Differential Case: Reassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Coat the sliding and rotating surfaces of the front differential side gear with gear oil.
2. Install the 2 front differential side gear thrust washers No. 1 onto the 2 front differential side gears.
3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential pinion thrust washers onto the front differential case.
  HINT:
  
  Revolving the front differential side gear, install the 2 front differential pinions and 2 front differential pinion thrust washers.
  
  Fig 1: Installing Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
1. Coat front differential pinion shaft No. 1 with MP grease.
2. Install front differential pinion shaft No. 1 onto 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: Installing Front Differential Pinion Shaft No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH

Fix 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 outside the specifications, replace the side gear thrust washer.

Fig 3: Measuring Front Differential Side Gear Backlash Using Dial Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Thrust washer thickness

THRUST WASHER THICKNESS SPECIFICATION

Parts No.	Thickness mm (In.)
41361-22140	0.95 (0.0374 In.)
41361-22020	1.00 (0.0394 In.)
41361-22150	1.05 (0.0413 In.)
41361-22030	1.10 (0.0433 In.)
41361-22160	1.15 (0.0452 In.)
41361-22040	1.20 (0.0472 In.)

HINT:

Because the thrust washer does not have any marks for distinction, measure the thickness with a micrometer to select a proper thrust washer.
Select washers of the same thickness for both the right and left.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch (ø3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.
  
  Fig 4: Identifying Pin Punch, Hammer & Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the front differential case hole.
  
  Fig 5: Staking Front Differential Case Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Clean the contact surfaces of the front differential case and ring gear.
2. Using a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).
3. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.
  
  Fig 6: Heating Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Aligning the 2 matchmarks, quickly install the front differential ring gear onto the front differential case.
5. Install the 8 bolts.
  Torque: 77 N*m (790 kgf*cm, 57 ft.*lbf)
  
  Fig 7: Placing Matchmarks On Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVE GEAR
1. Install the speedometer drive gear onto the front differential case.
  
  Fig 8: Identifying Speedometer Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002