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Differential Case: Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL DIFFERENTIAL SIDE GEAR 
    1. Coat the 2 front differential side gears, 2 No. 1 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers with ATF and install them to the differential case.
      Fig 1: Identifying Differential Side Gear
      GTY111950Courtesy 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: Identifying Front No. 1 Differential Pinion Shaft
      GTY111842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH  See step  1
  4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin.
      Fig 3: Installing Pinion Shaft Straight Pin
      GTY177050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Align the holes, and install the front differential pinion shaft straight pin.

    2. Using a chisel and hammer, stake the differential case.
      Fig 4: Staking Differential Case
      GTY202342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Stake the differential case after adjusting the backlash.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case rear tapered roller bearing to the front differential case.
      Fig 5: Installing Front Differential Case Rear Tapered Roller Bearing
      GTY205582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-30012 
        1. 09710-04081
      • SST: 09950-60010 
        1. 09951-00480
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Do not damage the bearing cage during bearing inner race installation.

    2. Using SST and a hammer, install a new front differential case rear tapered roller bearing (outer race) to the transaxle case.
      Fig 6: Installing Front Differential Case Rear Tapered Roller Bearing Outer Race
      GTY142248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-00810
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Ensure that there is no clearance between the bearing and transaxle case.

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case front tapered roller bearing to the front differential case.
      Fig 7: Installing Front Differential Case Front Tapered Roller Bearing
      GTY205583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09523-36010 
      • SST: 09950-60010 
        1. 09951-00540
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Do not damage the bearing cage during bearing inner race installation.

    2. Install the shim to the transaxle housing.
      Fig 8: Installing Front Differential Case Front Tapered Roller Bearing Outer Race
      GTY123034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, install a new front differential case front tapered roller bearing (outer race) to the transaxle housing.
      • SST: 09950-60020 
        1. 09951-00790
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Ensure that there is no clearance between the bearing and transaxle housing.

  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Remove packing material from the contact surfaces between the transaxle housing and case.
    2. Install the differential assembly to the transaxle case.
      Fig 9: Identifying Differential Assembly To Transaxle Case
      GTY205648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case with the 20 bolts.
      Fig 10: Identifying Transaxle Housing Bolts
      GTY303009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

      except Bolt A 

      Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) 

    4. Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 RPM.
      Fig 11: Measuring Turning Torque Of Counter Driven Gear
      GTY111921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 

      Turning torque

      0.89 to 1.31 N*m (9.08 to 13.35 kgf*cm, 7.88 to 11.59 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      SHIM THICKNESS

      Part No. Thickness [mm (in.)] Mark
      90564-69001 2.000 (0.0787) -
      90564-69002 2.025 (0.0797) -
      90564-69003 2.050 (0.0807) -
      90564-69004 2.075 (0.0817) -
      90564-69005 2.100 (0.0827) -
      90564-69006 2.125 (0.0837) -
      90564-69007 2.150 (0.0846) -
      90564-69008 2.175 (0.0856) -
      90564-69009 2.200 (0.0866) -
      90564-69010 2.225 (0.0876) -
      90564-69011 2.250 (0.0886) -
      90564-69012 2.275 (0.0896) -
      90564-69013 2.300 (0.0906) -
      90564-69014 2.325 (0.0915) -
      90564-69015 2.350 (0.0925) -
      90564-69016 2.375 (0.0935) -
      90564-69017 2.400 (0.0945) -
      90564-69020 2.425 (0.0955) -
      90564-69021 2.450 (0.0965) -
      90564-69022 2.475 (0.0974) -
      90564-69023 2.500 (0.0984) -
      90564-69024 2.525 (0.0994) -
      90564-69025 2.550 (0.100) -
      90564-69026 2.575 (0.101) -
      90564-69027 2.600 (0.102) -
      90564-69028 2.625 (0.103) -
      90564-69029 2.650 (0.104) -
      90564-69030 2.675 (0.105) -
      90564-69031 2.700 (0.106) -
      90564-69032 2.725 (0.107) -
      90564-69033 2.750 (0.108) -
      90564-69034 2.775 (0.109) -
      90564-69035 2.800 (0.110) -
      90564-69036 2.825 (0.111) -
      90564-69037 2.850 (0.112) -
      90564-69038 2.875 (0.113) -
    5. Remove the 20 bolts and the transaxle housing from the transaxle case.
      Fig 12: Identifying Transaxle Housing Bolt
      GTY177512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the front differential case from the transaxle case.
      Fig 13: Identifying Differential Assembly To Transaxle Case
      GTY205648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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).
      Fig 14: Heating Front Differential Ring Gear
      GTY170191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not heat the ring gear to more than 110°C (230°F).

    2. Clean the contact surface of the front differential case.
      Fig 15: Identifying Front Differential Ring Gear & Front Differential Case Matchmarks
      GTY304440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks, set the front differential ring gear to the front differential case.
      TEXT IN ILLUSTRATION

      *a Matchmark
    4. Install the 12 bolts.
      Fig 16: Identifying Bolts
      GTY111952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf) 

      NOTE:
      • Tighten the bolts after the front differential ring gear has cooled down sufficiently.
      • Tighten the bolts evenly in a diagonal pattern using several steps.
  9. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new transaxle case oil seal with a small amount of MP grease.
      Fig 17: Installing New Transaxle Case Oil Seal Using SST & Hammer
      GTY295698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap in the transaxle case oil seal.
      • SST: 09316-10010 
      • SST: 09950-70010 
        1. 09951-07100

      Oil seal tap in depth

      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      NOTE:

      Check that the oil seal is installed in the correct direction.

  10. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new front transaxle case oil seal with a small amount of MP grease.
      Fig 18: Installing Oil Seal
      GTY248725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap in the front transaxle case oil seal.
      • SST: 09308-14010 

      Oil seal tap in depth

      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      NOTE:

      Check that the oil seal is installed in the correct direction.

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