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Differential Case: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. 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 Gear
      G06011978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.
      Fig 2: Removing Front No 1 Differential Pinion Shaft
      G06011977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a pin punch and hammer, install the pinion shaft straight pin.
      Fig 3: Installing Front Differential Pinion Shaft Straight Pin
      G04976475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and hammer, stake the differential case.
      NOTE: Stake it after adjusting the backlash (See INSPECTION ).
      Fig 4: Staking Differential Case
      G04976476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing to the differential case.

      SST 09550-60010 (09951 -00480), 09950-70010 (09951-07100), 09710-04081 

      NOTE: Do not damage the bearing cage during installation of the bearing inner race.
      Fig 5: Installing Front Differential Case Front Tapered Roller Bearing
      G04976477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.

      SST 09950-60020 (09951 -00750), 09950-70010 (09951-07200) 

      Fig 6: Installing Front Differential Case Front Tapered Roller Bearing Outer Race To Transaxle Housing
      G05584055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.

      SST 09710-04081, 09550-60010 (09951 -00480), 09950-70010 (09951-07100) 

      NOTE: Do not damage the bearing when installing the bearing inner race.
      Fig 7: Installing Front Differential Case Rear Tapered Roller Bearing
      G04976479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing.

      SST 09550-60010 (09951 -00790), 09950-70010 (09951-00710) 

      NOTE: Make sure that there is no clearance between the bearing and transaxle housing.
      Fig 8: Installing Front Differential Case Rear Tapered Roller Bearing Outer Race To Transaxle Housing
      G04976480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Install the differential assembly to the transaxle case.
    2. Clean the contact surfaces of the transaxle case and transaxle housing.
      Fig 9: Installing Differential Assembly To Transaxle Case
      G04976481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case and tighten the 18 bolts.

      Torque: Bolt A 

      29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Bolt B 

      29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Bolt C 

      22 N*m (224 kgf*cm, 16 ft.*lbf) 

      Bolt D 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolt E 

      33 N*m (336 kgf*cm, 24 ft.*lbf) 

      Bolt F 

      25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Fig 10: Locating Bolts And Transaxle Housing
      G06011904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt length: 

      Bolt B, C, D, F: 

      50 mm (1.969 in.) 

      Bolt A, E: 

      42 mm (1.654 in.) 

    4. Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.

      SST 09564-32011 

    5. Using SST and a torque wrench, measure the rotating torque of the differential.

      SST 09564-32011 

      Rotating torque at 60 rpm: 

      New bearing: 

      0.20 to 1.0 N*m (2.0 to 10.2 kgf*cm, 1.8 to 8.9 in.*lbf) 

      Used bearing: 

      0.10 to 0.50 N*m (1.0 to 5.1 kgf*cm, 0.9 to 4.4 in.*lbf) 

      HINT:

      If the rotating torque is not within the specified range, refer to the table below to select a thrust washer so that the rotating torque is within the specified range.

      Fig 11: Measuring Rotating Torque Of Differential
      G04976483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      0 1.90 (0.0748) A 2.40 (0.0945)
      1 1.95 (0.0768) B 2.45 (0.0965)
      2 2.00 (0.0787) C 2.50 (0.0984)
      3 2.05 (0.0807) D 2.55 (0.1004)
      4 2.10 (0.0827) E 2.60 (0.1024)
      5 2.15 (0.0846) F 2.65 (0.1043)
      6 2.20 (0.0866) G 2.70 (0.1063)
      7 2.25 (0.0886) H 2.75 (0.1083)
      8 2.30 (0.0906) J 2.80 (0.1102)
      9 2.35 (0.0925) - -
    6. Remove the 18 bolts and the transaxle housing.
      Fig 12: Locating Bolts And Transaxle Housing
      G06011650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential assembly.
      Fig 13: Removing Differential Assembly
      G04976481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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).
      NOTE: Do not heat the ring gear to over 110°C (230°F).
    2. Clean the contact surface of the front differential case.
      Fig 14: Heating Front Differential Ring Gear
      G06011995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      G06011969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 10 bolts.

      Torque: 95 N*m (970 kgf*cm, 70 ft.*lbf) 

      NOTE: Tighten the bolts one at a time in diagonal order.
      Fig 16: Identifying Front Differential Ring Gear And Bolts
      G06011970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal.

      SST 09316-60011 (09316-00011) 

    2. Coat the lip of the oil seal with a small amount of MP grease.

      Oil seal drive in depth: 

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 

      Fig 17: Installing Transaxle Housing Oil Seal
      G06011998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal.

      SST 09649-17010, 09950-70010 (09951 -07150) 

    2. Coat the lip of the oil seal with a small amount of MP grease.

      Oil seal drive in depth: 

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 

      Fig 18: Installing Differential Side Bearing Retainer Oil Seal
      G06011999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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