Differential Case Reassembly

Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.

Coat the front No. 1 differential pinion shaft with ATF, and install it to the differential case.

Using a pin punch and hammer, install the pinion shaft straight pin.

Using a chisel and hammer, stake the differential case.

NOTICE:

Stake it after adjusting the backlash (COROLLA_ZRE142 RM0000018KM02LX_01_0001.html).

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

SST

09550-60010(09951-00480)
09950-70010(09951-07100)
09710-04081

NOTICE:

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

Using SST and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing.

SST

09950-60020(09951-00750)
09950-70010(09951-07200)

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

SST

09710-04081
09550-60010(09951-00480)
09950-70010(09951-07100)

NOTICE:

Do not damage the bearing when installing the bearing inner race.

Using SST and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing.

SST

09550-60010(09951-00790)
09950-70010(09951-00710)

NOTICE:

Make sure that there is no clearance between the bearing and transaxle housing.

Install the differential assembly to the transaxle case.

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

Install the transaxle housing to the transaxle case and tighten the 18 bolts.

Torque:

Bolt A:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Bolt B:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Bolt C:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Bolt D:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Bolt E:

33 N*m{336 kgf*cm, 24 ft.*lbf}

Bolt F:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Bolt length:

Bolt B, C, D, F:

50 mm (1.969 in.)

Bolt A, E:

42 mm (1.654 in.)

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

SST

09564-32011

Using SST and a torque wrench, measure the rotating torque of the differential.

SST

09564-32011

Rotating torque at 60 rpm:

New bearing:

0.20 to 1.0 N*m (2.0 to 10.2 kgf*cm, 1.8 to 8.9 in.*lbf)

Used bearing:

0.10 to 0.50 N*m (1.0 to 5.1 kgf*cm, 0.9 to 4.4 in.*lbf)

HINT:

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

Remove the 18 bolts and the transaxle housing.

Remove the differential assembly.

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

NOTICE:

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

Clean the contact surface of the front differential case.

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

NOTICE:

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

Tighten the 10 bolts.

Torque:

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

NOTICE:

Tighten the bolts one at a time in diagonal order.

Using SST and a hammer, drive in a new oil seal.

SST

09316-60011(09316-00011)

Coat the lip of the oil seal with a small amount of MP grease.

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

Using SST and a hammer, drive in a new oil seal.

SST

09649-17010
09950-70010(09951-07150)

Coat the lip of the oil seal with a small amount of MP grease.

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)