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. After applying ATF to the 2 front differential side gears, 2 side gear thrust washers No. 1, 2 front differential pinions and 2 pinion thrust washers, install them onto the front differential case.
  HINT:
  
  When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.
  
  Fig 1: Identifying Front Differential Side Gears, Side Gear Thrust Washers No. 1, Front Differential Pinions And Pinion Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
1. Install the pinion shaft so as to align the lock pin holes in the pinion shaft and differential case.
  
  Fig 2: Identifying Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT BACKLASH

Measure the side gear backlash while holding 1 pinion gear toward the case.
Standard backlash:

0.05 to 0.20 mm (0.0020 to 0.0079 in.)

If the backlash is outside the specifications, install the correct thrust washer to the side gear.

Referring to the table below, select thrust washers which will ensure that the backlash is within the specifications for both sides.

Fig 3: Identifying Side Gear Backlash

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Thrust washer thickness

THRUST WASHER THICKNESS SPECIFICATION

Thickness mm (in.)	Thickness mm (in.)
0.95 (0.0374)	1.10 (0.0433)
1.00 (0.0394)	1.15 (0.0453)
1.05 (0.0413)	1.20 (0.0472)

If the backlash is not within the specifications, install a thrust washer of a different thickness.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and a hammer, install the pinion shaft straight pin.
  
  Fig 4: Identifying Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the differential case.
  
  Fig 5: Identifying Differential Case
  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 to 230°F).
2. Clean the contact surface of the front differential case.
3. Install 4 new ring gear lock plates with the 8 bolts.
  Torque: 88 N*m (900 kgf*cm, 65 ft.*lbf)
  
  Fig 7: Identifying Ring Gear Lock Plates With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, stake the ring gear lock plate.
  SST 09930-00010
  
  Fig 8: Identifying Ring Gear Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case LH tapered roller bearing inner race onto the differential case.
  SST 09726-40010, 09950-60020 (09951 -00790)
  
  Fig 9: Identifying Front Differential Case LH Tapered Roller Bearing Inner Race Onto Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the shim and bearing outer race onto the transaxle case.
  SST 09950-60020 (09951-00720), 09950-60010 (09951-00650), 09950-70010 (09951-07100,09951-07200)
  
  Fig 10: Identifying Shim And Bearing Outer Race Onto Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVE GEAR
1. Install the speedometer drive gear onto the differential case.
  
  Fig 11: Identifying Speedometer Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the bearing inner race onto the differential case.
  SST 09950-60010 (09951 -00460), 09950-70010 (09951-07100)
  
  Fig 12: Identifying Bearing Inner Race Onto Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the tapered roller bearing onto the transaxle housing.
  SST 09950-70010 (09951 -07150), 09950-60020 (09951-00680)
  
  Fig 13: Identifying Tapered Roller Bearing Onto Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002