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Differential Case: Installation

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the rotating surfaces of the differential side gears with gear oil.
    2. Install the 2 differential side gear thrust washers to the 2 differential side gears.
    3. Install the 2 differential side gears, 2 differential pinions and 2 differential side gear thrust washers to the differential case.

      HINT:

      Install the 2 differential pinions with the differential pinion thrust washers while turning the differential pinion.

    Fig 1: Installing Front Differential Side Gear
    G04222809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Coat the rotating surface of the No. 1 differential pinion shaft with gear oil.
    2. Install the No. 1 differential pinion shaft to the differential case so that the hole for the differential pinion shaft straight pin is aligned with the hole in the differential case.
    Fig 2: Installing Front No. 1 Differential Pinion Shaft
    G04222810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch and a hammer, tap in the differential pinion shaft straight pin to the differential case.
      Fig 3: Taping In Differential Pinion Shaft Straight Pin
      G04222811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and hammer, stake the differential case hole.
    Fig 4: Staking Differential Case Hole
    G04222812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Hold the differential pinion to the differential case side. Using a dial indicator, measure the differential side gear backlash.

      Standard backlash: 

      0.10 to 0.20 mm (0.0039 to 0.0079 in.) 

      If the backlash is out of specification, select another differential side gear thrust washer and adjust it.

    Standard thrust washer thickness 

    Part No. Mark Thickness
    41361-28230 1 1.00 mm (0.394 in.)
    41361-28240 2 1.10 mm (0.0433 in.)
    41361-28250 3 1.20 mm (0.0472 in.)
    41361-28260 4 1.30 mm (0.512 in.)
    Fig 5: Measuring Differential Side Gear Backlash
    G04222813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Clean the contact surface of the differential case and differential ring gear.
    2. Using a heater, heat the differential ring gear to 90 to 110°C (194 to 230°F).
    3. After the moisture on the ring gear has completely evaporated, quickly install the differential ring gear to the differential case.
      Fig 6: Heating Differential Ring Gear To 90 To 110°C
      G04222814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Aligning the matchmarks, quickly install the front differential ring gear to the differential case with the 16 bolts.

      Torque: 106 N.m (1,080 kgf.cm, 78 ft. lbf) 

    Fig 7: Aligning Matchmarks
    G04222815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SPEEDOMETER DRIVE GEAR 
    1. Install the drive gear to the differential case.
    Fig 8: Installing Drive Gear To Differential Case
    G04222816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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