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Differential Case: Reassembly

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the sliding and rotating surfaces of the front differential side gear with gear oil.
      2. Fig 1: Identifying Front Differential Side Gear
      G04831939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 No. 1 front differential side gear thrust washers onto the 2 front differential side gears.
    3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential pinion thrust washers onto the front differential case.

      HINT:

      Revolving the front differential side gear, install the 2 front differential pinions and 2 front differential pinion thrust washers.

  2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT 
    1. Coat the No. 1 front differential pinion shaft with MP grease.
    2. Install the No. 1 front differential pinion shaft onto the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
      Fig 2: Identifying No. 1 Front Differential Pinion Shaft And Front Differential Case
      G04831938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

      Standard backlash: 

      0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

      If the backlash is outside the specifications, replace the side gear thrust washer.

      Fig 3: Measuring Front Differential Side Gear Backlash
      G04831935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust washer thickness 

      THICKNESS SPECIFICATIONS

      Parts No. Thickness mm (in.)
      41361 - 22140 0.95 (0.0374 in.)
      41361 - 22020 1.00 (0.0394 in.)
      41361 - 22150 1.05 (0.0413 in.)
      41361 - 22030 1.10 (0.0433 in.)
      41361 - 22160 1.15 (0.0452 in.)
      41361 - 22040 1.20 (0.0472 in.)

      HINT:

      • Because the thrust washer does not have any marks for distinction, measure the thickness with a micrometer to select a proper thrust washer.
      • Select washers of the same thickness for both the right and left.
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch (ø3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.
      Fig 4: Identifying Front Differential Pinion Shaft Straight Pin
      G04831945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the front differential case hole.
      Fig 5: Identifying Front Differential Case Hole
      G04831946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Clean the contact surfaces of the front differential case and ring gear.
    2. Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
      3. Fig 6: Heating Front Differential Ring Gear
      G04831947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.
    4. Aligning the 2 matchmarks, quickly install the front differential ring gear onto the front differential case.
      5. Fig 7: Identifying Matchmarks On Front Differential Ring Gear And Front Differential Case
      G04831933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 8 bolts.

      Torque: 77 N*m (789 kgf*cm, 57 ft.*lbf) 

  6. INSTALL SPEEDOMETER DRIVE GEAR 
    1. Install the speedometer drive gear onto the front differential case.
      Fig 8: Identifying Speedometer Drive Gear And Front Differential Case
      G04831932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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