Differential Case: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. After applying ATF to the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers, install them to the front differential case.
Fig 1: Identifying Front Differential Side Gear
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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.
INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT
1. Install the front No. 1 differential pinion shaft so as to align the lock pin holes in the pinion shaft and front differential case.
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (See INSPECTION )

Fig 2: Installing Front No. 1 Differential Pinion Shaft
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INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and a hammer, install the pinion shaft straight pin.
  
  Fig 3: Installing Pinion Shaft Straight Pin Using Pin Punch And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the differential case.
Fig 4: Staking Differential Case Using Chisel And Hammer
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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.
  
  Fig 5: Heating Front Differential Ring Gear
  Courtesy 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 6: Identifying Matchmarks On Front Differential Ring Gear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install 4 new ring gear lock plates with the 8 bolts.
  Torque: 88 N*m (898 kgf*cm, 65 ft.*lbf)
  
  Fig 7: Identifying Ring Gear Lock Plates With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, stake the ring gear lock plate.
  SST 09930-00010
  
  Fig 8: Staking Ring Gear Lock Plate Using SST
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INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case rear tapered roller bearing inner race to the differential case.
  SST 09726-40010, 09950-60020 (09951-00790)
  
  Fig 9: Installing Front Differential Case Rear Tapered Roller Bearing Inner Race To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the shim and bearing outer race to the transaxle case.
  SST 09950-60020 (09951-00720), 09950-60010 (09951-00650), 09950-70010 (09951-07100, 09951-07200)
  
  Fig 10: Installing Shim And Bearing Outer Race To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case front tapered roller bearing inner race to the differential case.
  SST 09950-60010 (09951-00460), 09950-70010 (09951-07100)
  
  Fig 11: Installing Front Differential Case Front Tapered Roller Bearing Inner Race To Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the front differential case front tapered roller bearing to the transaxle housing.
  SST 09950-70010 (09951-07150), 09950-60020 (09951-00680)
  
  Fig 12: Installing Front Differential Case Front Tapered Roller Bearing To Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002