Inspection [10/2017 - ]: Procedure

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.

   Courtesy 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.
   • Replace any parts that do not meet the specification.

HINT: 

• Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
• Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

  Serial Number	Factory
  3##########	for TMMWV Made
  ##A########	for AISIN AW Made

1. Install SST as shown in the illustration and tighten it.

   Courtesy 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.

   Courtesy 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

   0.20 mm (0.00787 in.) or less

   HINT: 

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

   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 front No. 1 differential side gear thrust washers which will ensure that the backlash is within the specification.

   Front No. 1 Differential Side Gear Thrust Washer Thickness

   FOR TMMWV MADE:
   
   

   Part No.	Thickness [mm (in.)]
   41361-0R010	0.9 (0.0354)
   41361-0R020	1.0 (0.0394)
   41361-0R030	1.1 (0.0433)
   41361-0R040	1.2 (0.0472)

   FOR AISIN AW MADE:
   
   

   Part No.	Thickness [mm (in.)]
   41361-33340	0.90 (0.0354)
   41361-33350	0.95 (0.0374)
   41361-33360	1.00 (0.0394)
   41361-33370	1.05 (0.0413)
   41361-33380	1.10 (0.0433)
   41361-33390	1.15 (0.0453)
   41361-33400	1.20 (0.0472)
   41361-33410	1.25 (0.0492)

1. Using a micrometer, measure the thickness of the front differential pinion thrust washer.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum Thickness

   0.90 mm (0.0354 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.

1. Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum Outer Diameter

   17.975 mm (0.708 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.