Differential Case: Reassembly

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. After applying ATF to the 2 front differential side gears, 2 front differential side gear thrust washers No. 1, 2 front differential pinion gears and 2 front differential pinion thrust washers, install them to the front differential case.
  HINT:
  
  At the time of installation, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes will be aligned with the holes in the differential case.
  
  Fig 1: Installing Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1
1. Install the front differential pinion shaft No. 1 so as to align the lock pin holes on the front differential pinion shaft No. 1 and differential case.
INSPECT BACKLASH (See INSPECTION )

Fig 2: Aligning Lock Pin Holes On Front Differential Pinion Shaft No. 1 And Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and a hammer, install the front differential pinion shaft straight pin.
  
  Fig 3: Installing Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the differential case.
  
  Fig 4: Staking Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using a ATF and heater, heat the front differential ring gear to 90 to 110°C (194 to 230.0°F)
2. Clean the contact surface of the front differential case.
  
  Fig 5: Heating Front Differential Ring Gear Using ATF And Heater
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 front differential ring gear set bolt lock plates and 8 bolts.
  Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf)
  
  Fig 6: Installing Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a hammer, stake the front differential ring gear set bolt lock plate.
  SST 09930-00010
INSTALL SPEEDOMETER DRIVE (ATM) GEAR

Fig 7: Staking Front Differential Ring Gear Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR 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 09316-60011 (09316-00011)
  
  Fig 8: Installing Front Differential Case Front Tapered Roller Bearing To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the front differential case front tapered roller bearing to the transaxle housing.
  SST 09950-60020 (09951-00750), 09950-70010 (09951-07150)
  
  Fig 9: Installing Front Differential Case Front Tapered Roller Bearing To Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case tapered roller bearing to the differential case.
  SST 09726-40010, 09950-60020 (09951-00790)
  
  Fig 10: Installing Front Differential Case Tapered Roller Bearing To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the shim and front differential case tapered roller bearing race to the transaxle case.
  SST 09950-60010 (09951-00650), 09950-60020 (09951-00720), 09950-70010 (09951- 07100, 09951-07200)
  
  Fig 11: Installing Shim And Front Differential Case Tapered Roller Bearing Race To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE OIL SEAL
1. Using SST a hammer, install a new oil seal to the front differential case.
  SST 09950-60010 (09951-00390), 09950-70010 (09951-07200)
  
  Oil seal in depth: 0 +- 0.5 mm (0 +- 0.020 in.)
INSPECT TAPERED ROLLER BEARING PRELOAD (See INSPECTION )

Fig 12: Installing Oil Seal To Front Differential Case Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002