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

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  1. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the front differential case.
      GTY482550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09726-36010 
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:
      • Do not damage the front differential case rear tapered roller bearing (inner race) cage when installing the front differential case rear tapered roller bearing (inner race).
      • Ensure that there is no clearance between the front differential case rear tapered roller bearing (inner race) and front differential case.
    2. Using SST and a hammer, install a new front differential case rear tapered roller bearing (outer race) to the transaxle case sub-assembly.
      GTY478519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-00890
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Ensure that there is no clearance between the front differential case rear tapered roller bearing (outer race) and transaxle case sub-assembly.

  2. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the front differential case.
      GTY473801Courtesy 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 front differential case front tapered roller bearing (inner race) cage when installing the front differential case front tapered roller bearing (inner race).
      • Ensure that there is no clearance between the front differential case front tapered roller bearing (inner race) and front differential case.
    2. Install the shim to the transaxle housing.
      GTY476627Courtesy 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. 09951-00890
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Ensure that there is no clearance between the front differential case front tapered roller bearing (outer race), shim and transaxle housing.

  3. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs with ATF.
      GTY430626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      ATF
    2. Install the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs to the front differential case.
      GTY475918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      NOTE:
      • Do not drop the front differential side gear, front No. 1 differential side gear thrust washer or conical spring.
      • Make sure that the conical spring is installed with the correct orientation.
    3. Install SST as shown in the illustration and tighten it.
      GTY477393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn *b Hold
      • SST: 09528-52010 
        1. 09528-05010
        2. 09953-05010
      NOTE:

      Do not overtighten SST as doing so will damage the front differential side gears, conical springs, 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 front differential side gears.
    4. Coat the 2 front differential pinions and 2 front differential pinion thrust washers with ATF.
      GTY584940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      ATF
    5. Using SST as shown in the illustration, rotate the front differential side gear and install the 2 front differential pinions and 2 front differential pinion thrust washers to the front differential case.
      • SST: 09528-52010 
        1. 09528-05030
      WARNING:

      Be careful not to pinch your fingers between the front differential pinion and front differential case.

      NOTE:

      Do not drop the front differential pinion or front differential pinion thrust washer.

      GTY482495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
  4. INSPECT FRONT DIFFERENTIAL PINION BACKLASH 

    See step  3

  5. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Coat the front No. 1 differential pinion shaft with ATF.
      GTY473922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
  6. INSPECT FRONT DIFFERENTIAL CASE 

    See step  1

  7. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a 5 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.
      GTY473924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, stake the front differential case.
      GTY481329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case sub-assembly.
    2. Install the differential case to the transaxle case sub-assembly.
      GTY425687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.
      GTY440874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 30.6 N*m (312 kgf*cm, 23 ft.*lbf) 

      Bolt (B) 

      Torque: 22.7 N*m (231 kgf*cm, 17 ft.*lbf) 

    4. Using SST, turn the differential case right and left 2 or 3 times to settle the bearings.
      GTY453107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 
    5. Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.
      • SST: 09564-33010 

      Turning Torque

      1.1 to 1.9 N*m (11 to 19 kgf*cm, 10 to 17 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: MM (IN.)

      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.225 (0.0876) 2.450 (0.0965) 2.675 (0.105)
      2.025 (0.0797) 2.250 (0.0886) 2.475 (0.0974) 2.700 (0.106)
      2.050 (0.0807) 2.275 (0.0896) 2.500 (0.0984) 2.725 (0.107)
      2.075 (0.0817) 2.300 (0.0906) 2.525 (0.0994) 2.750 (0.108)
      2.100 (0.0827) 2.325 (0.0915) 2.550 (0.100) 2.775 (0.109)
      2.125 (0.0837) 2.350 (0.0925) 2.575 (0.101) 2.800 (0.110)
      2.150 (0.0846) 2.375 (0.0935) 2.600 (0.102) 2.825 (0.111)
      2.175 (0.0856) 2.400 (0.0945) 2.625 (0.103) 2.850 (0.112)
      2.200 (0.0866) 2.425 (0.0955) 2.650 (0.104) 2.875 (0.113)
    6. Remove the 20 bolts and transaxle housing from the transaxle case sub-assembly.
      GTY450005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential case from the transaxle case sub-assembly.
      GTY425687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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).
      GTY321547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Clean the contact surface of the front differential case.
    3. Align the matchmarks, and install the front differential ring gear to the front differential case quickly.
      GTY472299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    4. Install the 12 bolts.
      GTY474611Courtesy 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.
  10. INSTALL FRONT DRIVE SHAFT OIL SEAL LH 
    1. Coat the lip of a new front drive shaft oil seal LH with MP grease.
    2. Using SST and a hammer, install the front drive shaft oil seal LH.
      GTY480025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-10010 
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

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

      NOTE:
      • Make sure that the front drive shaft oil seal LH is installed in the correct direction.
      • Do not damage the front drive shaft oil seal LH lip.
  11. INSTALL FRONT DRIVE SHAFT OIL SEAL RH 
    1. for Inside:
      1. Coat the lip of a new front drive shaft oil seal RH with MP grease.
      2. Using SST and a hammer, install the front drive shaft oil seal RH to the front differential case.
        • SST: 09950-60010 
          1. 09951-00410
        • SST: 09950-70010 
          1. 09951-07200

        Standard Depth

        21.5 to 22.5 mm (0.846 to 0.886 in.)

        NOTE:

        Do not damage the front drive shaft oil seal RH lip.

        GTY475752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Outside:
      1. Coat the lip of a new front drive shaft oil seal RH with MP grease.
      2. Using SST and a hammer, install the front drive shaft oil seal RH to the transaxle housing.
        GTY479570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09649-17010 
        • SST: 09950-70010 
          1. 09951-07200

        Standard Depth

        5.5 to 6.5 mm (0.217 to 0.256 in.)

        NOTE:
        • Make sure that the front drive shaft oil seal RH is installed in the correct direction.
        • Do not damage the front drive shaft oil seal RH lip.
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