Differential Case ASSY: Overhaul

1. Set the differential case in a vise.
2. Using SST, remove the bearing RH from the differential case.
   1. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04010)

Fig 1: Removing Bearing RH From Differential Case

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1. Set the differential case in a vise.
2. Using SST, remove the bearing LH from the differential case.
   1. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04010)

Fig 2: Removing Bearing LH From Differential Case

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1. Set the differential case in a vise.
2. Drive out the straight pin from the differential case using a pin punch (5 mm).
   Fig 3: Driving Out Straight Pin From Differential Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the following parts from the differential case.

Fig 4: Removing Differential Case Locating Parts

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1. Check the bearing for abnormal wear or color change.

HINT:

Replace the bearing with a new one if abnormal wear or color change is observed.

1. Apply ATF WS to the side gear thrust washer and install to the side gear.
2. Apply ATF WS to the side gear thrust washer and install 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 5: Installing Side Gear, Pinion And Pinion Shaft To Differential Case

   Courtesy 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.

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

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

   Side gear thrust washers 

   Fig 6: Measuring Side Gear Backlash

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   SIDE GEAR THRUST WASHERS SPECIFICATION
   
   

   Parts number	Washer thickness mm (in.)
   41361-22140	0.95 (0.0374 in.)
   41361-22020	1.00 (0.0394 in.)
   41361-22150	1.05 (0.0414 in.)
   41361-22030	1.10 (0.0433 in.)
   41361-22160	1.15 (0.0453 in.)
   41361-22040	1.20 (0.0472 in.)

6. Drive the straight pin into the differential case with a pin punch (5 mm).
   Fig 7: Driving Straight Pin Into Differential Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a chisel, calk the external circumference of the differential case straight pin hole.

Fig 8: Calking External Circumference Of Differential Case Straight Pin Hole

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1. Using SST and a press, install the bearing RH to the differential case.
   1. SST 09710-22021 (09710-01031), 09950-70010 (09951-07100)

HINT:

There are 24 bearing rollers in bearing RH.

Fig 9: Installing Bearing RH To Differential Case

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1. Using SST and a press, install the bearing LH to the differential case.
   1. SST 09710-22021 (09710-01031), 09950-70010 (09951-07100)

HINT:

There are 22 bearing rollers in bearing LH.

Fig 10: Installing Bearing LH To Differential Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002