Reassembly [10/2014 - ]: Procedure

1. Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical spring washers with ATF.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Front Differential Side Gear
   *2	Conical Spring Washer
   *3	Front No. 1 Differential Side Gear Thrust Washer
   	Toyota Genuine ATF WS

2. Install the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical spring washers to the front differential case.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Front Differential Side Gear
   *2	Conical Spring Washer
   *3	Front No. 1 Differential Side Gear Thrust Washer

   NOTE:

   • Do not drop the front differential side gear, front No. 1 differential side gear thrust washer or conical spring washer.
   • Make sure that the conical spring washer is installed with the correct orientation.
3. Install SST as shown in the illustration and tighten it.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Turn

   *b

   Hold

   • SST: 09528-52010 
     1. 09528-05010
     2. 09953-05010
   NOTE:

   Do not overtighten SST as doing so will damage the front differential side gears, conical spring washers, front No. 1 differential side gear thrust washers and front differential case.

   HINT: 

   • Tighten SST to create the necessary clearance to install the front differential pinions.
   • When installing the 2 front differential pinions, do not overtighten SST, as it is necessary to rotate the 2 front differential side gears.
4. Coat the 2 front differential pinions and 2 front differential pinion thrust washers with ATF.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Toyota Genuine ATF WS

5. Using SST as shown in the illustration, rotate the front differential side gear and install the 2 front differential pinions to 2 front differential pinion thrust washers.
   • SST: 09528-52010 
     1. 09528-05030
   WARNING:

   Be careful not to catch your fingers between the front differential pinion and front differential case.

   NOTE:

   Do not drop the front differential pinion or front differential pinion thrust washer.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Turn

See step  3

1. Coat the front No. 1 differential pinion shaft with ATF.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Toyota Genuine ATF WS

2. Install the front No. 1 differential pinion shaft 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.

See step  1

1. Using a 5 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Using a chisel and a hammer, stake the front differential case.

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1. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Do not heat the front differential ring gear to more than 110°C (230°F).

2. Clean the contact surface of the front differential case.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Matchmark

3. Align the matchmarks, and install the front differential ring gear to the front differential case quickly.
4. Install the 12 bolts.
   Fig 1: Front Differential Ring Gear Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 120 N.m (1224 kgf/cm, 89 ft.lbf) 

   NOTE:

   • Tighten the bolts after the front differential ring gear has cooled down sufficiently.
   • Tighten the bolts evenly in a diagonal pattern using several steps.