DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL NO. 2 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A017CTTE02

      Coat the front differential side gear thrust washer, front differential gear, front differential pinion, front differential pinion thrust washer, front differential pinion shaft holder, and 3 differential pinion shafts with ATF, and install them to the No. 2 differential case.

    2. A017DJUE01

      Using a pin punch and a hammer, install the 3 straight pins.

    3. A017D6ME02

      Using a snap ring expander, install the pinion shaft spacer snap ring.

  2. INSPECT FRONT DIFFERENTIAL


    1. A017DUYE01

      Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.

      Standard backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      Note

      Do not mount the surface of the front differential case which contacts with the bushing in a vise.

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      A 0.95 (0.0373) F 1.20 (0.0472)
      B 1.00 (0.0393) G 1.25 (0.0492)
      C 1.05 (0.0413) H 1.30 (0.0512)
      D 1.10 (0.0433) J 1.35 (0.0532)
      E 1.15 (0.0453) K 1.40 (0.0552)
    2. A017C2YE02

      Engage the front differential side to the above mentioned front differential case.

    3. Install the differential case LH to the front differential case and measure its center.

    4. After that, remove the differential case LH.

    5. A017FA8E01

      Using a straightedge and feeler gauge, measure the clearance between the front differential case and the front differential side gear.

      Tech Tips


      • t= Thrust washer thickness

      • L= Clearance

      • t= L-0.162 to 0.265 mm (0.0064 to 0.0104 in.)

      If the clearance is not within the specified range, refer to the table below and select a thrust washer so that the clearance is within the specified range.

      Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      A 0.95 (0.0373) F 1.20 (0.0472)
      B 1.00 (0.0393) G 1.25 (0.0492)
      C 1.05 (0.0413) H 1.30 (0.0512)
      D 1.10 (0.0433) J 1.35 (0.0532)
      E 1.15 (0.0453) K 1.40 (0.0552)

      If the clearance is not within the specified range, parts may have been assembled incorrectly, so check and reassemble it.

  3. INSTALL CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY


    1. A017DELE02

      Install the center differential side gear, conical spring washer, and No. 2 center differential side gear thrust washer RH from the differential case RH.

      Tech Tips

      Ensure that the conical washers are installed correctly.

    2. A017BPIE01

      Hold the differential case RH in a vice. Install the center differential pinion and pinion thrust washer to the differential spider and install them to the differential case RH.

      Note

      When holding the differential case RH in a vise, be sure to place aluminum plates between them and use a minimum force.

    3. A017E9IE01

      Pressing and holding the differential spider toward the differential case RH, measure the pinion's backlash with a dial indicator as illustrated.

      Standard backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
    4. A017EF2E01

      Temporarily install the No. 2 differential side gear thrust washer LH, center differential side gear conical spring washer, and No. 2 differential case to the differential case LH.

      Tech Tips

      Ensure that the conical washers are installed correctly.

    5. A017DGTE01

      Install the differential intermediate case to the differential case and secure the assembled parts with the 4 bolts.

    6. A017DXHE01

      Remove the differential spider, 5 center differential pinions, and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and secure the case.

    7. A017CR6E01

      Pressing and holding the differential spider toward the differential intermediate case, measure the pinion's backlash with a dial indicator.

      Standard backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
    8. A017BWAE01

      Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case.

    9. A017EBNE02

      Remove the No. 2 differential case from the differential case LH.

    10. A017G6PE01

      Install the selected No. 2 differential side gear thrust washer LH and center differential planetary gear to the differential case LH.

    11. A017C45E04

      Install the No. 2 differential case to the differential case LH again.

    12. A017CSHE02

      Install the adjusted differential case RH to the intermediate case and tighten the 15 bolts using a "TORX" socket wrench (T50).

      Torque:
      63 N*m  { 642 kgf*cm, 46 ft.*lbf }

      Note

      Align the matchmarks.

  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A017FVYE01

      Using SST and a press, install the front differential case tapered roller bearing FR to the differential case.

      SST
      09950-70010   ( 09951-07100 )
      09649-17010

      Note

      Do not damage the bearing cage while installing the bearing inner race.

    2. A017BRDE01

      Using SST, install the outer race of the tapered roller bearing FR.

      SST
      09527-17011
      09950-60020   ( 09951-01030 )

      Note


      • Clearance is not allowed between the plate washer and transaxle housing.

      • When replacing the bearing, be sure to replace both outer and inner races.

      • When replacing the bearing, be sure to replace both left and right bearings as a set.

  5. INSTALL FRONT DIFFERENTIAL SIDE GEAR


    1. A017F11E01

      Using SST and a press, install the front differential case tapered roller bearing RR to the differential case.

      SST
      09316-20011
      09214-76011

      Note

      Do not damage the bearing cage while installing the bearing inner race.

    2. Install the front differential case shim RR to the transaxle case.

      If the bearing is new, select a front differential case shim RR of proper thickness starting from the thinner ones. If the bearing is reused, select a front differential case shim RR starting from the same thickness as the one installed before disassembly.

    3. A017G8BE01

      Using SST, install the outer race of the front differential case tapered roller bearing RR.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07100 )

      Note

      Clearance is not allowed between the differential case shim and transaxle case.

  6. ADJUST TAPERED ROLLER BEARING PRELOAD


    1. A017CZKE01

      Install the intermediate case to the differential case LH and secure them with the 4 bolts.

    2. Install the differential assembly to the transaxle case.

    3. A017BQUE04

      Clean the matching surfaces of the transaxle case and transaxle housing.

    4. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.

      Torque:
      Bolt A
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt B
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
      Bolt C
      29 N*m  { 295 kgf*cm, 21 ft.*lbf }
      Bolt D
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Apply adhesive or equivalent to bolts A and D

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Bolt length
      Bolt A, B
      50 mm (1.969 in.)
      Bolt C
      42 mm (1.654 in.)
      Bolt D
      72mm (2.835 in.)

      Note

      Apply adhesive to the bolts and tighten them within 10 minutes of application

      Tech Tips

      Bolt A is a non-reusable bolt. However, bolt A can be used after cleaning it.

    5. A017GAYE02

      Using SST, turn the differential assembly right and left 2 or 3 times to allow the bearing to settle.

      SST
      09564-32011

    6. Using SST and a torque wrench, measure the turning torque of the differential case assembly.

      SST
      09564-32011
      Torque:
      New bearing (*)
      0.2 to 0.69 N*m  { 2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf }
      Used bearing (*)
      0.10 to 0.35 N*m  { 1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf }

      Tech Tips


      • (*): Turning torque at 60 rpm

      • If the turning torque is not within the specified range, refer to the table below and select a thrust washer so that the turning torque is within the specified range.

      Flange thickness: mm (in.)
      Mark Thickness Mark Thickness
      0 2.000 (0.0787) 9 2.450 (0.0965)
      j 2.025 (0.0797) T 2.475 (0.0974)
      1 2.050 (0.0807) A 2.500 (0.0984)
      K 2.075 (0.0817) U 2.525 (0.0994)
      2 2.100 (0.0827) B 2.550 (0.1004)
      L 2.125 (0.0837) V 2.575 (0.1014)
      3 2.150 (0.0846) C 2.600 (0.1024)
      M 2.175 (0.0857) W 2.625 (0.1034)
      4 2.200 (0.0866) D 2.650 (0.1043)
      N 2.225 (0.0876) X 2.675 (0.1053)
      5 2.250 (0.0886) E 2.700 (0.1063)
      P 2.275 (0.0896) Y 2.725 (0.1073)
      6 2.300 (0.0906) F 2.750 (0.1083)
      Q 2.325 (0.0915) AA 2.775 (0.1093)
      7 2.350 (0.0925) G 2.800 (0.1102)
      R 2.375 (0.0935) AB 2.825 (0.1112)
      8 2.400 (0.0945) H 2.850 (0.1122)
      S 2.425 (0.0954) - -
    7. A017F8ME01

      Remove the 16 bolts and the transaxle housing.

    8. A017CZKE02

      Remove the differential assembly.

  7. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A017EA9E08

      Using ATF and heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F).

      Note

      Do not heat the ring gear to more than 110°C (230.0°F).

    2. Clean the contact surface of the front differential case.

    3. A017BT6E02

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

      Note


      • Do not install the bolts while the ring gear is hot.

      • Check the number and position of the gear teeth.

    4. A017BPOE01

      Temporarily install the 8 bolts as shown in the illustration.

    5. A017B1BE01

      Remove the 4 bolts shown in the illustration.

    6. Temporarily install the remaining 8 set bolts.

    7. Fully tighten the set bolts.

      Torque:
      95 N*m  { 970 kgf*cm, 70 ft.*lbf }

      Note

      Tighten the bolts a little at a time in a diagonal pattern.

  8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL


    1. A017DX9E01

      Using SST and a hammer, install a new oil seal.

      SST
      09223-15020
      09950-70010   ( 09951-07100 )
      Standard installation depth
      -0.5 to 0.2 mm (-0.020 to 0.008 in.)

    2. Coat the lip of oil seal with a little MP grease.

  9. INSTALL TRANSAXLE HOUSING OIL SEAL


    1. A017FPGE02

      Wrap vinyl tape around SST at the place 6.0 mm (0.236 in.) above the bottom end until the thickness of the wrapped tape is approximately 5.0 mm (0.197 in.).

      SST
      09950-60020   ( 09951-00730 )

      Note

      Remove foreign matter such as grease on the SST before winding the tape.

    2. Coat the lip of oil seal with a little MP grease.

    3. A017C99E02

      Using SST, install a new oil seal.

      SST
      09950-60020   ( 09951-00730 )
      09950-70010   ( 09951-07150 )
      Standard installation depth
      5.5 to 6.5 mm (0.217 to 0.256 in.)

      Note

      Stop pressing when the wrapped vinyl tape contacts the transaxle housing.