DIFFERENTIAL CASE (for Hatchback) > REASSEMBLY

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1. INSTALL DIFFERENTIAL GEAR KIT


    C081320E01

  1. 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.


2. INSTALL FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    C081321E01

  1. 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.



3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    C081322E01

  1. 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.)
    If the backlash is outside the specifications, install the correct front differential side gear thrust washer to the front differential side gear.

  1. 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)
    If the backlash is not within the specifications, install a front differential side gear thrust washer of a different thickness.


4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    C081323E01

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



    C081324E01

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



5. INSTALL FRONT DIFFERENTIAL RING GEAR


D025177E01

  1. Clean the contact surface of the differential case and the 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).

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


    D025172E09

  1. 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.

    Text in Illustration 
    *a
    		Matchmark


    C081325E03

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

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


    C081326E01

  1. Using SST, stake the 4 ring gear lock plates.

    SST
    09930-00010  


6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    C068169E03

  1. 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)


    C068191E03

  1. 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)


7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    C162532E01

  1. 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)


    C068208E04

  1. 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)