Center Differential: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

INSTALL LOW GEAR
1. Clean the contact surface of the differential case.
2. Heat the low gear in boiling water.
3. Carefully remove the low gear from the water.
4. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.
  
  Fig 1: Heating Low Gear In Boiling Water
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER

Install the front side gear and thrust washer.

Fig 2: Installing Front Side Gear & Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the pinion shaft, 2 pinion gears and thrust washers to the front differential case.

Fig 3: Installing Pinion Shaft, 2 Pinion Gears & Thrust Washers To Front Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the front case backlash.

HINT:

Push the pinion shaft.

Maximum backlash: 0.05 mm (0.0020 in.)

If the backlash is greater than the maximum, replace the thrust washer with one of the correct size and reinstall the thrust washer.

Fig 4: Measuring Front Case Backlash

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard snap ring thickness

STANDARD SNAP RING THICKNESS

Thickness mm (in.)	Thickness mm (in.)
1.70 (0.0669)	2.45 (0.0965)
1.85 (0.0728)	2.60 (0.1024)
2.00 (0.0787)	2.75 (0.1083)
2.15 (0.0846)	2.90 (0.1142)
2.30 (0.0906)	3.05 (0.1201)

Use the procedures described for the front case backlash to measure the rear case backlash.
Install the straight pin to the pinion shaft.

Fig 5: Installing Straight Pin To Pinion Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL THRUST WASHER AND REAR SIDE GEAR

Fig 6: Installing Thrust Washer & Rear Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DIFFERENTIAL CASE
1. Install the differential case with the 12 set bolts.
  Torque: 88 N*m (900 kgf*cm, 65 ft.*lbf)
2. Turn the pinion gear.
3. Loosen the 12 case set bolts.
4. Torque the 12 case set bolts.
  Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf)
  
  Fig 7: Installing Differential Case With 12 Set Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TAPER ROLLER BEARING
1. Using SST and a press, press in the taper roller bearing.
  SST 09316-12010
  
  Fig 8: Pressing In Taper Roller Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH HUB
1. Using SST and a press, press in the clutch hub.
  SST 09316-12010, 09316-60011 (09316-00011)
  
  Fig 9: Pressing In Clutch Hub Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HIGH SPEED OUTPUT GEAR BUSH
1. Apply MP grease to the straight pin.
2. Install the straight pin as shown.
  
  Fig 10: Installing Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in the high speed output gear bushing.
  SST 09316-12010, 09316-60011 (09316-00011)
  
  NOTE: Before pressing on the front differential case, align the groove on the bushing with the pin on the shaft.
  
  Fig 11: Pressing In High Speed Output Gear Bushing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:

Make sure to install the high and low clutch sleeve in the correct direction.
INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR
1. Apply gear oil to the needle roller bearing.
2. Install the needle roller bearing and high speed output gear.
  
  Fig 12: Installing High & Low Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT TAPER ROLLER BEARING
1. Using SST and a press, press in the taper roller bearing.
  SST 09316-12010, 09316-60011 (09316-00011)
  
  Fig 13: Pressing In Taper Roller Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE GEAR PIECE
1. Using SST and a press, press in the drive gear piece.
  SST 09316-12010, 09316-60011 (09316-00011)
  
  Fig 14: Installing Front Drive Gear Piece Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL SNAP RING

Select a snap ring that will allow the minimum axial play.

Standard snap ring thickness

STANDARD SNAP RING THICKNESS

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.00 (0.0787)	G	2.60 (0.1024)
B	2.10 (0.0827)	H	2.70 (0.1063)
C	2.20 (0.0866)	J	2.80 (0.1102)
D	2.30 (0.0906)	K	1.80 (0.0709)
E	2.40 (0.0945)	L	1.90 (0.0748)
F	2.50 (0.0984)	-	-

Fig 15: Installing Snap Ring

Using a snap ring expander, install a new snap ring.

CHECK HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See DISASSEMBLY )