Reassembly [08/2014 - ]: Procedure

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

INSTALL DIFFERENTIAL SIDE GEAR

Coat the 2 differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical spring washers with Toyota Genuine ATF WS.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Differential Side Gear
*2	Conical Spring Washer
*3	Front No. 1 Differential Side Gear Thrust Washer
	Toyota Genuine ATF WS

Install the 2 differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical spring washers to the front differential case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Differential Side Gear
*2	Conical Spring Washer
*3	Front No. 1 Differential Side Gear Thrust Washer

Set SST as shown in the illustration and tighten it.

SST: 09528-52010
1. 09528-05010
2. 09953-05010

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn

Hold

NOTE:

Do not overtighten SST, as doing so will damage the differential side gears, conical spring washers, front No. 1 differential side gear thrust washers and front differential case.

HINT:

Tighten SST to create the necessary clearance to install the front differential pinions.
When installing the front differential pinions, do not overtighten SST, as it is necessary to rotate the differential side gears.

Coat the 2 front differential pinions and 2 front differential pinion thrust washers with Toyota Genuine ATF WS.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Toyota Genuine ATF WS

Using SST as shown in the illustration, rotate the differential side gear and install the 2 front differential pinions and 2 front differential pinion thrust washers.

SST: 09528-52010
1. 09528-05030

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn

WARNING:

Be careful not to catch your fingers between the front differential pinions and front differential case.

NOTE:

Do not drop the front differential pinions and front differential pinion thrust washers.

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
See step 3

INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

Coat the front No. 1 differential pinion shaft with Toyota Genuine ATF WS.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Toyota Genuine ATF WS

Install the front No. 1 differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.

INSPECT FRONT DIFFERENTIAL CASE
See step 1
INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT
See step 2

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Align the holes in the front differential case and front No. 1 differential pinion shaft and install the front differential pinion shaft straight pin.

Using a chisel and hammer, stake the front differential case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DIFFERENTIAL RING GEAR

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 front differential ring gear to more than 110°C (230°F).

Clean the contact surface of the front differential case.

Matchmark

Align the matchmarks, set the front differential ring gear to the front differential case.

Install and tighten the 12 bolts.

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.

INSTALL TRANSAXLE CASE OIL SEAL RH (INNER)

Coat the lip of a new transaxle case oil seal RH (inner) with MP grease.

Using SST and a hammer, install the transaxle case oil seal RH (inner).

SST: 09950-60010
1. 09951-00410
SST: 09950-70010
1. 09951-07200

Oil seal drive in depth

21.5 to 22.5 mm (0.847 to 0.885 in.)