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Differential Case: Reassembly

  1. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER (See  INSPECTION   ) 
  2. INSPECT FRONT DIFFERENTIAL PINION SHAFT NO. 1 (See  INSPECTION   ) 
  3. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the sliding and rotating surface of the 2 front differential side gears with gear oil.
    2. Install the 2 front differential side gear thrust washers to the 2 front differential side gears.

      HINT:

      Install the front differential side gear thrust washer that has the same thickness as the removed one.

    3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side pinion thrust washers to the front differential case.

      HINT:

      Turning the front differential side gear, align the 2 front differential pinions with the hole of the front differential case.

      Fig 1: Identifying Front Differential Side Gear
      G04977504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1 
    1. Coat the rotating surface of the front differential pinion shaft No. 1 with gear oil.
    2. Install the front differential pinion shaft No. 1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
      Fig 2: Installing No. 1 Front Differential Pinion Shaft
      G04977503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Fixing the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

      Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 

      If the backlash is out of specification, replace the side gear thrust washer.

      Fig 3: Adjusting Front Differential Side Gear Backlash
      G04831935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust washer thickness: 

      THICKNESS REFERENCE

      Part No. Thickness: mm (In.)
      41361-22140 0.95 (0.0374)
      41361-22020 1.00(0.0394)
      41361-22150 1.05(0.0413)
      41361-22030 1.10(0.0433)
      41361-22160 1.15(0.0453)
      41361-22040 1.20 (0.0472)

      HINT:

      • Because the washer does not have any identification mark, measure the front thickness with a micrometer to select a proper thrust washer.
      • Select washers that has the same thickness as both the right and left.
  6. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch (ø 3 mm) and a hammer, install the front differential pinion shaft straight pin to the front differential case.
      Fig 4: Identifying Front Differential Pinion Shaft Straight Pin
      G05234888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the front case hole.
      Fig 5: Identifying Front Case Hole
      G05234889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Clean the contact surface of the front differential case and front differential ring gear.
    2. Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F)
    3. After the moisture on the ring gear has completely evaporated, quickly install the front differential ring gear to the front differential case.
      Fig 6: Cleaning Front Differential Case And Front Differential Ring Gear
      G05194547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the both matchmarks, quickly install the 8 bolts with the front differential ring gear to the front differential case.

      Torque: 77 N*m (789 kgf*cm, 57 ft.*lbf) 

      Fig 7: Identifying Matchmarks On Front Differential Ring Gear To Front Differential Case
      G05234891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL SPEEDOMETER DRIVE (MTM) GEAR 
    1. Install the speedometer drive (MTM) gear to the front differential case.
      Fig 8: Identifying Speedometer Drive (MTM) Gear
      G04831932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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