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Reassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  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.
      GTY521624Courtesy 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.
      GTY586434Courtesy 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.

  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.
      GTY472307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-12010 
      • SST: 09649-17010 
      • 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.
    3. Using SST and a hammer, install a new front differential case front tapered roller bearing (outer race) to the transaxle housing.
      GTY718104Courtesy 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 front tapered roller bearing (outer race), shim and transaxle housing.

  3. INSTALL FRONT DIFFERENTIAL SIDE GEAR 
    1. Coat the front differential side gear, front No. 1 differential side gear thrust washer and conical spring with ATF.
      GTY707381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.
      GTY725266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.
      GTY721877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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 front differential pinion and front differential pinion thrust washer with ATF.
      GTY481280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      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.
      GTY479471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      • SST: 09528-52010 
        1. 09528-05030
      WARNING:

      Be careful not to catch 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.

  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
      TEXT IN ILLUSTRATION

      ATF
    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 hammer, stake the front differential case.
      GTY481329Courtesy 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 front differential case.
    3. Align the matchmarks, and install the front differential ring gear to the front differential case quickly.
      GTY736930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.
  9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.
    2. Install the front differential case to the transaxle case.
      GTY367226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case with the 20 bolts.
      GTY720703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 

      Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) 

      Bolt B 

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

    4. Using SST, turn the differential assembly right and left 2 or 3 times to settle the bearing.
      GTY699521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 
    5. Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.
      • SST: 09564-33010 

      Turning torque

      1.05 to 1.93 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

      Part No. Thickness
      mm (in.)
      90564-A0183 2.000 (0.0787)
      90564-A0184 2.025 (0.0797)
      90564-A0185 2.050 (0.0807)
      90564-A0186 2.075 (0.0817)
      90564-A0187 2.100 (0.0827)
      90564-A0188 2.125 (0.0837)
      90564-A0189 2.150 (0.0846)
      90564-A0190 2.175 (0.0856)
      90564-A0191 2.200 (0.0866)
      90564-A0192 2.225 (0.0876)
      90564-A0193 2.250 (0.0886)
      90564-A0194 2.275 (0.0896)
      90564-A0195 2.300 (0.0906)
      90564-A0196 2.325 (0.0915)
      90564-A0197 2.350 (0.0925)
      90564-A0198 2.375 (0.0935)
      90564-A0199 2.400 (0.0945)
      90564-A0200 2.425 (0.0955)
      90564-A0201 2.450 (0.0965)
      90564-A0202 2.475 (0.0974)
      90564-A0203 2.500 (0.0984)
      90564-A0204 2.525 (0.0994)
      90564-A0205 2.550 (0.100)
      90564-A0206 2.575 (0.101)
      90564-A0207 2.600 (0.102)
      90564-A0208 2.625 (0.103)
      90564-A0209 2.650 (0.104)
      90564-A0210 2.675 (0.105)
      90564-A0211 2.700 (0.106)
      90564-A0212 2.725 (0.107)
      90564-A0213 2.750 (0.108)
      90564-A0214 2.775 (0.109)
      90564-A0215 2.800 (0.110)
      90564-A0216 2.825 (0.111)
      90564-A0217 2.850 (0.112)
      90564-A0218 2.875 (0.113)
    6. Remove the 20 bolts and transaxle housing from the transaxle case.
      GTY707204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the front differential case from the transaxle case.
      GTY367226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new transaxle case oil seal with MP grease.
    2. Using SST and a hammer, install the transaxle case oil seal to the transaxle case.
      GTY711832Courtesy 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 transaxle case oil seal is installed in the correct direction.

  11. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL 
    1. Coat the lip of a new front differential case oil seal with MP grease.
    2. Using SST and a hammer, install the front differential case oil seal to the front differential case.
      GTY478037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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.)

  12. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new front transaxle case oil seal with MP grease.
    2. Using SST and a hammer, install the front transaxle case oil seal to the transaxle housing.
      GTY694563Courtesy 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:

      Check that the front transaxle case oil seal is installed in the correct direction.

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