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 front differential pinions and 2 pinion thrust washers with ATF, and install them to the differential case.
  
  Fig 1: Identifying Front Differential Side Gears, Side Gear Thrust Washers And Front Differential Pinions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FRONT DIFFERENTIAL PINION SHAFT
1. Coat the front differential pinion shaft with ATF, and install it to the differential case.
INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH (See INSPECTION )
INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and 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 hammer, stake the differential case.
  
  Fig 4: Identifying 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 tapered roller bearing rear inner race to the differential case.
  SST 09608-06041
  
  Fig 5: Identifying Pressing In Front Differential Case Tapered Roller Bearing Rear Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in the case washer and front differential case tapered roller bearing rear outer race to the transaxle case.
  SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
  
  Fig 6: Identifying Tapping In Case Washer
  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 tapered roller bearing front inner race to the differential case.
  SST 09608-06041
  
  Fig 7: Identifying Pressing In Front Differential Case Tapered Roller Bearing Front Inner Race
  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 09950-60020 (09951-00680), 09950-70010 (09951-07100), 09950-60010 (09951-00340)
  
  Fig 8: Identifying Tapping In Front Differential Case Tapered Roller Bearing Front Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using ATF and heater, heat the front differential ring gear to 90 to 1i0°C (194.0 to 230.0°F).
2. Clean the contact surface of the front differential case.
3. Align the matchmarks, and install the front differential ring gear case quickly.
  
  Fig 10: Identifying Matchmarks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 10 bolts.
  Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
  
  Fig 11: Identifying Front Differential Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT TAPERED ROLLER BEARING PRELOAD

Install the differential assembly to the transaxle case.

Fig 12: Identifying Differential Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the transaxle housing to the transaxle case.
Install 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 bolt B and C

HINT:

Each bolt length is indicated below.

Bolt length:

50 mm (1.97 in.) for bolt A and B

42 mm (1.65 in.) for bolt C

Fig 13: Identifying Transaxle Housing With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, turn the differential.
SST 09564-32011

Fig 14: Identifying Differential
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and torque wrench, measure the preload 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) for new

0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) for used

Fig 15: Identifying Preload Of Differential

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard adjusting shim thickness

ADJUSTING SHIM THICKNESS SPECIFICATION

Mark	Thickness
0	1.90 mm (0.074 in.)
1	1.95 mm (0.077 in.)
2	2.00 mm (0.079 in.)
3	2.05 mm (0.081 in.)
4	2.10 mm (0.083 in.)
5	2.15 mm (0.085 in.)
6	2.20 mm (0.087 in.)
7	2.25 mm (0.089 in.)
8	2.30 mm (0.091 in.)
9	2.35 mm (0.093 in.)
A	2.40 mm (0.094 in.)
B	2.45 mm (0.096 in.)
C	2.50 mm (0.098 in.)
D	2.55 mm (0.100 in.)
E	2.60 mm (0.102 in.)
F	2.65 mm (0.104 in.)
G	2.70 mm (0.106 in.)
H	2.75 mm (0.108 in.)
J	2.80 mm (0.110 in.)

Remove the 16 bolts.

Fig 16: Identifying Transaxle Housing Bolts

Using a practic-faced hammer, remove the transaxle housing.

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 09350-32014 (09351-32150), 09950-70010 (09951-07150)
  
  Fig 18: Identifying Transaxle Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL

Fig 19: Identifying Differential Side Bearing Retainer Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 09350-32014 (09351-32150), 09950-70010 (09951-07150)