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Differential Case: Reassembly

  1. INSTALL DIFFERENTIAL CASE SUB-ASSEMBLY NO.2 
    1. Coat the front differential side gear thrust washer No.1, front differential planetary ring gear, front differential pinion No.2, front differential pinion thrust washer No.2, front differential pinion shaft holder, front differential pinion shaft and 2 differential pinion shafts with ATF, install them to the differential case No.2.
      Fig 1: Identifying Front Differential Side Gear Thrust Washer And Front Differential Pinion
      G05246464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and a hammer, install 3 straight pins.
      Fig 2: Installing Straight Pins
      G05246465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install the pinion shaft spacer snap ring.
      Fig 3: Installing Pinion Shaft Spacer Snap Ring
      G05246466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT FRONT DIFFERENTIAL 

    HINT:

    (See INSPECTION )

  3. INSTALL CTR DIFFERENTIAL PLANETARY GEAR ASSEMBLY 
    1. Install the center differential side gear, conical spring washer and center differential side gear thrust washer No.2 RH from the differential case RH.

      HINT:

      Ensure that the conical washers is installed correctly.

      Fig 4: Identifying Center Differential Side Gear And Differential Case RH
      G05137565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the differential case RH by vice. Install the center differential pinion and pinion thrust washer to the differential spider and install them to the differential case RH.
      NOTE: When holding the differential case RH by vise, be sure to place an aluminum sheet between them and use a minimum force
      Fig 5: Holding Differential Case RH By Vice
      G05246468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pressing and holding the differential spider toward the differential case RH, measure the pinion's backlash with a dial indicator as illustrated.

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

      If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value.

      Thrust washer thickness: mm (in.) 

      THRUST WASHER THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
      Fig 6: Measuring Pinion Backlash
      G05246452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the differential side gear thrust washer No.2 LH, center differential side gear conical spring washer and differential case No.2 to the differential case LH.

      HINT:

      Ensure that the conical washers is installed correctly.

      Fig 7: Identifying Differential Side Gear Thrust Washer And Differential Case LH
      G05246453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the differential intermediate case to the above and fix them with 4 bolts.
      Fig 8: Identifying Differential Intermediate Case
      G05246454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. remove the differential spider, 5 center differential pinions and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and fix the case.
      Fig 9: Identifying Differential Spider And Center Differential Pinions
      G05246455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Pressing and holding the differential spider toward the differential intermediate case, measure the pinion's backlash with a dial indicator.

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

      If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value.

      Thrust washer thickness: mm (in.) 

      THRUST WASHER THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
      Fig 10: Measuring Pinion Backlash
      G05246456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case.
      Fig 11: Identifying Differential Case LH And Differential Intermediate Case
      G05246457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the differential case No.2 from the differential case LH.
      Fig 12: Removing Differential Case No. 2 From Differential Case LH
      G05137556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the selected differential side gear thrust washer No.2 LH and center differential planetary gear to the differential case LH.
      Fig 13: Identifying Differential Side Gear Thrust Washer And Center Differential Planetary Gear
      G05137574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Install the differential case No.2 to the differential case LH again.
      Fig 14: Installing Differential Case No. 2 To Differential Case LH
      G05137575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. install the adjusted differential case RH to the intermediate case and tighten the 15 bolts using a Torx socket wrench (T50).

      Torque: 63 N*m (642 kgf*cm, 46 ft.*lbf) 

      NOTE: Align the matchmarks.
      Fig 15: Identifying Differential Case RH Bolts
      G05246478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case tapered roller bearing FR to the differential case.

      SST 09950-70010 (09951-07100), 09649-17010 

      NOTE: Do not make a damage on the bearing cage during the bearing inner race installation.
      Fig 16: Installing Front Differential Case Tapered Roller Bearing FR To Differential Case
      G05246479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the outer race of the tapered roller bearing FR.

      SST 09527-17011, 09950-60020 (09951-01030) 

      NOTE: Clearance is not allowed between the plate washer and transaxle housing.
      Fig 17: Installing Outer Race Of Tapered Roller Bearing FR
      G05137578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Using SST and a press, install the front differential case tapered roller bearing RR to the differential case.

      SST 09316-20011, 09214-76011 

      NOTE: Do not make a damage on the bearing cage during the bearing inner race installation.
    2. Install the front differential case shim RR to the transaxle case.
      Fig 18: Installing Front Differential Case Tapered Roller Bearing RR To Differential Case
      G05246481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the bearing is new, check to select a front differential case shim RR of proper thickness starting from the thinner ones. If the bearing is reused, check to select a front differential case shim RR starting from the same thickness as one installed before disassembly.

    3. Using SST, install the outer race of the front differential case tapered roller bearing RR.

      SST 09950-60020 (09951 -00890), 09950-70010 (09951-07100) 

      NOTE: Clearance is not allowed between the differential case shim and transaxle case.
  6. ADJUST TAPERED ROLLER BEARING PRELOAD 

    HINT:

    (See INSPECTION )

    Fig 19: Installing Outer Race Of Front Differential Case Tapered Roller Bearing RR
    G05137580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DIFFERENTIAL RING GEAR 
    1. Using ATF and heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
      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.
      Fig 20: Heating Front Differential Ring Gear
      G05001109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the match-marks, install the front differential ring gear case quickly.
      NOTE: Do not install the bolts while the ring gear is hot.
      Fig 21: Identifying Matching Marks On Front Differential Ring Gear
      G05246484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the 8 bolts as shown in the illustration.
      Fig 22: Installing Front Differential Ring Gear Bolts
      G05246485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts shown in the illustration.
    6. Temporarily install the remaining 8 set bolts.
    7. Fully tighten the set bolts.

      Torque: 95.1 N*m (970 kgf*cm, 70 ft.*lbf) 

      NOTE: Tighten the bolts a little at a time in diagonal order.
      Fig 23: Identifying Front Differential Ring Gear
      G05246486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.

      SST 09223-15020, 09950-70010 (09951 -07100) 

    2. Coat the rip of oil seal with a little MP grease.
      Fig 24: Installing Differential Side Bearing Retainer Oil Seal
      G05246487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Wind a vinyl tape around SST at the place 6.0 mm (0.236 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).

      SST 09950-60020 (09951-00730) 

      NOTE: Remove foreign matter such as grease on the SST before winding the tape.
    2. Coat the rip of oil seal with a little MP grease.
      Fig 25: Winding Vinyl Tape Around SST
      G05246488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install a new oil seal.

      SST 09950-60020 (09951 -00730), 09950-70010 (09951-07150) 

      Standard press in depth: 5.5 - 6.5 mm (0.217 - 0.256 in.) 

      NOTE: Stop pressing when the would vinyl tape is contact with the transaxle housing.
      Fig 26: Installing Transaxle Housing Oil Seal
      G05246489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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