Differential Case: Reassembly

1. Install the correct thrust washers and side gears. Refer to the table 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.

   Standard backlash: 

   0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

   THRUST WASHERS - STANDARD BACKLASH TABLE
   
   

   Thickness mm (in.)	Thickness mm (in.)
   0.95(0.0374)	1.10(0.0433)
   1.00(0.0394)	1.15(0.0453)
   1.05(0.0413)	1.20(0.0472)

2. Install the thrust washers and side gears in the differential case.
3. Install the pinion shaft.
   Fig 1: Installing 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.

   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 2: Measuring Side Gear Backlash Using A Dial Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TAPERED ROLLER BEARING 

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

SST 09350-32014 (09351to32120, 09351to32140)

HINT:

Set SST to the bearing inner race securely.

Fig 3: Installing Tapered Roller Bearing Using SST And A Press

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TAPERED ROLLER BEARING 

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 4: Installing Vehicle Speed Sensor Drive Gear

   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 5: Installing Side Bearing Using SST And A Press

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.
   Fig 6: Installing Ring Gear On Differential Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

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

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: 

   TORQUE SPECIFICATION TABLE
   
   

   w/o LSD	77 N.m (790 kgf.cm, 57 ft.lbf)
   w/ LSD	101 N.m (1,030 kgf.cm, 74 ft.lbf)

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.

   Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

   Fig 7: Installing Transmission Case To Transaxle Case With 16 Bolts

   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): 

   PRELOAD (AT STARTING) SPECIFICATION TABLE
   
   

   New bearing	0.78 to 1.57 N.m (7.96 to 16.0 kgf.cm, 0.58 to 1.16 in.lbf)
   Reused bearing	0.49 to 0.98 N.m (5.0 to 10.0 kgf.cm, 0.36 to 1.72 in.lbf)

   Fig 8: Measuring Preload Using SST And A Torque Wrench

   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.

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.

   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 9: Assembling Differential Case Assembly And Output Shaft Assembly On Transaxle Case

   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): 

If the preload is not within the specification 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.