Differential Case: Reassembly

1. Install the correct thrust washers and side gears. Refer to the Fig 1 below, select thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides.
   1. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 
   Fig 1: Thickness Specification Chart

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the thrust washers and side gears in the differential case.
3. Install the pinion shaft.
   Fig 2: Installing Correct Thrust Washers And Side Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a dial indicator, check the side gear backlash. Measure the side gear backlash while holding one pinion toward the differential case.
   1. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

   If the backlash is not within the specification, install a thrust washer of different thickness.

5. Using a pin punch and a hammer, tap in the straight pin through the differential case and hole in the pinion shaft.
6. Using a chisel and a hammer, caulk the pin holes around the circumference of the differential case.

Fig 3: Checking Side Gear Backlash Using Dial Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a press, press in a new tapered roller bearing.

SST 09350-32014 (09351-32120, 09351-32140)

HINT:

Set SST to the bearing inner race securely.

Fig 4: Pressing New Tapered Roller Bearing Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place the vehicle speed sensor drive gear in position to stop turning, and install the vehicle speed sensor drive gear.
   NOTE: Be sure to install the vehicle speed sensor drive gear in the correct direction, as shown in the illustration.
   Fig 5: Installing Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in a new side bearing.

   SST 09316-60011 (09316-00011), 09350-32014 (09351-32120)

HINT:

Set SST to the bearing inner race securely.

Fig 6: Pressing New Side Bearing Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the contact surface of the differential case.
2. Heat the ring gear in boiling water.
3. Carefully take the ring gear out of the water.
4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

   HINT:

   Align the matchmarks on the differential case and contact the ring gear.

   Fig 7: Installing Ring Gear To Differential Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Temporarily install the 8 set bolts.
   CAUTION: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.
6. After the ring gear has cooled sufficiently, torque the ring gear set bolts uniformly at a time.

   Torque: 

1. Install the differential case assembly to the transaxle case.
   NOTE: Place it gently to protect the diff side bearing from being damaged.
2. Install the transmission case to the transaxle case with the 16 bolts.
   1. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
   Fig 8: Installing Differential Case Assembly To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a torque wrench, turn the differential case assembly right and left 2 or 3 times to allow the bearings to settle.

   SST 09564-32011

4. Using SST and a torque wrench, measure the preload.

   SST 09564-32011

   Preload (at starting): 

Fig 9: Measuring Preload Using SST And Torque Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 10: Preload Specification Chart

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the preload is not within the specification and when there is a clearance, remove the transmission case side outer race of the tapered roller bearing with SST (See DISASSEMBLY ), and select the thick shim. Then, exchange the shim and measure the preload again.

HINT:

The preload will change by about 0.3 to 0.4 N.m (3 to 4 kgf.cm, 2.6 to 3.5 in. .lbf) corresponding to a change of 0.05 mm (0.0020 in.) in shim thickness.

Fig 11: Thickness Specification Chart

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Assemble the differential case assembly and output shaft assembly on the transaxle case, then on top of that, assemble the transmission case with the 16 bolts.
   1. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
2. Install the snap ring in the outer groove of the output shaft center bearing.
   Fig 12: Turning Output Shaft Using Socket Wrench And Torque Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a socket wrench (27 mm) and a torque wrench, turn the output shaft right and left 2 or 3 times to allow the bearings to settle.
4. Using a socket wrench (27 mm) and a torque wrench, measure the preload.

   Preload (at starting): 

Fig 13: Preload Specification Chart

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the preload is not within the specification and when there is a clearance, remove the transmission case side outer race of the tapered roller bearing with SST (See DISASSEMBLY ), and select the thick shim. Then, exchange the shim and measure the preload again.

HINT:

The preload will change by about 0.3 to 0.4 N.m (3 to 4 kgf.cm, 2.6 to 3.5 in..lbf) corresponding to a change of 0.05 mm (0.0020 in.) in shim thickness.

Fig 14: Thickness Specification Chart

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002