LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 1998 >> Avalon XLS >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Automatic Transmission Overhaul - A-540E, A-540H & A-541E >> Overhaul >> Differential Assembly (A-540H) Disassembly & Reassembly >> Reassembly

Differential Assembly (A-540H) Disassembly & Reassembly: Reassembly

  1. 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.
  2. 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.
  3. Install plates and discs, starting with plate, alternating with disc and ending with disc. 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.
  4. Install following parts into front differential left case: side gear thrust washer, side gear, 4 differential pinion gears, 4 pinion gear thrust washers and differential spider. Use a dial indicator to measure backlash of one pinion gear while holding side gear toward case. See Fig 1. Backlash should be .002-.008" (.05-.20 mm).
  5. If backlash exceeds specification, install thrust washers of different thickness. DO NOT overtighten the vise. See SIDE GEAR THRUST WASHER SPECIFICATIONS  table. Perform same procedure described in step  4 for front differential right case. See Fig 1.
    SIDE GEAR THRUST WASHER SPECIFICATIONS

    ID Mark Thickness - In. (mm)
    A .0394 (1.000)
    B .0413 (1.050)
    C .0433 (1.100)
    D .0453 (1.150)
    E .0472 (1.200)
    F .0492 (1.250)
    G .0512 (1.300)
    Fig 1: Measuring Front Differential Side Gear Backlash
    G93B25784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install front differential left case to right case. Align match marks on left and right cases. Tighten Torx screws to 24 ft. lbs. (33 N.m). Install front differential case to ring gear right case. Align flukes of discs in hydraulic multi-plate clutch. Install No. 2 washer.
  7. Clean ring gear 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 contact surface of ring gear with cleaning solvent. Quickly install ring gear on differential case. Align match marks on ring gear left case and ring gear. Install ring gear and left case on right case. Install 12 bolts. Align match marks on ring gear left and right cases. Tighten bolts to 91 ft. lbs. (124 N.m).
  8. Ensure front differential turns smoothly. Place speedometer drive gear on ring gear case. Install snap ring. Install oil seal rings to ring gear right case. Install ring gear case sleeve. Install right case bearing outer race.
scientia non olet · About LEMON Manuals