Differential Case: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER (see )INSPECTION
INSPECT FRONT DIFFERENTIAL PINION SHAFT NO. 1 (see )INSPECTION
INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Coat the sliding and rotating surface of the 2 front differential side gears with gear oil.
2. Install the 2 front differential side gear thrust washers to the 2 front differential side gears.
  HINT:
  
  Install the front differential side gear thrust washer that has the same thickness as the removed one.
3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side pinion thrust washers to the front differential case.
Fig 1: Identifying Front Differential Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Turning the front differential side gear, align the 2 front differential pinions with the hole of the front differential case.
INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1
1. Coat the rotating surface of the front differential pinion shaft No. 1 with gear oil.
2. Install the front differential pinion shaft No. 1 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.
Fig 2: Identifying Front Differential Pinion Shaft No.1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH

Fixing 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 (0.0020 to 0.0079 in.)

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

Thrust washer thickness:

THRUST WASHER THICKNESS SPECIFICATION CHART

Part No.	Thickness: mm (in.)
41361-22140	0.95 (0.0374)
41361-22020	1.00 (0.0394)

Fig 3: Measuring Front Differential Side Gear Backlash

THICKNESS SPECIFICATION CHART

HINT:

Because the washer does not have any identification mark, measure the front thickness with a micrometer to select a proper thrust washer.
Select washers that has the same thickness as both the right and left.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch (ø 3 mm) and a hammer, install the front differential pinion shaft straight pin to the front differential case.
  
  Fig 4: Installing Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the front case hole.
Fig 5: Staking Front Case Hole
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Clean the contact surface of the front differential case and front differential ring gear.
2. Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F)
3. After the moisture on the ring gear has completely evaporated, quickly install the front differential ring gear to the front differential case.
  
  Fig 6: Heating Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the both matchmarks, and quickly install the 8 bolts with the front differential ring gear to the front differential case.
Torque: 77 N*m (789 kgf*cm, 57 ft.*lbf)

Fig 7: Aligning Both Matchmarks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVE (MTM) GEAR
1. Install the speedometer drive (MTM) gear to the front differential case.
Fig 8: Installing Speedometer Drive (MTM) Gear To Front Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002