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Differential Case: Reassembly: Reassembly

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  1. INSTALL DIFFERENTIAL SIDE GEAR 
    1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
      Fig 1: Identifying Differential Side Gear
      GTY111950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.
      Fig 2: Locating Front No. 1 Differential Pinion Shaft
      GTY111842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH  See step  1
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch (3 mm) and hammer, install the pinion shaft straight pin.
      Fig 3: Installing Pinion Shaft Straight Pin
      GTY128980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Align the holes, and install the pinion shaft straight pin.

    2. Using a chisel and hammer, stake the differential case.
      Fig 4: Staking Differential Case
      GTY128998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.
      Fig 5: Installing Front Differential Case Rear Tapered Roller Bearing Using SST
      GTY111845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-30012 
        1. 09710-04081
      • SST: 09950-60010 
        1. 09951-00480
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Do not damage the bearing cage during bearing inner race installation.

    2. Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle case.
      Fig 6: Installing Front Differential Case Rear Tapered Roller Bearing Outer Race Using SST
      GTY142248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        1. 09951-07150
      • SST: 09950-60020 
        1. 09951-00790
      NOTE:

      Ensure that there is no clearance between the bearing and transaxle case.

  6. 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.
      Fig 7: Identifying Certification ECU E58 Connector Using SST
      GTY111846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-30012 
        1. 09710-04081
      • SST: 09950-60010 
        1. 09951-00480
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Do not damage the bearing cage during bearing inner race installation.

    2. Install the shim to the transaxle housing.
    3. Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.
      Fig 8: Installing Front Differential Case Front Tapered Roller Bearing Outer Race Using SST
      GTY123034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Ensure that there is no clearance between the bearing and transaxle housing.

  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Install the differential assembly to the transaxle case.
      Fig 9: Identifying Differential Assembly To Transaxle Case
      GTY182430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the contact surfaces of the transaxle case and transaxle housing.
    3. Install the transaxle housing to the transaxle case with the 20 bolts.
      Fig 10: Identifying Transaxle Case Bolts
      GTY169208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 

      Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 

      Bolt B 

      Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) 

    4. Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.
      Fig 11: Measuring Turning Torque Of Counter Driven Gear
      GTY111921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 
    5. Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.
      • SST: 09564-33010 

      Turning torque

      1.05 to 1.93 N*m (10.70 to 19.67 kgf*cm, 9.29 to 17.08 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      SHIM THICKNESS: MM (IN.)

      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.225 (0.0876) 2.450 (0.0965) 2.675 (0.1054)
      2.025 (0.0797) 2.250 (0.0886) 2.475 (0.0974) 2.700 (0.1063)
      2.050 (0.0807) 2.275 (0.0896) 2.500 (0.0984) 2.725 (0.1073)
      2.075 (0.0817) 2.300 (0.0906) 2.525 (0.0994) 2.750 (0.1083)
      2.100 (0.0827) 2.325 (0.0915) 2.550 (0.1004) 2.775 (0.1093)
      2.125 (0.0837) 2.350 (0.0925) 2.575 (0.1014) 2.800 (0.1102)
      2.150 (0.0847) 2.375 (0.0935) 2.600 (0.1024) 2.825 (0.1112)
      2.175 (0.0856) 2.400 (0.0945) 2.625 (0.1034) 2.850 (0.1122)
      2.200 (0.0866) 2.425 (0.0955) 2.650 (0.1043) 2.875 (0.1132)
    6. Remove the 20 bolts and the transaxle housing from the transaxle case.
      Fig 12: Identifying Transaxle Housing Bolts
      GTY141583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential assembly from the transaxle case.
      Fig 13: Identifying Differential Assembly To Transaxle Case
      GTY182430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
      Fig 14: Applying Heat To Front Differential Ring Gear
      GTY149390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    3. Align the matchmarks, and install the front differential ring gear case quickly.
      Fig 15: Identifying Matchmarks On Front Differential Ring Gear And Differential Case
      GTY111951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not install the bolts while the ring gear is hot.

    4. Install and tighten the 12 bolts.
      Fig 16: Locating Bolts
      GTY111952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 120 N*m (1223 kgf*cm, 88 ft.*lbf) 

      NOTE:

      Tighten the bolts a little at a time in diagonal order.

  9. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new transaxle case oil seal with MP grease.
    2. Using SST and a hammer, install the transaxle case oil seal.
      Fig 17: Installing Front Transaxle Case Oil Seal Using SST
      GTY137598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-10010 
      • SST: 09950-70010 
        1. 09951-07100

      Oil seal drive in depth

      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new front transaxle case oil seal with MP grease.
    2. Using SST and a hammer, install the front transaxle case oil seal.
      Fig 18: Installing Front Transaxle Case Oil Seal Using SST
      GTY111847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-14010 

      Oil seal drive in depth

      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

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