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Inspection [11/2015 - 11/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT FRONT DIFFERENTIAL CASE 
    1. Using SST, rotate the front differential side gear as shown in the illustration.
      • SST: 09528-52010 
        1. 09528-05030

      Standard

      The front differential side gear does not lock when rotated in either direction.

      GTY472106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If the front differential side gear locks, perform all inspections.
      • If the front differential side gear still locks even after replacing the malfunctioning parts, replace the front differential case.
  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT 
    1. Using SST and a dial indicator, measure the front differential side gear thrust amount.
      • SST: 09528-52010 
        1. 09528-05030
      GTY473613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Differential Side Gear Thrust Amount

      Front Differential Side Gear Thrust Amount

      0.08 mm (0.00315 in.) or less

      HINT: 

      • Measure the front differential side gear thrust amount while slowly rotating the front differential side gear.
      • Make sure to measure the front differential side gear thrust amount for both of the front differential side gears.

      If the result is not as specified, replace the 2 front differential side gears, 2 front differential pinions and 2 conical springs.

  3. INSPECT FRONT DIFFERENTIAL PINION BACKLASH 
    1. Install SST as shown in the illustration and tighten it.
      GTY478060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn *b Hold
      • SST: 09528-52010 
        1. 09528-05010
        2. 09953-05010

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Secure the front differential case with front differential ring gear in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    3. Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.
      GTY479155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front No. 1 Differential Pinion Shaft
    4. Using a dial indicator, measure the front differential pinion backlash.

      Standard Backlash

      0.15 mm (0.00591 in.) or less

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select a front No. 1 differential side gear thrust washer which will ensure that the backlash is within the specification.

      FRONT NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER THICKNESS:

      Part No. Thickness (mm (in.))
      41361-06010 1.50 (0.0591)
      41361-06020 1.55 (0.0610)
      41361-06030 1.60 (0.0630)
      41361-06040 1.65 (0.0650)
      41361-06050 1.70 (0.0669)
      41361-06060 1.75 (0.0689)
      41361-06070 1.80 (0.0709)
      41361-06080 1.85 (0.0728)
      41361-06090 1.90 (0.0748)

      HINT: 

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

  4. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER 
    1. Using a micrometer, measure the thickness of the front differential pinion thrust washer.
      GTY420984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum Thickness

      0.54 mm (0.0213 in.)

      HINT: 

      Measure the most worn portion of the front differential pinion thrust washer.

      If the thickness is less than the minimum, replace the front differential pinion thrust washer.

  5. INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.
      GTY184353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum Outer Diameter

      20.499 mm (0.807 in.)

      HINT: 

      Measure the most worn portion of the front No. 1 differential pinion shaft.

      If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.

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