Differential Case: Reassembly

INSTALL DIFFERENTIAL CASE SUB-ASSEMBLY NO. 2
1. Coat the front No. 1 differential side gear thrust washer, front differential planetary ring gear, front No. 2 differential pinion, front No. 2 differential pinion thrust washer, front differential pinion shaft holder, front differential pinion shaft, and 2 differential pinion shafts with ATF, and install them to the No. 2 differential case.
  
  Fig 1: Identifying Front Differential Planetary Ring Gear, Differential Pinion And Front Differential Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and a hammer, install the 3 straight pins.
  
  Fig 2: Installing Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a snap ring expander, install the pinion shaft spacer snap ring.
INSPECT FRONT DIFFERENTIAL (See INSPECTION )

Fig 3: Installing Pinion Shaft Spacer Snap Ring
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INSTALL CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY

Install the center differential side gear, conical spring washer, and No. 2 center differential side gear thrust washer RH from the differential case RH.

Fig 4: Identifying Center Differential Side Gear And Differential Case RH
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HINT:

Ensure that the conical washers are installed correctly.
Hold the differential case RH in a vice. Install the center differential pinion and pinion thrust washer to the differential spider and install them to the differential case RH.
NOTE: When holding the differential case RH in a vise, be sure to place aluminum plates between them and use a minimum force.

Fig 5: Holding Differential Case RH In Vice
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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.

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)	-	-

Fig 6: Measuring Pinion's Backlash

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 7: Identifying Differential Side Gear Thrust Washer And Center Differential Side Gear Conical Spring Washer
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Install the differential intermediate case to the differential case and secure the assembled parts with the 4 bolts.

Fig 8: Identifying Differential Intermediate Case
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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 9: Identifying Differential Spider And Center Differential Pinions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 10: Measuring Pinion's Backlash

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)	-	-

Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case.

Fig 11: Disconnecting Differential Case LH And Differential Intermediate Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the No. 2 differential case from the differential case LH.

Fig 12: Removing Differential Case From Differential Case LH
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Install the selected No. 2 differential side gear thrust washer LH and center differential planetary gear to the differential case LH.

Fig 13: Identifying Differential Side Gear Thrust Washer LH And Center Differential Planetary Gear
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Install the No. 2 differential case to the differential case LH again.

Fig 14: Installing No 2 Differential Case To Differential Case LH
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Install the adjusted differential case RH to the intermediate case and tighten the 15 bolts using a Torx socket wrench (T50).
Torque: 63 N*m (642 kgf*cm, 46 ft.*lbf)

NOTE: Align the matchmarks.

Fig 15: Identifying Differential Case RH Bolts
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INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case tapered roller bearing FR to the differential case.
  SST 09950-70010 (09951-07100), 09649-17010
  
  NOTE: Do not damage the bearing cage while installing the bearing inner race.
  
  Fig 16: Installing Front Differential Case Tapered Roller Bearing FR To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the outer race of the tapered roller bearing FR.
  SST 09527-17011, 09950-60020 (09951-01030)
  NOTE:
  - Clearance is not allowed between the plate washer and transaxle housing.
  - When replacing the bearing, be sure to replace both outer and inner races.
  - When replacing the bearing, be sure to replace both left and right bearings as a set.
    
    Fig 17: Installing Outer Race Of Tapered Roller Bearing FR
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Using SST and a press, install the front differential case tapered roller bearing RR to the differential case.
  SST 09316-20011,09214-76011
  
  NOTE: Do not damage the bearing cage while installing the bearing inner race.
  
  Fig 18: Installing Front Differential Case Tapered Roller Bearing RR To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front differential case shim RR to the transaxle case.
  If the bearing is new, select a front differential case shim RR of proper thickness starting from the thinner ones. If the bearing is reused, select a front differential case shim RR starting from the same thickness as the one installed before disassembly.
3. Using SST, install the outer race of the front differential case tapered roller bearing RR.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07100)
  
  NOTE: Clearance is not allowed between the differential case shim and transaxle case.
ADJUST TAPERED ROLLER BEARING PRELOAD (See INSPECTION )

Fig 19: Installing Outer Race Of Front Differential Case Tapered Roller Bearing RR
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using ATF and 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).
  
  Fig 20: Heating Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Clean the contact surface of the front differential case.
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.
  - Check the number and position of the gear teeth.
    
    Fig 21: Identifying Matchmarks On Ring Gear And Differential Case
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the 8 bolts as shown in the illustration.
  
  Fig 22: Installing Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 4 bolts shown in the illustration.
6. Temporarily install the remaining 8 set bolts.
7. Fully tighten the set bolts.
  Torque: 95 N*m (970 kgf*cm, 70 ft.*lbf)
  
  NOTE: Tighten the bolts a little at a time in a diagonal pattern.
  
  Fig 23: Identifying Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
1. Using SST and a hammer, install a new oil seal.
  SST 09223-15020, 09950-70010 (09951-07100)
  
  Standard installation depth: 5.5 to 0.2 mm (-0.020 to 0.008 in.)
2. Coat the lip of oil seal with a little MP grease.
  
  Fig 24: Installing Differential Side Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING OIL SEAL
1. Wrap vinyl tape around SST at the place 6.0 mm (0.236 in.) above the bottom end until the thickness of the wrapped tape is approximately 5.0 mm (0.197 in.).
  SST 09950-60020(09951-00730)
  
  NOTE: Remove foreign matter such as grease on the SST before winding the tape.
  
  Fig 25: Wraping Vinyl Tape Around SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the lip of oil seal with a little MP grease.
3. Using SST, install a new oil seal.
  SST 09950-60020 (09951-00730), 09950-70010 (09951-07150)
  
  Standard installation depth: 5.5 to 6.5 mm (0.217 to 0.256 in.)
  
  NOTE: Stop pressing when the wrapped vinyl tape contacts the transaxle housing.
  
  Fig 26: Installing Transaxle Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002