DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. B004JHMC02
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      B006Z38 Toyota Genuine ATF WS

      Coat the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs with Toyota Genuine ATF WS.

    2. B004HGCC01
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer

      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.

      Note


      • Do not drop the front differential side gears, front No. 1 differential side gear thrust washers or conical springs.

      • Make sure that the conical springs are installed with the correct orientation.

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

      B004LM0C01
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 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.

      Tech Tips


      • 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. B004HH5C02
      B006Z38 Toyota Genuine ATF WS

      Coat the 2 front differential pinions and 2 front differential pinion thrust washers with Toyota Genuine ATF WS.

    5. B004KGAC01
      *a Turn

      Using SST as shown in the illustration and rotate the front differential side gear and install the 2 front differential pinions to 2 front differential pinion thrust washers.

      SST
      09528-52010   ( 09528-05030 )

      CAUTION:

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

      Note

      Do not drop the front differential pinions or front differential pinion thrust washers.

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B004IDCC01
      B006Z38 Toyota Genuine ATF WS

      Coat the front No. 1 differential pinion shaft with Toyota Genuine ATF WS.

    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.

  4. INSPECT FRONT DIFFERENTIAL CASE

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  5. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. B004NYB

      Using a 5 mm pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.

    2. B004M0Q

      Using a chisel and a hammer, stake the front differential case.

  6. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. B004JX8

      Using Toyota Genuine ATF WS and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

      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. B004MVBC01
      *a Matchmark

      Align the matchmarks, and install the front differential ring gear to the front differential case quickly.

    4. B004NI9

      Install the 12 bolts.

      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.