Center Differential: Reassembly

WARNING: This page is about a different car, the 2002 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Install low gear .
1. Clean the contact surface of the differential case.
2. Heat the low gear in boiling water.
  
  Fig 1: Heating Low Gear In Boiling Water
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Carefully remove the low gear from the water.
4. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.
Install thrust washer and front side gear .

Fig 2: Installing Thrust Washer & Front Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install pinion shaft, 2 pinion gears and 2 thrust washers .
1. Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case.
  
  Fig 3: Installing Pinion Gears To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the front case backlash.
  
  Fig 4: Measuring Front Case Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Push the pinion shaft.
  
  Maximum backlash: 0.05 mm (0.0020 in.)
  
  If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.
  
  Fig 5: Identifying Thrust Washer Thickness Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. In the same way, measure the rear case backlash.
Install straight pin to pinion shaft .
Install rear side gear and thrust washer .
Install differential rear case .
1. Install the differential rear case and 12 set bolts.
  
  Fig 6: Torquing Differential Rear Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 88 N.m (900 kgf.cm, 65 ft.lbf)
2. Turn the pinion gear.
3. Loosen the 12 rear case set bolts.
4. Torque the 12 rear case set bolts.
  Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf)
Install rear taper roller bearing .
1. Using SST and a press, install the rear taper roller bearing.
  
  Fig 7: Installing Rear Taper Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-12010
Install clutch hub .
1. Using SST and a press, install the clutch hub.
  
  Fig 8: Installing Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-12010, 09316-60011 (09316-00011)
Install high speed output gear bushing .
1. Apply MP grease to the straight pin.
2. Install the straight pin, as shown in Fig 9.
  
  Fig 9: Installing Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the high speed output gear bushing.
  
  Fig 10: Installing High Speed Output Gear Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-12010, 09316-60011 (09316-00011)
  
  NOTE: Before pressing on the differential front case, align the groove on the bushing with the pin on the shaft.
Install high and low clutch sleeve .

Fig 11: Installing High & Low Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Make sure to install the high and low clutch sleeve in the correct direction.
Install needle roller bearing and high speed output gear .
1. Apply gear oil to the needle roller bearing.
2. Install the needle roller bearing and high speed output gear.
Install front taper roller bearing .
1. Using SST and a press, install the front taper roller bearing.
  
  Fig 12: Install Front Taper Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-12010, 09316-60011 (09316-00011)
Install front drive gear piece .
1. Using SST and a press, install the front drive gear piece.
  
  Fig 13: Installing Front Drive Gear Piece
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-12010, 09316-60011 (09316-00011)
Install snap ring .
1. Select a snap ring that will allow the minimum axial play.
  
  Fig 15: Displaying Various Snap Ring Dimensions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install a new snap ring.
Inspect high speed output gear radial and thrust clearance. See step 1 under DISASSEMBLY .