Reassembly [09/2022 - ]: Procedure

1. Coat the front differential side gear, front No. 1 differential side gear thrust washer and conical spring with gear oil.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Install the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs to the front No. 1 differential case sub-assembly.

   Courtesy 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 and conical spring.
   • Make sure that the conical spring is installed in the correct orientation.
3. Set 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
   NOTE:

   Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, front No. 1 differential side gear thrust washer and front No. 1 differential case sub-assembly.

   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 gear oil.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Gear Oil

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Turn

   • SST: 09528-52010 
     1. 09528-05030
   WARNING:

   Be careful not to catch your fingers between the front differential pinion and front No. 1 differential case sub-assembly.

   NOTE:

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

See step  3

1. Coat a front No. 1 differential pinion shaft with gear oil.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Gear Oil

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

See step  1

1. Using a 5 mm pin punch and hammer, install the front differential pinion shaft straight pin to the front No. 1 differential case sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Using a chisel and hammer, stake the front No. 1 differential case sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a heater, heat the front differential ring gear to 90 to 100°C (194 to 212°F).
   WARNING:

   Use thick gloves to protect your hands as the front differential ring gear is hot.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Clean the contact surface of the front No. 1 differential case sub-assembly and front differential ring gear.
3. While aligning the matchmarks, quickly install the front differential ring gear to the front No. 1 differential case sub-assembly with the 16 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Matchmark

   Torque: 106 N.m (1081 kgf/cm, 78 ft.lbf)