Differential Case: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Coat the 2 front differential side gears, 2 side gear thrust washers, 2 font differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
  
  Fig 1: Identifying Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT
1. Coat the No. 1 front differential pinion shaft with ATF, and install it to the differential case.
  
  Fig 2: Identifying No. 1 Front Differential Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE STRAIGHT PIN
1. Using a pin punch and a hammer, tap in the pinion shaft straight pin.
  
  Fig 3: Identifying Tapping In Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the differential case.
  NOTE: Stake it after adjusting the backlash.
  
  Fig 4: Identifying Staking Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, press in the front differential case rear tapered roller bearing to the differential case.
  SST 09550-60010, 09950-60020 (09951 -00680), 09950-70010 (09951 -07100)
  
  Fig 5: Identifying Pressing In Front Differential Case Rear Tapered Roller Bearing To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in the front differential case tapered roller bearing front outer race to the transaxle housing.
  SST 09550-60010, 09950-60020 (09951-00680), 09950-70010 (09951-07100, 09951-00890)
  
  Fig 6: Identifying Tapping In Front Differential Case Tapered Roller Bearing Front Outer Race To Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press in the front differential case rear tapered roller bearing to the differential case.
  SST 09550-60010, 09950-60020 (09951 -00680), 09950-70010 (09951-07100, 09951-00890)
  
  Fig 7: Identifying Pressing In Front Differential Case Rear Tapered Roller Bearing To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in the front differential case tapered roller bearing front outer race to the transaxle housing.
  SST 09550-60010, 09950-60020 (09951-00680), 09950-70010 (09951-07100, 09951-00890)
  
  NOTE: Clearance is not allowed between the bearing and transaxle housing.
  
  Fig 8: Identifying Tapping In Front Differential Case Tapered Roller Bearing Front Outer Race To Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Install the differential assembly to the transaxle case.

Fig 9: Identifying Differential Assembly To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean the matching surfaces of the transaxle case and transaxle housing.
Install the transaxle housing to the transaxle case and tighten them with the 16 bolts
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A

29 N*m (296 kgf*cm, 21 ft.*lbf) for bolts B and C

HINT:

Each bolt length is indicated below.

Fig 10: Identifying Transaxle Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length:

50 mm (1.969 in.) for bolt A

50 m (1.969 in.) for bolt B

42 mm (1.654 in.) for bolt C

NOTE: Usually, bolt A is non-reusable bolt. In this case, however, it can be used after cleaning it.
Using SST, return the differential assembly right and left 2 or 3 times to allow the bearing settle.
SST 09564-32011

Using SST and torque wrench, measure the turning torque of the differential.

SST 09564-32011

Torque: Standard turning torque at 60 rpm

0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf)

HINT:

If the turning torque is not within the specified value, refer to the table below and select a thrust washer which turning torque is within the specified value.

Fig 11: Identifying Turning Torque Of Differential

Standard flange thickness

STANDARD FLANGE THICKNESS

Mark	Thickness	Mark	Thickness
0	2.00 mm (0.0787 in.)	9	2.45 mm (0.0965 in.)
1	2.05 mm (0.0807 in.)	A	2.50 mm (0.0984 in.)
2	2.10 mm (0.0827 in.)	B	2.55 mm (0.1004 in.)
3	2.15 mm (0.0846 in.)	C	2.60 mm (0.1024 in.)
4	2.20 mm (0.0866 in.)	D	2.65 mm (1.1043 in.)
5	2.25 mm (0.0886 in.)	E	2.70 mm (0.1063 in.)
6	2.30 mm (0.0906 in.)	F	2.75 mm (0.1083 in.)
7	2.35 mm (0.0925 in.)	G	2.80 mm (0.1102)
8	2.40 mm (0.0945 in.)	H	2.85 mm (0.1122 in.)

Remove the 16 bolts and the transaxle housing.

Fig 12: Locating Transaxle Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the differential assembly.

Fig 13: Identifying Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F)
  NOTE: Do not overheat the ring gear to 110°C (230.0°F) or more.
  
  Fig 14: Identifying Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Clean the contract surface of the front differential case.
3. Align the matchmarks, and install the front differential ring gear case quickly.
  NOTE: Do not install the bolts while the ring gear is hot.
  
  Fig 15: Identifying Matchmarks On Front Differential Ring Gear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 14 bolts.
  Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
  
  NOTE: Tighten the bolts a little at a time in diagonal order.
  
  Fig 16: Identifying Front Differential Ring Gear Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
1. Coat the lip of a new oil seal with a little amount of MP grease.
2. Using SST and a hammer, tap in the oil seal.
  SST 09223-15020, 09950-70010 (09951-07100)
  
  Fig 17: Identifying Tapping In Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING OIL SEAL
1. Coat the lip of a new oil seal with a little amount of MP grease.
2. Using SST and a hammer, tap in the oil seal.
  SST 09710-30050, 09950-70010 (09951-07100)
  
  Fig 18: Identifying Tapping Transaxle Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002