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Differential Assembly: Reassembly

NOTE: Coat all sliding and rotating surfaces with ATF prior to reassembly.
  1. Using appropriate race installer and a hammer, install transaxle housing bearing race. Install plate washer of lesser thickness than washer removed during disassembly into transaxle case. Using appropriate race installer and a hammer, install transaxle case bearing race. See Figure.
  2. Coat front differential side gear thrust washer, front differential side gear, front differential pinion shaft holder, 4 front differential pinion thrust washers and 4 front differential pinion gears with ATF, and install components into front differential case. Install 3 pinion shafts into front differential case. See Figure.
  3. Mount front differential case in soft-jawed vise. DO NOT damage surface of front differential case which contacts vise. Using a dial indicator, measure front differential pinion gear backlash while holding front differential side gear toward front differential case. See Fig 1.
  4. Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order from "B" to "G", and are available in thicknesses from .039" (1.00 mm) to .049" (1.25 mm) in increments of .002"(.05 mm).
    Fig 1: Measuring Front Differential Pinion Gear Backlash
    G00011289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Engage side gear to front differential case. Install left side differential case to front differential case. Ensure side gear is centered. Once side gear is centered, remove left side differential case.
  6. Using a straightedge and feeler gauge, measure clearance between front differential case and side gear. See Fig 2. Use the following formula to determine correct thrust washer thickness for specified clearance: thrust washer thickness equals clearance (feeler gauge thickness) minus .006-.011" (.16-.27 mm).
  7. Thrust washers are marked in alphabetical order from "A" to "K" (except "I"), and are available in thicknesses from .037" (.95 mm) to .055" (1.40 mm) in increments of .002" (.05 mm). If clearance is not as specified, ensure components were assembled correctly.
    Fig 2: Measuring Front Differential Case-To-Side Gear Clearance
    G00011290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install spacer to front differential case. Wrap vinyl tape around case prior to snap ring installation to avoid damaging front differential case. Install snap ring on front differential case as shown. See Fig 3. Install spacer to right side differential case. Slide down spacer to install 4 center differential pinion shafts.
  9. Install center differential side gear thrust washer No. 1, conical washer, center differential side gear, pinion shaft holder, differential pinion gears, thrust washers and pinion shafts to right side differential case. Ensure conical washer is installed correctly into right side differential case. See Figure. Mount right side differential case in soft-jawed vise. Using dial indicator, measure center differential pinion gear backlash, while holding center differential side gear toward case. See Fig 4.
  10. Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order from "MA" to "MN" (except "MI"), and are available in thicknesses from .032" (.80 mm) to .055" (1.40 mm) in increments of .002" (.05 mm).
    Fig 3: Installing Snap Ring To Front Differential Case
    G00182315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Measuring Center Differential Pinion Gear Backlash
    G00182316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. NOTE: In the following step, the .039" (1.00 mm) thick center differential side gear thrust washer No. 2 is used for reference when checking backlash.
    Fig 5: Installing Components Into Right Side Differential Case
    G00182317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Temporarily install front differential case, front differential side gear, front differential side gear thrust washer, a .039" (1.00 mm) thick center differential side gear thrust washer No. 2 (temporarily) and center differential side gear thrust washer No. 2 to right side differential case. See Fig 5. Engage front differential side gear and pinion gear of right side differential case.
  12. Clean contact surface of center differential side gear thrust washer No. 2 and left side differential case. Apply Plastigage on center differential side gear thrust washer No. 2 as shown in Fig 6, in 4 positions directly above pinion shafts in right side differential case.
  13. Install left side differential case downward. Align match marks on right side differential case and left side differential case. See Fig 7. Temporarily install right side differential case and 4 service bolts to left side differential case. See Fig 8. Tighten bolts to 24 ft. lbs. (33 N.m). Remove 4 bolts and left side differential case.
  14. Measure Plastigage at its widest point. See Fig 9. Standard clearance should be .006-.010" (.16-.25 mm). If standard clearance is not as specified, select appropriate thrust washer No. 2 to ensure backlash is within specification. Try to select a thrust washer of the same size. Thrust washers are marked in numeric and alphabetic order and are available in thicknesses from 032" (.80 mm), marked with a zero, to .049" (1.25 mm), marked with the number "9", and from .051" (1.30 mm), marked with the letter "A", to .055" (1.40 mm), marked with the letter "C". Thrust washers increase in increments of .002" (.05 mm).
    Fig 6: Installing Plastigage On Center Differential Side Gear Thrust Washer No. 2
    G00182318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Aligning Differential Cases
    G00182319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 8: Installing 4 Service Bolts To Differential Cases
    G00182320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 9: Measuring Plastigage At Its Widest Point
    G00182321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Remove left side differential case, center differential side gear thrust washer No. 2 and temporary .039" (1.00 mm) thick center differential side gear thrust washer No. 2. Install conical washer and center differential side gear thrust washer No. 2 (previously selected) from differential case. Ensure conical washer is installed correctly. See Fig 10.
  16. Install left side differential case onto right side differential case and align match marks. See Fig 7. Temporarily install right side differential case and 4 service bolts to left side differential case. See Fig 8. Tighten service bolts to 24 ft. lbs. (33 N.m).
    Fig 10: Installing Conical Washer
    G00182322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Using appropriate adapter and press, install differential case tapered roller bearings. Remove any material from transaxle housing and transaxle case mating surfaces. DO NOT allow oil to contact surfaces. Install differential assembly into transaxle case. Install transaxle housing onto transaxle case. Install 5 lower bolts inside transaxle housing and tighten to 16 ft. lbs. (22 N.m). Install all other bolts and tighten to 21 ft. lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside transaxle housing. See Figure.
  18. Temporarily install transfer assembly intermediate shaft. See Fig 11. Turn intermediate shaft right and left several times to allow bearings to seat. Remove intermediate shaft. Using appropriate adapter and INCH-lb. torque wrench, measure differential preload. See Fig 12. Preload should be 1.8-6.1 INCH lbs. (.20-.69 N.m) for NEW bearings and .9-3.1 INCH lbs. (.10-.35 N.m) for used bearings.
  19. If preload is not within specification, remove 16 transaxle housing bolts. Using a plastic hammer, remove transaxle housing from transaxle case. Remove differential assembly from transaxle case and replace plate washer behind transaxle case bearing race. See Figure.
  20. Plate washers are marked in numeric and alphabetic order and are available in thicknesses from .079" (2.00 mm), marked with a zero, to .096" (2.45 mm), marked with the number "9", and from .098" (2.50 mm), marked with the letter "A", to .112" (2.85 mm), marked with the letter "H". Washers increase in increments of .002" (.05 mm). Recheck preload after washer replacement.
    Fig 11: Installing Transfer Assembly Intermediate Shaft
    G00182323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 12: Measuring Differential Preload
    G00011293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F (100°C) in water. DO NOT heat ring gear above 230°F (110 °C).
  22. Carefully remove ring gear from water and quickly align match marks made during disassembly. Install ring gear on differential case. Install but DO NOT tighten 8 ring gear bolts, in pairs of 2, in a crisscross pattern. Ensure ring gear is properly seated and aligned. Remove 4 service bolts previously installed. See Fig 8. Install remaining 8 ring gear bolts and tighten all bolts to 70 ft. lbs. (95 N.m). Install NEW oil seal in transaxle case. Coat oil seal lip with lubricant.
  23. For transaxle housing oil seal, wrap vinyl tape around seal installer at a position .236" (6.00 mm) above bottom end of installer, until thickness of tape is about .197" (5.00 mm). Coat NEW oil seal lip with lubricant. Install oil seal until wound vinyl tape contacts transaxle housing. Oil seal installed depth should be .22-.26" (5.5-6.5 mm).
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