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Differential Case: Reassembly

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Apply ATF to the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers and install them to the differential case.
      Fig 1: Installing Front Differential Side Gear
      G04377951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1 
    1. Coat the front differential pinion shaft No.1 with ATF, and install it to the differential case.
  3. INSPECT BACKLASH 

    HINT:

    (See INSPECTION )

    Fig 2: Identifying Front Differential Pinion Shaft No. 1
    G04496940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch and a hammer, install the pinion shaft straight pin.
      Fig 3: Installing Pinion Shaft Straight Pin
      G04377953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the differential case.
      NOTE: Stake the differential case after adjusting the backlash.
      Fig 4: Staking Differential Case
      G04377954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing to the differential case.

      SST 09316-12010, 09550-60010 (09951-00490), 09950-70010 (09951-07100) 

      NOTE: Do not damage the bearing cage when installing the bearing inner race.
      Fig 5: Installing Front Differential Case Front Tapered Roller Bearing
      G04377955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing.

      SST 09550-60010 (09951-00490), 09950-60020 (09951-00910) 

      Fig 6: Installing Front Differential Case Tapered Roller Bearing Front Outer Race To Transaxle Housing
      G04377956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing to the differential case.

      SST 09316-12010, 09550-60010 (09951-00490), 09950-70010 (09951-07100, 09951-07150) 

      NOTE: Do not damage the bearing cage when installing the bearing inner race.
      Fig 7: Installing Front Differential Case Rear Tapered Roller Bearing
      G04377957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front differential case tapered roller bearing rear outer race to the transaxle housing.

      SST 09950-70010 (09951-07100, 09951-07150), 09950-60020 (09951-00890) 

      NOTE: No clearance is allowed between the bearing and transaxle housing.
      Fig 8: Installing Front Differential Case Tapered Roller Bearing Rear Outer Race
      G04377958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Install the differential assembly to the transaxle case.
      Fig 9: Identifying Differential Gear Assembly
      G04377959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the mating surfaces of the transaxle case and transaxle housing.
    3. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.
      Fig 10: Installing 16 Bolts
      G04377960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A 

      25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Bolt B 

      33 N*m (337 kgf*cm, 24 ft.*lbf) 

      Bolt C 

      29 N*m (295 kgf*cm, 21 ft.*lbf) 

      Bolt D 

      22 N*m (226 kgf*cm, 16.0 ft.*lbf) 

      HINT:

      Apply seal packing or equivalent to bolts A and D.

      Seal packing: 

      THREE BOND 2403 or equivalent 

      Bolt length: 

      Bolt A: 

      50 mm (1.969 in.) 

      Bolt B: 

      50 mm (1.969 in.) 

      Bolt C: 

      42 mm (1.654 in.) 

      Bolt D: 

      72 mm (2.835 in.) 

      HINT:

      Usually, bolt A is non-reusable. In this case, however, the bolt can be used after cleaning it.

    4. Using SST, turn the differential assembly to the right and left 2 or 3 times to settle the bearing.
      Fig 11: Measuring Turning Torque Of Differential
      G04377961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09564-32011 

    5. Using SST and a torque wrench, measure the turning torque of the differential.

      SST 09564-32011 

      Turning torque at 60 rpm: 

      New bearing: 

      0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf) 

      Used bearing: 

      0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) 

      HINT:

      If the turning torque is not as specified, refer to FLANGE THICKNESS  to select a thrust washer so that the specified value is achieved.

      Flange thickness: mm (in.) 

      FLANGE THICKNESS SPECIFICATIONS

      Mark Thickness
      0 2.00 (0.0787)
      1 2.05 (0.0807)
      2 2.10 (0.0827)
      3 2.15 (0.0846)
      4 2.20 (0.0866)
      5 2.25 (0.0886)
      6 2.30 (0.0906)
      7 2.35 (0.0925)
      8 2.40 (0.0945)
      9 2.45 (0.0965)
      A 2.50 (0.0984)
      B 2.55 (0.1004)
      C 2.60 (0.1024)
      D 2.65 (0.1043)
      E 2.70 (0.1063)
      F 2.75 (0.1083)
      G 2.80 (0.1102)
      H 2.85 (0.1122)
    6. Remove the 16 bolts and the transaxle housing.
      Fig 12: Removing 16 Bolts From Transaxle Housing
      G04377962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential assembly.
      Fig 13: View Of Differential Gear Assembly
      G04377619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Using ATF and heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
      NOTE: Do not heat the ring gear to more than 110°C (230.0°F).
    2. Clean the contact surface of the front differential case.
      Fig 14: Heating Front Differential Ring Gear
      G04377964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks, and install the front differential ring gear case quickly.
      NOTE: Do not install the bolts while the ring gear is hot.
      Fig 15: Aligning Matchmarks
      G04377965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 14 bolts.

      Torque: 95.0 N*m (970 kgf*cm, 70 ft.*lbf) 

      NOTE: Tighten the bolts a little at a time in a diagonal pattern.
      Fig 16: Identifying Differential 14 Bolts
      G04377966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.
      Fig 17: Installing Transaxle Housing Oil Seal
      G04377967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09223-15020, 09950-70010 (09951-07150) 

    2. Coat the lip of oil seal with a little MP grease.

      Oil seal installation depth: 

      0 +- 0.5 mm (0 +- 0.0197 in.) 

  10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.

      SST 09710-30050, 09950-70010 (09951-07150) 

    2. Coat the lip of the oil seal with a little MP grease.

      Oil seal installation depth: 

      0 +- 0.5 mm (0 +- 0.0197 in.) 

      Fig 18: Installing Differential Side Bearing Retainer Oil Seal
      G04377968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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