DIFFERENTIAL CASE REASSEMBLY

PROCEDURE

  1. INSTALL FRONT DIFFERENTIAL SIDE GEAR

    1. C288461C05

      *1

      Front Differential Side Gear

      *2

      Conical Spring Washer

      *3

      Front No. 1 Differential Side Gear Thrust Washer
      V100135

      Toyota Genuine ATF WS

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

    2. C313977C03

      *1

      Front Differential Side Gear

      *2

      Conical Spring Washer

      *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 spring washers to the front differential case.

      Note:

      • Do not drop the front differential side gear, front No. 1 differential side gear thrust washer or conical spring washer.

      • Make sure that the conical spring washer is installed with the correct orientation.

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

      C313979C02

      *a

      Turn

      *b

      Hold

      09528-52010

      09528-05010

      09953-05010

      Note:

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

      Tip:

      • Tighten SST to create the necessary clearance to install the front differential pinions.

      • When installing the 2 front differential pinions, do not overtighten SST, as it is necessary to rotate the 2 front differential side gears.

    4. C287727C02
      V100135

      Toyota Genuine ATF WS

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

    5. C314901C02

      *a

      Turn

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

      09528-52010

      09528-05030

      CAUTION:

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

      Note:

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

  2. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  3. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT

    1. C313975C01
      V100135

      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. C313973

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

      Note:

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

    2. C313972

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

  6. INSTALL FRONT DIFFERENTIAL RING GEAR

    1. D025215

      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. C323295C03

      *a

      Matchmark

      Clean the contact surface of the front differential case.

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

    4. C323296

      Install the 12 bolts.

      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.

  7. INSTALL TRANSAXLE CASE OIL SEAL RH (INNER)

    1. Coat the lip of a new transaxle case oil seal RH (inner) with MP grease.

    2. C324343N01

      Using SST and a hammer, install the transaxle case oil seal RH (inner).

      09950-60010

      09951-00410

      09950-70010

      09951-07200

      Oil seal drive in depth

      21.5 to 22.5 mm (0.847 to 0.885 in.)