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Differential Case: Installation

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  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: Identifying Front Differential Side Gear
    G05389085Courtesy 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: Identifying Front No. 1 Differential Pinion Shaft
    G05389086Courtesy 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: Tapping In Differential Pinion Shaft Straight Pin
      G05389087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and hammer, stake the differential case hole.
    Fig 4: Identifying Differential Case Hole
    G05389088Courtesy 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.

    Fig 5: Measuring Differential Side Gear Backlash
    G05389089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Standard thrust washer thickness 

    THRUST WASHER THICKNESS SPECIFICATION

    Part No. Mark Thickness
    41361-28230 1 1.00 mm (0.0394 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 (0.0512 in.)
  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: Identifying Differential Ring Gear
      G05389090Courtesy 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: Identifying Matchmarks
    G05389091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SPEEDOMETER DRIVE GEAR 
  1. Install the drive gear to the differential case.
Fig 8: Identifying Speedometer Drive Gear
G05389092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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