Differential Case: Reassembly

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF, and install them into the differential case.
  
  Fig 1: Identifying Front Differential Side Gears, Side Gear Thrust Washers And Front Differential Pinions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT
1. Coat the front differential pinion shaft with ATF, and install it into the differential case.
  
  Fig 2: Identifying Front Differential Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH

Using a dial indicator, measure the backlash of the side gear.

Standard backlash:

0.05 to 0.20 mm (0.0020 to 0.0070 in.)

Standard thrust washer thickness

Fig 3: Measuring Backlash Of Side Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

STANDARD THRUST WASHER THICKNESS

Mark	Thickness	Mark	Thickness
1	1.0 mm (0.0394 in.)	3	1.2 mm (0.0472 in.)
2	1.1 mm (0.0433 in.)	4	1.3 mm (0.0512 in.)

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and hammer, tap in the pinion shaft straight pin.
  
  Fig 4: Tapping Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and hammer, stake the differential case.
  
  Fig 5: Staking Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, press in the front differential case tapered roller bearing rear inner race to the differential case.
  SST 09608-06041
  
  Fig 6: Pressing Front Differential Case Tapered Roller Bearing Rear Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in the case washer and front differential case tapered roller bearing rear outer race to the transaxle case.
  SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
  
  Fig 7: Tapping Case Washer And Front Differential Case Tapered Roller Bearing Rear Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press the front differential case tapered roller bearing front inner race into the differential case.
  SST 09608-06041
  
  Fig 8: Pressing Front Differential Case Tapered Roller Bearing Front Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap the front differential case tapered roller bearing front outer race into the transaxle housing.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07100), 09950-60010 (09951-00340)
  
  Fig 9: Tapping Front Differential Case Tapered Roller Bearing Front Outer Race
  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.
  
  Fig 10: Heating Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the matchmarks, and install the front differential ring gear case quickly.
  
  Fig 11: Aligning Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 10 bolts.
  Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
  
  Fig 12: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT TAPERED ROLLER BEARING PRELOAD

Install the differential assembly into the transaxle case.
Install the transaxle housing into the transaxle case.

Fig 13: Identifying Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the 18 bolts.

Torque:

22 N*m (220 kgf*cm, 16 ft.*lbf) for bolt A

29 N*m (300 kgf*cm, 21 ft.*lbf) for bolt B and C

10 N*m (102 kgf*cm, 7.4 ft.*lbf) for bolt D

Each bolt length is indicated below.

BOLT LENGTH CHART

Bolt	Length	Head
A	50 mm (1.969 in.)	12 mm (0.47 in.)
B	50 mm (1.969 in.)	12 mm (0.47 in.)
C	42 mm (1.654 in.)	12 mm (0.47 in.)
D	50 mm (1.969 in.)	10 mm (0.39 in.)

Fig 14: Identifying Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, turn the differential.
SST 09564-32011

Fig 15: Turning Differential Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and torque wrench, measure the preload of the differential.

SST 09564-32011

Torque: Standard turning torque at 60 rpm

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

0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) for used

Fig 16: Measuring Preload Of Differential

Standard adjusting shim thickness

STANDARD ADJUSTING SHIM THICKNESS

Mark	Thickness
0	1.90 mm (0.074 in.)
1	1.95 mm (0.077 in.)
2	2.00 mm (0.079 in.)
3	2.05 mm (0.081 in.)
4	2.10 mm (0.083 in.)
5	2.15 mm (0.085 in.)
6	2.20 mm (0.087 in.)
7	2.25 mm (0.089 in.)
8	2.30 mm (0.091 in.)
9	2.35 mm (0.093 in.)
A	2.40 mm (0.094 in.)
B	2.45 mm (0.096 in.)
C	2.50 mm (0.098 in.)
D	2.55 mm (0.100 in.)
E	2.60 mm (0.102 in.)
F	2.65 mm (0.104 in.)
G	2.70 mm (0.106 in.)
H	2.75 mm (0.108 in.)
J	2.80 mm (0.110 in.)

Using a plastic-faced hammer, remove the transaxle housing.

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 09350-32014 (09351-32150), 09950-70010 (09951-07150)
  
  Fig 19: Tapping Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 09350-32014 (09351-32150), 09950-70010 (09951-07150)
  
  Fig 20: Tapping Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002