Differential Assembly (A-241/243 Series): Reassembly
WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 1994 Toyota MR2, 1993 Toyota MR2, 1993 Toyota Celica, 1992 Toyota MR2, and 1992 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
- Coat 4 "O" rings with ATF. Install "O" rings on reaction sleeve and pistons. Install No. 1 piston, No. 2 piston and reaction sleeve to ring gear mounting right case.
- Place return spring on piston. Install A/T Tool Set (09350-32014) on piston return spring retainer, compress spring with arbor press. Install snap ring.
- On A-241H, install in order: plate, disc, plate, disc, plate, disc, plate, disc, plate, disc, plate, disc, plate, disc, and flange. Install flange with flat end facing downward. Install snap ring. Check operation of clutch pistons. Plug one hole with your hand. Apply compressed air into other hole. Ensure pistons move. Install No. 1 thrust washer.
- On A-241H, install following parts in front differential left case: side gear thrust washer, side gear, 2 differential pinion gears, 2 pinion gear thrust washers, pinion shaft and pinion shaft pin. Use a dial indicator to measure backlash of one pinion gear while holding side gear toward case. See Fig 1. Backlash should be .0020-.0079" (.050-.200 mm). If backlash exceeds specification, install thrust washers of different thickness. DO NOT overtighten vise.
- Perform same procedure described in step 4 for front differential right case. See Fig 1.
- Install front differential left case to right case. Align match marks on left and right cases. Tighten Torx screws to 25 ft. lbs. (33 N.m). Install front differential case to ring gear mounting right case. Align flukes of discs in hydraulic multi-plate clutch. Install No. 2 washer.
- Clean ring gear mounting left case contact surface. Heat ring gear to about 212°F (100°C) in an oil bath. DO NOT heat ring gear above 230°F (110°C). Clean control surface of ring gear with cleaning solvent. Quickly install ring gear on differential case. Align match marks on ring gear mounting left case and ring gear. Install ring gear and mounting left case on mounting right case. Install 12 bolts. Align match marks on ring gear mounting left and right cases. Tighten bolts to 91 ft. lbs. (124 N.m).
- Ensure front differential turns smoothly. Place speedometer drive gear on ring gear mounting case. Install snap ring. Install oil seal rings to ring gear mounting right case. Install ring gear mounting case sleeve.