Differential Case: Reassembly

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Install the 2 thrust washers to the front differential side gears 2 each.
  
  Fig 1: Installing Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 front differential side gears with the 2 thrush washers, 2 front differential pinions, 2 pinion thrust washers in to the front differential case.
  
  Fig 2: Installing Front Differential Side Gears With Thrush Washers
  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 in both the pinion shaft and front differential case.
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (See INSPECTION )

Fig 3: Inspecting Differential Side Gear Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and hammer, drive the front differential pinion shaft straight pin into the hole in the front differential pinion shaft through the front differential case.
  
  Fig 4: Installing Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Stake the front differential case.
  
  Fig 5: Staking Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Clean the contact surface of the front differential case.
2. Heat the front differential ring gear in water and boil for 10 minutes.
3. Carefully remove the front differential ring gear from the water.
4. After the moisture on the front differential ring gear has completely evaporated, quickly install the front differential ring gear to the front differential case.
  
  Fig 6: Installing Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install 4 new front differential ring gear set bolt lock plates and 8 bolts, tightening them temporarily and evenly. When the front differential ring gear has cooled sufficiently, fully tighten the 8 bolts.
  Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf)
  
  Fig 7: Installing Front Differential Ring Gear Set Bolt Lock Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a drift punch and hammer, stake the front differential ring gear set bolt lock plate.
  HINT:
  
  Stake a claw for the flat side of the nut. For the claw contacting a corner of the nut, stake only the half on the tightened side.
  
  Fig 8: Staking Front Differential Ring Gear Set Bolt Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002