Differential Case (For Hatchback) Reassembly

After applying Toyota Genuine ATF WS to the differential gear kit (2 front differential pinions and 2 front differential side gears), 2 front differential side gear thrust washers and the 2 front differential pinion thrust washers, and install them to the front differential case.

HINT:

When installing them, set the alignment of the front differential pinions perpendicular to that of the front differential side gear and rotate them so that their holes are aligned with the holes in the differential case.

Install the front No. 1 differential pinion shaft so as to align the straight pin holes in the front No. 1 differential pinion shaft and the differential case.

Measure the front differential side gear backlash while holding 1 pinion gear toward the case.

Standard backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

Referring to the table below, select front differential side gear thrust washers which will ensure that the backlash is within the specifications for both sides.

Thrust Washer Thickness:

Part No.	Thickness mm (in.)
41361-17010	0.95 (0.0374)
41361-17020	1.00 (0.0394)
41361-17030	1.05 (0.0413)
41361-17040	1.10 (0.0433)
41361-17050	1.15 (0.0453)
41361-17060	1.20 (0.0472)

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

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

Clean the contact surface of the differential case and the front differential ring gear.

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

CAUTION:

Use thick gloves to protect your hands as the front differential ring gear is hot.

After moisture on the front differential ring gear has completely evaporated, align the matchmarks on the front differential ring gear and the differential case, and quickly install them.

Install 4 new ring gear lock plates with the 8 bolts.

Torque:

88 N*m{898 kgf*cm, 65 ft.*lbf}

Using SST, stake the 4 ring gear lock plates.

SST

09930-00010

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

SST

09726-40010
09950-60020(09951-00790)

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

SST

09950-60020(09951-00720)
09950-60010(09951-00650)
09950-70010(09951-07100,09951-07200)

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

SST

09950-60010(09951-00460)
09950-70010(09951-07100)

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

SST

09950-70010(09951-07150)
09950-60020(09951-00680)