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Differential Case: Reassembly

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the sliding and rotating surfaces of the front differential side gears with gear oil.
    2. Install the 2 front No. 1 differential side gear thrust washers onto the 2 front differential side gears.
    3. Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential pinion thrust washers onto the front differential case.
      Fig 1: Identifying Front Differential Side Gear
      G04831939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      While rotating the front differential side gears, install the 2 front differential pinions and 2 front differential pinion thrust washers.

  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Coat the front No. 1 differential pinion shaft with MP grease.
    2. Install the front No. 1 differential pinion shaft onto 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: Identifying Front No. 1 Differential Pinion Shaft
      G04831938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH 
    1. Install 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 (0.00197 to 0.00787 in.) 

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

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

      Thrust Washer Thickness 

      THRUST WASHER THICKNESS REFERENCE CHART

      Parts 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 (0.0452)
      41361-22040 1.20 (0.0472)

      HINT:

      • Measure the thickness with a micrometer to select a proper thrust washer because the thrust washers do not have any distinguishing marks.
      • Select washers of the same thickness for both the right and left sides.
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch (ø3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.
      Fig 4: Installing Front Differential Pinion Shaft Straight Pin Onto Front Differential Case
      G04831945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the front differential case hole.
      Fig 5: Staking Front Differential Case Hole
      G04831946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Clean the contact surfaces of the front differential case and ring gear.
    2. Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
      Fig 6: Heating Front Differential Ring Gear To 90 To 110°C (194 To 230°F)
      G06013024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After moisture on the ring gear has completely evaporated, align the matchmarks and quickly install the front differential ring gear onto the front differential case.
    4. Install the 8 bolts.

      Torque: 77 N*m (790 kgf*cm, 57 ft.*lbf) 

      Fig 7: Identifying Matchmarks On Front Differential Ring Gear And Front Differential Case
      G06045393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SPEEDOMETER DRIVE GEAR 
    1. Install the speedometer drive gear onto the front differential case.
      Fig 8: Identifying Speedometer Drive Gear
      G04831932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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