DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A004PVUE01
      Text in Illustration
      *1 Differential Side Gear
      *2 Conical Spring Washer
      *3 No. 1 Front Differential Side Gear Thrust Washer
      A004NPW Toyota Genuine ATF WS

      Coat the 2 differential side gears, 2 No. 1 front differential side gear thrust washers and 2 conical spring washers with ATF.

    2. A004QKGE07
      Text in Illustration
      *1 Differential Side Gear
      *2 Conical Spring Washer
      *3 No. 1 Front Differential Side Gear Thrust Washer

      Install the 2 differential side gears, 2 No. 1 front differential side gear thrust washers and 2 conical spring washers to the differential case.

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

      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      A004MVIE06
      Text in Illustration
      *a Turn *b Hold

      Note

      Do not overtighten SST, as doing so will damage the differential side gears, conical spring washers, No.1 front differential side gear thrust washers and 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 differential side gears.

    4. A004U9L

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

      Text in Illustration
      A004NPW Toyota Genuine ATF WS
    5. A004TO3E04
      Text in Illustration
      *a Turn

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

      SST
      09528-52010   ( 09528-05030 )

      CAUTION:

      Be careful not to catch your fingers between the front differential pinions and differential case.

      Note

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

  2. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A004OEO

      Coat a No. 1 front differential pinion shaft with ATF.

      Text in Illustration
      A004NPW Toyota Genuine ATF WS

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

  4. INSPECT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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  5. INSPECT DIFFERENTIAL CASE

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  6. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    A004SQV

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

      Note

      Align the holes in the differential case and No. 1 front differential pinion shaft and install the front differential pinion shaft straight pin.

    2. A004RKR

      Using a chisel and hammer, stake the differential case.

  7. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. A004RVI

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

      Note

      Do not heat the ring gear to more than 110°C (230°F).

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

    3. A004OF4E01
      Text in Illustration
      *a Matchmark

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

      Note

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

    4. A004UDE

      Install and tighten the 12 bolts.

      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }

      Note

      Tighten the bolts in diametrically opposite pairs.