DIFFERENTIAL CASE REASSEMBLY


  1. INSTALL DIFFERENTIAL SIDE GEAR


    1. A01IRLME01
      Text in Illustration
      *1 Differential Side Gear
      *2 Conical Spring Washer
      *3 No. 1 Front Differential Side Gear Thrust Washer
      A01ISM9 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. A01IPI8E02
      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 )
      A01IO7JE02
      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. A01ITQX

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

      Text in Illustration
      A01ISM9 Toyota Genuine ATF WS
    5. A01INLFE04
      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


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

      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      A01ITQQE02
      Text in Illustration
      *a Turn *b Hold

    2. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. A01IQGUE01
      Text in Illustration
      *1 No. 1 Front Differential Pinion Shaft

      Install the No. 1 front differential pinion shaft to the front differential pinion as shown in the illustration.

    4. Using SST and a dial indicator, measure the front differential pinion backlash.

      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Standard Backlash
      0.05 to 0.15 mm (0.00197 to 0.00590 in.)

      If the backlash is not as specified, replace the No. 1 front differential side gear thrust washers with washers of a different thickness. Use the table below to select a No. 1 front differential side gear thrust washer which will ensure that the backlash is within the specification.

      No. 1 Front Differential Side Gear Thrust Washer Thickness
      Thickness Thickness
      1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.)
      1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.)
      1.60 mm (0.0630 in.) 1.85 mm (0.0728 in.)
      1.65 mm (0.0650 in.) 1.90 mm (0.0748 in.)
      1.70 mm (0.0669 in.) -

      Tech Tips

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01IQO2

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

      Text in Illustration
      A01ISM9 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


    1. A01IN5YE02
      Text in Illustration
      *a Thrust Amount

      Using SST and a dial indicator, measure the thrust amount of the differential side gear.

      SST
      09528-52010   ( 09528-05030 )
      Standard Thrust Amount
      0.08 mm (0.00314 in.) or less

      Tech Tips


      • Measure the differential side gear thrust amount while slowly rotating the differential side gear.

      • Make sure to measure the differential side gear thrust amount for both of the differential side gears.

      If the result is not as specified, replace the 2 conical spring washers, 2 differential side gears and 2 front differential pinions.

  5. INSPECT DIFFERENTIAL CASE


    1. A01IR8VE02

      Using SST, rotate the differential side gear as shown in the illustration.

      SST
      09528-52010   ( 09528-05030 )
      Standard
      The front differential side gear does not lock when rotated in either direction.

      • If the differential side gear locks, perform all remaining inspection procedures.

      • Replace any parts that do not meet the specifications.

      • If the differential side gear locks after performing the inspection procedures, replace the differential case.

  6. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    A01INGI

    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. A01ITM8

      Using a chisel and hammer, stake the differential case.

  7. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01ITENE01

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

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during bearing inner race installation.

  8. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A01ISS7E02

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

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )

      Note

      Do not damage the bearing cage during bearing inner race installation.

  9. 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).

      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. A01IRGME06
      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. A01IRO8

      Install and tighten the 12 bolts.

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

      Note

      Tighten the bolts in diametrically opposite pairs.