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Differential Case: Reassembly

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Apply ATF to the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers and install them to the differential case.
      Fig 1: Identifying Front Differential Pinions, Pinion Thrust Washers, Front Differential Side Gears And Side Gear Thrust Washers
      G05272374Courtesy 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.
      2. Fig 2: Installing No. 1 Front Differential Pinion Shaft
      G05272373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT BACKLASH (See  INSPECTION   ) 
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch and a hammer, install the pinion shaft straight pin.
      Fig 3: Installing Pinion Shaft Straight Pin
      G05001098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the differential case.
      NOTE: Stake the differential case after adjusting the backlash.
      Fig 4: Staking Differential Case
      G05001099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing to the differential case.

      SST 09316-12010, 09550-60010 (09951-00490), 09950-70010 (09951-07100) 

      Fig 5: Installing Front Differential Case Front Tapered Roller Bearing
      G05001100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the bearing cage when installing the bearing inner race.
    2. Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing.

      SST 09550-60010 (09951 -00490), 09950-60020 (09951-00910) 

      Fig 6: Installing Front Differential Case Tapered Roller Bearing Front Outer Race To Transaxle Housing
      G04976478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing to the differential case.

      SST 09316-12010, 09550-60010 (09951-00490), 09950-70010 (09951-07100, 09951-07150) 

      NOTE: Do not damage the bearing cage when installing the bearing inner race.
      Fig 7: Installing Front Differential Case Front Tapered Roller Bearing To Differential Case
      G05001102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front differential case tapered roller bearing rear outer race to the transaxle housing.

      SST 09950-70010 (09951 -07100, 09951 -07150), 09950-60020 (09951-00890) 

      NOTE: No clearance is allowed between the bearing and transaxle housing.
      Fig 8: Installing Front Differential Case Tapered Roller Bearing Front Outer Race To Transaxle Housing
      G04976480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Install the differential assembly to the transaxle case.
      Fig 9: Installing Differential Assembly To Transaxle Case
      G05272386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the mating surfaces of the transaxle case and transaxle housing.
    3. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.
      Fig 10: Identifying Transaxle Housing Bolts
      G05000920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A 

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

      Bolt B 

      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) 

      HINT:

      Apply adhesive or equivalent to bolts A and D.

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Bolt length: 

      Bolt A, B: 

      50 mm (1.969 in.) 

      Bolt C: 

      42 mm (1.654 in.) 

      Bolt D: 

      72 mm (2.835 in.) 

      NOTE: Apply adhesive to the bolts and tighten them within 10 minutes of application.

      HINT:

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

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

      SST 09564-32011 

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

      SST 09564-32011 

      Turning torque at 60 rpm: 

      New bearing: 

      0.20 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) 

      Fig 11: Measuring Turning Torque
      G04976483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If the turning torque is not as specified, refer to the table below to select a thrust washer so that the specified value is achieved.

      Flange thickness: mm (in.) 

      THICKNESS CHART

      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) - -
    6. Remove the 16 bolts and the transaxle housing.
      Fig 12: Locating Transaxle Housing Bolts
      G04976122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential assembly.
      Fig 13: Removing Differential Assembly
      G05272386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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 110C (230.0°F).
    2. Clean the contact surface of the front differential case.
      Fig 14: Heating Front Differential Ring Gear
      G04976486Courtesy 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: Aligning Matchmarks
      G05272365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 14 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 16: Identifying Front Differential Ring Gear Bolts
      G05001111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.

      SST 09223-15020, 09950-70010 (09951 -07150) 

    2. Coat the lip of oil seal with a little MP grease.

      Oil seal installation depth: 

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

      Fig 17: Installing Oil Seal
      G04976489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.

      SST 09710-30050, 09950-70010 (09951-07150) 

    2. Coat the lip of the oil seal with a little MP grease.

      Oil seal installation depth: 

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

      Fig 18: Installing Differential Side Bearing Retainer Oil Seal
      G05001113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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