case.
      Fig 9: Removing/Installing Differential Assembly
      G05582791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the contact surfaces of the transaxle case and transaxle housing.
    3. Install the transaxle housing to the transaxle case and tighten them with the 18 bolts.
      Fig 10: Identifying Transaxle Housing To Transaxle Case Bolts
      G06043580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A and D 

      22 N*m (225 kgf*cm, 16 ft.*lbf) 

      Bolt B and C 

      29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Bolt E 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT:

      Each bolt length is indicated below.

      Bolt length: 

      Bolt A 50 mm (1.969 in.) 

      Bolt B 50 mm (1.969 in.) 

      Bolt C 42 mm (1.654 in.) 

      Bolt D 72 mm (2.834 in.) 

      Bolt E 50 mm (1.969 in.) 

      NOTE: Usually, bolts A are non-reusable bolts. In this case, however, they can be used after cleaning.
    4. Using SST, turn the differential assembly right and left 2 or 3 times to allow the bearing to settle.

      SST 09564-32011 

    5. Using SST and a torque wrench, measure the differential preload.

      SST 09564-32011 

      Standard preload at 60 rpm: 

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

      Fig 11: Measuring Differential Preload
      G04976483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If the preload is not within the specified value, refer to the table below and select an appropriate thrust washer to adjust preload to within the specified value.

      Thrust Washer Thickness 

      THRUST WASHER THICKNESS CHART

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      0 2.00 (0.0787) J 2.025 (0.0797)
      1 2.05 (0.0807) K 2.075 (0.0816)
      2 2.10 (0.0827) L 2.125(0.0836)
      3 2.15 (0.0846) M 2.175 (0.0856)
      4 2.20 (0.0866) N 2.225 (0.0875)
      5 2.25 (0.0886) P 2.275 (0.0895)
      6 2.30 (0.0906) Q 2.325 (0.0915)
      7 2.35 (0.0925) R 2.375 (0.0935)
      8 2.40 (0.0945) S 2.425 (0.0954)
      9 2.45 (0.0965) T 2.475 (0.0974)
      A 2.50 (0.0984) U 2.525 (0.0994)
      B 2.55 (0.1004) V 2.575(0.101)
      C 2.60 (0.1024) W 2.625(0.103)
      D 2.65 (1.1043) X 2.675(0.105)
      E 2.70 (0.1063) Y 2.725 (0.107)
      F 2.75 (0.1083) AA 2.775(0.109)
      G 2.80 (0.1102) AB 2.825(0.111)
      H 2.85 (0.1122) - -
    6. Remove the 18 bolts and the transaxle housing.
      Fig 12: Locating Transaxle Housing Bolts
      G06043338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential assembly.
    Fig 13: Removing/Installing Differential Assembly
    G05582791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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).
      NOTE: Do not heat the ring gear to over 110°C (230F).
    2. Clean the contact surface of the front differential case.
      Fig 14: Heating Front Differential Ring Gear
      G05388647Courtesy 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 Case
      G06043673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 14 bolts.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      NOTE: Gradually tighten the bolts in diagonal order.
      Fig 16: Identifying Front Differential Ring Gear Bolts
      G05582771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL 
    1. Coat the lip of a new oil seal with a small amount of MP grease.
    2. Using SST and a hammer, tap in the oil seal.

      SST 09223-15020, 09950-70010 (09951-07100) 

      Standard depth: 

      -0.5 to 0.2 mm (-0.0197 to 0.00787 in.) 

      Fig 17: Tapping Differential Side Bearing Retainer Oil Seal Using SST And Hammer
      G06043675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Coat the lip of a new oil seal with a small amount of MP grease.
    2. Using SST and a hammer, tap in the oil seal.

      SST 09649-17010, 09950-70010 (09951-07150) 

      Standard depth: 

      5.5 to 6.5 mm (0.217 to 0.256 in.) 

      Fig 18: Tapping Transaxle Housing Oil Seal Using SST And Hammer
      G06043259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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