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Reassembly [12/2013 - 08/2014]: Procedure

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  1. INSTALL DIFFERENTIAL SIDE GEAR 
    1. Coat the 2 differential side gears, 2 front No. 1 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.
      GTY438340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Pinion
      *2 Front Differential Pinion Thrust Washer
      *3 Differential Side Gear
      *4 Front No. 1 Differential Side Gear Thrust Washer
  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.
      GTY314187Courtesy 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 3 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the differential case.
      GTY128980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Using a chisel and a hammer, stake the differential case.
      GTY128998Courtesy 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 differential case.
      GTY444554Courtesy 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 rear tapered roller bearing cage when installing the front differential case rear tapered roller bearing.
      • Ensure that there is no clearance between the front differential case rear tapered roller bearing and 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.
      GTY454578Courtesy 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 front differential case rear tapered roller bearing outer race and transaxle case sub-assembly.

  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 differential case.
      GTY454134Courtesy 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 front differential case front tapered roller bearing cage when installing the front differential case front tapered roller bearing.
      • Ensure that there is no clearance between the front differential case front tapered roller bearing and differential case.
    2. Install the shim to the transaxle housing.
    3. Using SST and a hammer, install a new front differential case front tapered roller bearing outer race to the transaxle housing.
      GTY438088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-00790
      • 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.

  7. 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.
      GTY205648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.
      GTY438665Courtesy 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.
      GTY429288Courtesy 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

      1.5 to 1.7 N*m (16 to 17 kgf*cm, 14 to 15 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.
      GTY425142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the differential case from the transaxle case sub-assembly.
      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).
      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 differential case.
    3. Align the matchmarks, and install the front differential ring gear to the differential case quickly.
      GTY447750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
      NOTE:

      Do not install the bolts while the front differential ring gear is hot.

    4. Install and tighten the 12 bolts.
      GTY314354Courtesy 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 FRONT DRIVE SHAFT OIL SEAL RH 
    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 case sub-assembly.
      GTY441338Courtesy 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:

      Check that the front drive shaft oil seal RH is installed in the correct direction.

  10. INSTALL FRONT DRIVE SHAFT OIL SEAL LH 
    1. Coat the lip of a new front drive shaft oil seal LH with MP grease.
      GTY439510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front drive shaft oil seal LH to the transaxle housing.
      • SST: 09308-14010 

      Standard Depth

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

      NOTE:

      Check that the front drive shaft oil seal LH is installed in the correct direction.

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