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Differential Case: Reassembly

  1. INSTALL DIFFERENTIAL CASE 
    1. Apply ATF WS to the side gear thrust washer and install it to the side gear.
    2. Apply ATF WS to the side gear thrust washer and install it to the pinion.
    3. Install the side gear and pinion to the differential case.
    4. Install the pinion shaft to the differential case so that the straight pin holes of the pinion shaft and differential case are aligned.
      Fig 1: Installing Side Gear And Pinion To Differential Case
      G04474280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Set the pinion side and inspect the side gear backlash.

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

      HINT:

      • Replace the side gear thrust washers with the same size for both the right and left side gears if the value is outside the specified range.
      • Ensure that rotation is smooth if side gear backlash is within the specified range.
        Fig 2: Measuring Side Gear Backlash
        G04474281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the backlash exceeds the specified range, replace the side gear thrust washer with thinner one.

      If the backlash is less then the specified range, replace the side gear thrust washer with thicker one.

      Standard side gear thrust washer thickness 

      SIDE GEAR THRUST WASHER THICKNESS SPECIFICATION

      Part No. Washer thickness
      41361-22140 0.95 mm (0.0374 in.)
      41361-22020 1.00 mm (0.0394 in.)
      41361-22150 1.05 mm (0.0414 in.)
      41361-22030 1.10 mm (0.0433 in.)
      41361-22160 1.15 mm (0.0453 in.)
      41361-22040 1.20 mm (0.0472 in.)
    6. Using a 5 mm pin punch, tap in the straight pin to the differential case.
      Fig 3: Tapping In Straight Pin To Differential Case
      G04474282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a chisel, caulk the external circumference of the differential case straight pin hole.
      Fig 4: Caulking External Circumference Of Differential Case Straight Pin Hole
      G04474283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL DIFFERENTIAL CASE RH TAPERED ROLLER BEARING 
    1. Using SST and a press, press in the bearing RH to the differential case.

      SST 09710-22021 (09710-01031), 09950-70010 (09951-07100) 

      HINT:

      There are 24 bearing rollers in bearing RH.

      Fig 5: Installing Differential Case RH Tapered Roller Bearing
      G04474284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL DIFFERENTIAL CASE LH TAPERED ROLLER BEARING 
    1. Using SST and a press, press in the bearing LH to the differential case.

      SST 09710-22021 (09710-01031), 09950-70010 (09951-07100) 

      HINT:

      There are 22 bearing rollers in bearing LH.

      Fig 6: Installing Differential Case LH Tapered Roller Bearing
      G04474285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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